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Production-Readiness Fixtures and NPI Hardware for Defense Communications

±«Óătv Helps a Satellite Communications Leader Accelerate the Path from Design to Production
  • Defense Contractor

    Client

    Defense Contractor

  • Aerospace & Defense

    Industry

    Aerospace & Defense

  • CNC Machining, Quick-Turn Sheet Metal Fabrication, Prototyping, Design for Manufacturability, Kitting & Assembly

    Capability

    CNC Machining, Quick-Turn Sheet Metal Fabrication, Prototyping, Design for Manufacturability, Kitting & Assembly

Overflow Capacity
Reduced Schedule Drag
Improved Field-Install Consistency

Closing the Gap Between Design and Production for Secure Communications Hardware

A leading  was under pressure to move new secure communications and antenna system designs into production faster. But small-volume assembly aids, gauges, test stands, and line fixtures kept becoming hidden schedule blockers, even when the core electronics were otherwise ready to ship. ±«Óătv brought four facilities and multiple manufacturing technologies together to delivesatellite communications and defense technology companyr the production-readiness hardware that kept these critical programs on track.

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The Problem

  • The company’s engineering teams were developing secure terminal, ground-station, and defense communications hardware on aggressive timelines.

  • While the electronic designs were progressing on schedule, the physical tooling needed to validate, assemble, and test those designs was not keeping pace.

  • Assembly fixtures, gauges, handling aids, and line-support equipment were being improvised or delayed, creating hidden bottlenecks that threatened delivery dates for high-visibility defense programs.

  • The challenge was compounded by the sheer variety of hardware involved. Each new product introduction required a unique set of fixtures and validation tools—from precision nests and drill guides to setup plates and protective covers.

  • Without a manufacturing partner that could deliver this breadth of NPI hardware quickly and reliably, rework rates climbed and first-pass assembly yields suffered.

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The Solution

  • ±«Óătv deployed a coordinated, multi-site approach that matched each type of production-readiness hardware to the right manufacturing technology and facility:

  • Hartland, WI led fast-turn additive manufacturing for rapid fixture iterations, fit-check tools, and early validation hardware, getting functional tooling into engineers’ hands in days rather than weeks.

  • Ithaca, NY led CNC fixture development for durable, repeatable tooling that could withstand production-line use.

  • Denver, CO produced precision gauges, nests, and machined setup hardware with the tight tolerances required for secure communications assemblies.

  • Round Rock, TX supplied fabricated carts, panels, and line-support equipment sized for pilot builds and low-volume production runs.

  • Across all four sites, ±«Óătv delivered documentation packages focused on repeatability and receiving-friendly inspection records, so each fixture arrived production-ready, not just prototype-ready.

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The Results

  • By combining additive speed with CNC precision and sheet metal scale, ±«Óătv cut the company’s NPI cycle time and eliminated the tooling bottlenecks that had been delaying program milestones.

  • Rework caused by improvised or poorly fitting assembly aids dropped significantly, and first-pass assembly readiness improved across multiple product lines.

  • Rework caused by improvised or poorly fitting assembly aids dropped significantly, and first-pass assembly readiness improved across multiple product lines.

  • Just as importantly, the company avoided over-investing in expensive hard tooling during the early stages of production.

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