Medical Products
Joint Preservation Innovations, a surgical instrument innovation startup, wanted to make arthroscopic surgeries more accurate and efficient for orthopedic surgeons.
Our team helped redesign the original concept to be manufacturable. Employing expert micro-mechanism design using biocompatible materials, the resulting design met performance and cost targets. We also supported all the prototyping and testing efforts.
Professional & Consumer Products
Cosco Industries, a leading manufacturer of office products, wanted to innovate date stamping with easy to use features.
Our team supported the original industrial design team to engineer a working, cost effective design that was awarded a utility patent. The design utilized advanced 3D modeling techniques and a wide variety of manufacturing processes, including injection molding, metal stamping and others.
Nordent Manufacturing, a leading manufacturer of dental products, had an idea for a new state of the art sharpener.
Our team worked directly with Sales to implement the original idea into a working proven concept. The concept was then engineered using cost effective manufacturing processes and we sourced all parts with our vetted global supply chain. The entire product is assembled and packaged at Dream to Product’s own US based facility.
Industrial Products
Metraflex, a leading manufacturer of engineered piping products, expansion joints, and flow control solutions for commercial and industrial systems, wanted to revolutionaize industrial scale water filtration.
Our team worked closely with the in-house engineers and employed expert 3D modeling skills to create the complex engineered geometry the product required. Metraflex trusted our team to create a new version of the product for every pipe size. This water strainer design has won awards and considered one of the most efficient industrial scale strainers in the world.
Lighting Products
Loggerhead Tools
Loggerhead Tools, a tool manufacturer known for innovative hand tools and the patented Bionic Wrench®, needed to find a new assembly facility.
Our team supported transfer of 4 production lines located in Pennsylvania into 1 consolidated high capacity line in our own facility in Evanston, IL. Assembly fixtures and stations were reengineered to be more space and time efficient to meet a tight production deadline. Our team also created a Quality Control Plan as part of ISO 9001 certified process.
Beastgrip
Beastgrip, a global brand producing professional mobile filmmaking rigs, lenses, and accessories for content creators, needed to scale their assembly capacity to catch bigger orders.
Our team not only supported the design of the Beastgrip Pro, but also created a new assembly line in Dream to Product’s own USA based facility. We doubled the total production capacity to support larger orders. Our team also created a Quality Control Plan as part of our ISO 9001 certified process.
Azul 3D Printing
Azul 3D Printing, an advanced manufacturing company developing high-speed industrial 3D printing technology, needed to increase assembly capacity to meet tight shipping deadlines.
Our team set up a production area in our own USA based facility, created detailed assembly instructions and a Quality Control Plan as part of our ISO 9001 certified process. Our work included assembly using many different fasteners, torques and adhesives. In addition, we wired all the control boxes and created detailed documentation.
Budscout
Budscout, a consumer products company focused on innovative solutions within emerging retail categories, needed help with a new robot for monitoring marijuana plant growth.
Our team took over the mechanical design from another design team to solve several performance issues. Employing expert mechanical engineering design practices, we solved the issues plaguing the robots. In addition, we assembled the first production lot of robots in our own facility with plans to continue production in progressively larger volumes.
Queen of Snow Globes
Queen of Snow Globes, a specialty brand known for designing and producing collectible snow globes for corporate gifts and retail, wanted to have a US based assembly facility to support growing sales.
Our team developed a proprietary water mix and new processes to degass prior to assembly. The bases are also fully customized with in-house painting and high resolution laser marking capabilities. The artwork is made in the USA with our vetter supplier of full color nylon 3D prints.
Lawrence Screw Products
Lawrence Screw Products, a U.S. manufacturer of precision cold-headed fasteners and specialty components for automotive, aerospace, and industrial applications, needed to increase kitting capacity to catch a big opportunity.
Our team set up 4 kitting lines and staffed them with an urgent timeline. The challenge included the size and shape of the items making them impossible to automate with traditional machines. We engineered and built custom pick bins and fill trays to keep labor costs low. Quality control and customer approvals were managed through our ISO 9001 quality processes. Almost 2 million kits across over 25 SKUs were successfully made in our USA facility.
Modern Sprout
Modern Sprout, a consumer brand creating design-driven indoor gardening kits and lifestyle products sold through major retailers, needed help increasing capacity to catch bigger retail orders.
Our team set up a kitting line to make 140,000 hydroponic grow kits across 8 different SKUs. A Quality Control Plan and other supporting documents were created as part of our ISO 9001 quality management system. The kits were packaged and palletized according the the retailer specification and shipped directly to retail distribution.
FUM
FUM, a Canada based wellness company producing inhalation devices designed as alternatives to traditional smoking and vaping habits, needed a partner to support launching their product line into the US market.
Our team acquired blister packing equipment and quickly gained expertise to successfully utilize this type of packaging, commonly used for retail. In addition, we supported the blister design and manufacturing process and sourced the custom tooling. We met aggressive deadlines to deliver 500,000 units across 12 unique SKUs.
Chevron
Chervon Limited, a global manufacturer of power tools and lawn equipment, needed help fixing a problem discovered with it’s SKIL branded concrete saw. The product was already made and packaged overseas, but needed to be rewired. The challenge is fixing a product when the factory is overseas.
Our team created detailed plan and estimated all costs to help determine the return on investment. We created instructions, including a Quality Control Plan to solve numerous challenges, then executed the rework in our own facility. Key solutions:
– installing 8 different fastener with 6 different screw torques using a color coding system
– saving the expensive retail boxes by using heated platens to soften the box glue before opening
– 100% testing the rewired product to ensure quality
Hydragun
Hydragun is a global manufacturer of therapy devices including massagers and water chillers. Their products are made overseas for sale in the US market. For their handheld massage gun, they discovered a tight fit problem with their accessories. For their water chiller, they discovered a problem with the pump and firmware.
Our team solved the tight fit issue with the massage gun and set up a rework area to unbox, fix, rebox and heat shrink the original box so it could still be sold as a new item.
The water chiller had bigger challenges: the product was too heavy for one person to lift, the firmware needed to be reflashed, 100% water testing was needed to verify rework. Our team executed the rework by implementing many solutions:
- Using an overhead crane to lift the chillers
- Using 5 gallon buckets to run extended water tests
- Using a custom made circuit to touch the correct pins to upload new firmware
Philips
Phillips, a global manufacturer of many electronics products across many industries, discovered a problem with their wifi enabled smart outlet and risked missing a retail delivery deadline.
Our team quickly developed and documented a rework process in our own facility that ensured the product was not damaged when opening the housings, the wiring was arranged correctly and the new packaging was retail ready. The reworked product was finished in time to be sold at retail.