Case studies

Three programmes, start to finish

A photograph of a chair tells you very little. What tells you something is how the requirement changed on the way to production, and who caught the problems.

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The programmes below are representative of the work we do. Customer names and identifying design details are withheld under confidentiality.

Aluminum deep-seat sofa collection on a coastal terrace

Custom aluminum sofa frame

Deep-seat sofa frame for a U.S. outdoor furniture brand

Requirement

A deep-seat sofa collection with a teak-look armrest detail and a five-year coastal warranty, at a landed cost the brand's existing supplier could not reach.

Design adjustment

The armrest and seat rail were redesigned as a single extruded section instead of two joined parts. Wall thickness was reduced where the load case allowed and kept heavy at the leg junction.

Sampling

Dies cut in-house; first articles produced on production tooling and sent for load testing and cushion fitting. One radius change was made and re-sampled.

Mass production

Frames welded on fixtures, coated to the approved coastal specification, then assembled and packed retail-ready.

Outcome

Fewer weld joints, a lower part count, and a frame that passed the brand's salt-spray requirement.

Aluminum fire pit table with wind guard on a poolside terrace

Fire pit structure development

Fire table body and tank enclosure for an outdoor living brand

Requirement

A rectangular fire table in two lengths sharing one design language, built around a burner and control package the customer had already certified with their component supplier.

Design adjustment

Both lengths were engineered onto one extrusion family so the second size needed no additional tooling. The tank cabinet was re-proportioned to allow front access without breaking the visual line.

Sampling

Structures sampled with the customer's burner assembly fitted, checked for clearance, ventilation openings and wind guard fit.

Mass production

Produced in China, packed in double-wall cartons with foam bracing after a transit drop review.

Outcome

Two SKUs off one tooling set, and a packaging format that cut transit damage claims.

Custom extruded aluminum profiles on the press run-out

Component supply programme

Kitted frame components for a furniture manufacturer

Requirement

A manufacturer with its own assembly lines needed an upstream supplier who could hold hole-pattern tolerance across a full season instead of drifting batch to batch.

Design adjustment

Hole patterns were moved onto dedicated jigs and two near-identical brackets were consolidated into one part number used in both positions.

Sampling

A pilot batch was measured against the drawing and assembled on the customer's own line before the programme was released.

Mass production

Components kitted by assembly rather than bundled by part number, so the line no longer sorted parts before starting.

Outcome

Fewer part numbers to manage, and a measurable reduction in assembly-line rework.

Inside the plants

Where these programmes were built

Every project above ran through this floor — extrusion, fabrication, tooling and despatch.

Numbered extrusion dies stored in the mold library

Packed goods staged in the despatch warehouse

Your programme could be the fourth one on this page.

Send the brief and the constraint you cannot solve. That second part is usually where we are most useful.

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