Topflight’s innovative product development department can help design your product for manufacturability as well as provide input on required validation and testing methods. Our engineering services begin in our rapid prototype lab, where our highly skilled engineering staff can utilize an existing Illustrator AI, Corel Draw, DWG AutoCAD or DXF file to produce a prototype, or can assist in creating a drawing according to your specifications. Collaborative engineer-to-engineer communication allows for an innovative design partnership approach.
Topflight’s rapid prototype lab gives designers and engineers the opportunity to test performance on pre-commercial quantities of parts before committing to expensive production tooling and setup costs. Prototyping offers the flexibility of evaluating and changing a design with the assurance of future scalability to production quantities.
Customers can request sample materials on hundreds of adhesives and substrates such as papers, films, foams, conductive tapes, filter media, membranes, wovens, non-wovens, hydrogels, hydrocolloids, skin contact, plastics, and foils. Die-cut components and multi-layer laminations in multiple configurations can be ordered to test design alternatives. Many samples can be turned around in 48 hours or less on in-stock materials. Most samples can be produced on equipment that does not require tooling, like the CO2 laser or flatbed cutter/plotter. All prototype equipment is matched to full-scale production equipment, ensuring ramp-up manufacturability.
Components can be cut, kiss-cut, scored, perforated, marked, channeled or etched in multiple layers to produce a fully functional piece. Parts such as medical device components, gaskets, seals, overlays, faceplates, and labels can be produced within days on in-stock substrates and adhesives.
The flatbed cutter/plotter cuts most materials without the need for backing. Tangential controls ensure accurate, clean corners on thicker materials or intricate designs on more delicate materials. Sizes up to 23.2″x 16.9″ can be produced. Heads are interchangeable, allowing for marking (pen); cutting; perfing; or flipside scoring/creasing.
The CO2 laser has the benefit of cutting or laser ablating complex designs without investing in tooling. Maximum part size is 14.6″x 26.75″. Proof of concept designs can be tested on a prototype laser before being transferred to an in-line production laser. Common applications include channels for microfluidics; via holes and circuits for printed electronics; test strips; biosensor and diagnostic components; and consumer products samples.
The punch press provides prototype simulation of a matched-metal press suitable for foams and other materials where high degrees of cutting precision are required. Tooling for this press is very inexpensive, allowing for multiple design iterations.
No matter what your application, Topflight will help you ensure that your component or product looks and behaves exactly as you need it to, before investing money into expensive tools and dies.