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DFF Case Studies

Read our precision machining case studies that detail how our precise manufacturing and engineering made an organizational impact for our customers through their real-life accounts.

Each story is presented in a problem / solution / results manner to give a glimpse into the types of specialized solutions and strategies that may someday benefit your own facility.

In Vitro Diagnostics Case Study

PROBLEM:
A longtime customer, an in vitro diagnostics company with a successful 75-year history, was experiencing a higher than desired failure rate on a highly sought-after and regulated blood analyzer.

SOLUTION:
DFF reverse engineered the 300-part assembly, diagnosing a design modification that would improve accuracy and meet FDA regulations.

RESULTS:
Production of the blood analyzer has doubled.

Stator Housing Case Study

PROBLEM:
Our customer, a leader in the electric propulsion ground vehicle market, was in need of a more efficient and effective manufacturing process for a stator housing sub-assembly designed for large hybrid electric motors.

SOLUTION:
DFF developed a new process of thermal shrink-fitting to eliminate stresses on
the assembly.

RESULTS:
Pleased with the results, the customer approved the assembly and awarded DFF the BETA run for production, and the opportunity to produce another stator housing assembly already in production.

FMS Case Study

Here at DFF, our flexible manufacturing system (FMS) capabilities allow us to support customers who require overflow production or regularly need specific parts. In this case study, you’ll discover the benefits of partnering with us in an FMS capacity:

  • Reduced labor costs with our lights-out machining capabilities in our modern, climate-controlled facility.
  • An array of available machinery to accommodate low volume/high mix set ups with little notice.
  • Machines that operate efficiently under 24/7 production to meet your needs.

We are always willing to help our customers with design improvements, and possess the experience, equipment, resources and knowledge to offer sound recommendations to improve products and processes—while reducing costs. Click the button below to learn more about our flexible manufacturing system.

A Focus on Quality and Critical Dimensions

PROBLEM:
A global leader in the semiconductor industry was dissatisfied with the quality of high vacuum chambers being produced by a manufacturing partner.

SOLUTION:
DFF was solicited to remedy the issue, ultimately developing chambers that stood up to strict helium leak detection tests and passed real-world testing with flying colors.

RESULTS:
Pleased with the success of the initial partnership, the company turned to DFF to produce a second set of specialized parts, which likewise passed strict testing requirements. 

DFM Case Study

PROBLEM:
A global aerospace and defense company’s jet needed to be outfitted with 8-foot-long munition magazines, and a custom solution was required.

SOLUTION:
3D printed magazines from DFF for concept approval.

RESULTS:
A 6-month project yielded a beta product currently in testing.