Sikorski MFG

Case studies

Problems solved. Products built.

A selection of engineering projects across product design, injection mold engineering, and prototype-to-production development.

01Injection Mold Engineering
Two-Shot Enclosure for Industrial Controls

Two-Shot Enclosure for Industrial Controls

Redesigned a single-material enclosure as a two-shot molded assembly to eliminate a secondary assembly operation and improve IP sealing performance.

Challenge

The client's existing enclosure required a separate gasket and four assembly steps to achieve IP54 sealing. Unit cost was high and field failure rates were unacceptable.

Solution

We redesigned the part as a two-shot molded component — rigid ABS substrate with overmolded TPE sealing features. Mold design included a rotating platen system with optimized cooling for both shots.

Results

4

Assembly steps eliminated

22%

Unit cost reduction

IP65

Sealing rating achieved

02SolidWorks Product Design
Handheld Medical Device Housing

Handheld Medical Device Housing

Full SolidWorks development of a handheld diagnostic device housing — from industrial design intent through production-ready part files and mold design package.

Challenge

The client had an industrial design concept in Rhino with no manufacturing intent. They needed a complete SolidWorks model ready for tooling in 10 weeks.

Solution

We rebuilt the geometry in SolidWorks with full draft, wall thickness compliance, and snap-fit assembly features. DFM review was conducted in parallel with modeling to compress the schedule.

Results

10wk

Concept to tooling-ready

0

Tooling revisions required

6

Mold components designed

03Design for Manufacturability
DFM Rescue — Consumer Product Launch

DFM Rescue — Consumer Product Launch

Identified and resolved 14 critical tooling issues in a consumer product design that had already been quoted by three toolmakers — preventing an estimated $80K in tooling revisions.

Challenge

A consumer goods company had received tooling quotes but noticed inconsistencies. They engaged us for a DFM review before committing to a toolmaker.

Solution

Our DFM analysis identified 14 issues including insufficient draft on textured surfaces, a weld line directly on a structural feature, and an undercut requiring an unquoted side action. We delivered a prioritized report with recommended geometry changes.

Results

14

Critical issues identified

$80K

Estimated tooling cost avoided

3wk

Review turnaround

04Prototype to Production
Structural Bracket — Prototype to First Article

Structural Bracket — Prototype to First Article

Engineering support from SLA prototype evaluation through production mold first article for a structural mounting bracket used in commercial HVAC equipment.

Challenge

The client had a functional prototype but needed to transition to injection molding for production volumes. The part had complex geometry and tight dimensional requirements.

Solution

We designed the production mold, coordinated the toolmaker build, and provided on-site support during mold trials. Three design iterations were managed through engineering change orders before first article approval.

Results

3

Mold trial iterations

100%

First article dimensions in spec

16wk

Prototype to production approval

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