Value Added Engineering
Our experienced engineering staff is accustomed to working closely with our OEM customers throughout the design, development, and product launch process. We have substantial in-house expertise in the following product development areas:
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Product Design
Wausaukee Composites can assume full design responsibilities, or work in concert with your in-house or independent design team(s) to develop production-efficient product designs, patterns, prototypes and production tooling. We offer Pro/Engineer®, AutoCAD®, and SolidWorks® design capability.
Product design, material and performance specifications, and special characteristics are considered during the product development process. Design for manufacturability recommendations, including the identification of key product cost drivers, are communicated during team feasibility reviews.
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Pattern Fabrication
Pattern fabrication is performed by way of CNC machining via 3D solid model data, ensuring that part dimensions are accurate. Pattern materials are selected to provide the most cost or performance effective solution for your specific project needs. Pattern materials utilized include: tooling board (REN), high-density foam, mahogany, and aluminum.
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Production Mold Fabrication
Wausaukee Composites has the in-house capability of fabricating production molds for open and closed cavity molding processes including: Open Molding, Light Resin Transfer Molding (LRTM), Resin Transfer Molding (RTM), Vacuum Assisted Resin Transfer Molding (VARTM), Closed Cavity Bag Molding (CCBM), Sheet Molding Compound (SMC), and Reaction Injection Molding (RIM).
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Prototyping
Wausaukee Composites offers several product prototyping solutions; such as short lead-time parts manufactured using temporary tooling and the open molding process. Wausaukee Composites can also provide rapid prototyping solutions, including SLS, which allow your ideas to be turned into parts virtually overnight.
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Precision Engineered Jigs and Fixtures
Wausaukee Composites utilizes SurfCAM® in conjunction with PRO/Engineer® to upload models to our CNC machining center for precise and repeatable fixture design, development and fabrication. Additional machining and fabrication equipment maintained on-site includes: mills, lathes, and MIG and TIG welders.
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First Article Inspection (FAI)
Wausaukee Composites maintains calibrated measuring equipment traceable to national standards (NIST). Our equipment includes a FARO Arm and Bendix CMM to validate the most difficult first article dimensions. Hard copy or electronic inspection reports are available, as well as supporting process capability studies and gage repeatability and reproducibility (Gage R&R) studies.
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Advanced Product Quality Planning (APQP)
Wausaukee Composites utilizes the AIAG prescribed format for APQP. The Production Part Approval Process (PPAP) includes the development of process related documentation, including: Flow Charts, Failure Mode and Effects Analysis (FMEA), Control Plans, material certifications and performance testing results. PPAPs can be submitted electronically or via hard copy.
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Material and Process Selection
Material and process selections are based on product performance specifications, such as lamination schedules or end use needs, with consideration given to costs, environmental impact, manufacturability, capability, capacity, material handling, and capital equipment requirements.
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Value Improvement Engineering
Utilize Wausaukee Composites' Engineering resources to identify cost reduction opportunities and product performance improvements, such as: design consultation for new product development, lowest cost manufacturability, material and process selection, key product cost driver analyses, multi-part consolidation, secondary hardware design and specification, strength/weight improvement, surface cosmetic standards, weather and UV resistance, and industry/regulation compliance just to name a few.
