The production process is like a swamp hike.
Those who want to arrive with dry feet must carefully plan the journey.
Limitless’ production process has been meticulously developed, keeping in mind what our customers value most – precision and efficiency.
In this article, we’ll break down Limitless’ production piece into eight stages and briefly explore what happens in each.
Let boot drying be left to Sunday adventurers.
First stage: price inquiry!
Producing cool components for a shelf can also be exciting, but we still prefer it when someone actually needs them.
So, the production process begins with a price inquiry that has landed in our email.
An ideal inquiry includes:
- Component drawings
- 3D model
- Batch size
- Deadline
Second stage: creating the offer!
When all the necessary information is available in the inquiry, we can start composing the price quote. The formula for this is quite simple:
Cost of the subsequent components = raw material cost + cycle time
Depending on the inquiry, subcontracting services may be added to the formula. For example, surface coating, wire and sinker EDM (Electrical Discharge Machining), vibratory finishing.
Third stage: production preparation!
First, it’s necessary to procure and prepare the raw material. Standard-sized conventional materials are generally in stock for small batches.
Next, it’s required to translate the component model into a language understandable to the machine, meaning creating a program. For this, we use the Autodesk Fusion 360 CAD/CAM system. Manual programming is not our playground.
When the program is ready and simulated on the computer, it’s time to set up the machine and tools for work. Typically, one component requires two setups.
For simpler components, we start by machining the top surface and sides, and in the second setup, we remove the material used to hold the component.
For more complex components, we use a five-axis Matsuura – this allows us to access all five sides of the component with a single setup.
Fourth stage: production of sample component!
This is the part of the production process where the first raw material is placed on the machine, and a sample component exits, undergoing a thorough inspection.
If necessary, we make adjustments in the program and produce sample components until the result is perfect, meaning the component meets the required tolerances inside and out.
Fifth stage: batch production!
The hard work of humans is done, now it’s time to let the machine have fun. In this phase, the machine is running at full speed, chips are flying, and components are being produced one after another.
Of course, this is under the watchful eye of the operator, whose sacred duty is to ensure that the machine doesn’t falter, the tools remain intact, and the components are within the specified tolerances.
Sixth stage: post-processing!
This is the part of the process that actually occurs simultaneously with production, and here we give the component its final touch. We clean it from chips, wash it free from emulsion, and prepare it for the next step.
Seventh stage: subcontracting!
When our work is completed, the batch moves on to the subcontracting phase if necessary. Here, the components receive the required surface coating or final finishing.
Once our subcontracting partners have also completed their work, production reaches the final stage.
Eighth stage: component assembly and shipping!
This part probably doesn’t need much explanation. Here, we exchange one last look at the work done, neatly package the components with best wishes, and send them on their way to the customer.
