A production problem may need a machined part, a fixture, a different material, rapid tooling, or a combined shop sequence. The tool matters less than the result.
Custom tooling and fixtures
Obsolete or hard-to-source components
Fit-up problems inside an existing assembly
Prototype and small-batch work
Fabricated assemblies crossing several processes
Equipment modifications and repair components
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Custom TPU receiver sleeve
A 3D-printed TPU sleeve removed excess clearance between a receiver tube and two powder-coated poles.
Problem
Two powder-coated poles needed to join through a receiver tube, but excess clearance prevented a clean, tight fit.
Barnes scope
Instead of adding more steel fabrication, Barnes designed and 3D printed a custom TPU sleeve that filled the gap at the connection.
Result
The flexible sleeve created the required fit while protecting the finished poles. Sometimes the best welding solution involves no welding at all.
Parts, tooling, fixtures, and fabricated assemblies
The shop can move between conventional processes and newer tools when the job calls for it.
Tooling & fixtures
Purpose-built aids, press tooling, and fixtures for repeatable work or a defined production need.
Machined components
Parts developed from drawings, models, samples, or existing assemblies when sourcing is difficult.
Fabricated assemblies
Cutting, forming, rolling, machining, welding, and finishing coordinated around one build.
Prototype & low volume
Physical prototypes and small batches that help test a direction before larger commitments are made.
Manufacturing flexibility
Use the tool that fits the problem
The TPU sleeve solved a steel fit-up problem without more welding. The printed press die formed a small batch without committing to long-life tooling. Both jobs matched the process to the required result.
Define
Model
Prototype
Build
Improve
Continuous improvement
Fix the work and improve the process
3S, visual management, standard work, and employee-led problem solving make shop work clearer and more repeatable. The examples show what changed on the floor.
