From Inquiry to Delivery

A transparent, step-by-step manufacturing workflow engineered for precision, predictability, and partnership. See exactly how we bring your components to life.

A Structured Path to Production

Every project follows a proven 6-phase methodology designed to eliminate bottlenecks, ensure first-pass quality, and deliver on schedule.

1
Day 1-3 Engineering Discovery

Discovery & Technical Review

Your project begins with a dedicated engineering liaison. We review your CAD files, material requirements, tolerances, and volume targets to establish feasibility and baseline costing.

  • DFM Assessment
  • Material Specification
  • Capacity & Timeline Planning
  • Transparent Quotation
2
Day 3-7 Optimization Design

Design Optimization & DFM

Our engineering team refines your geometry for manufacturability. We identify cost-saving adjustments, reduce machining time, and enhance structural integrity without compromising function.

  • Geometry Optimization
  • Tolerance Rationalization
  • Cost-Reduction Strategies
  • Revised CAD Submission
3
Day 7-14 Validation Prototyping

Prototyping & First Article Inspection

Before full production, we produce engineering prototypes. Each undergoes First Article Inspection (FAI) with comprehensive dimensional reports and material certification.

  • Engineering Samples
  • FAI Report (AS9102)
  • Fit & Function Testing
  • Design Sign-Off
4
Day 14-18 Setup Tooling

Production Setup & Tooling

We program CNC machines, fabricate custom fixtures, and calibrate quality checkpoints. Our lean manufacturing approach ensures rapid changeovers and consistent repeatability.

  • CAM Programming
  • Custom Fixture Design
  • Process Validation (PPAP)
  • Operator Briefing
5
Day 18+ Manufacturing Scale

Full-Scale Manufacturing

Production runs across our automated cell network. Real-time monitoring tracks spindle health, cycle times, and scrap rates. You receive weekly production dashboards and milestone updates.

  • High-Volume Machining
  • In-Process Quality Checks
  • Progress Reporting
  • Scrap Control (<0.5%)
6
Final Stage Logistics Delivery

Final Inspection & Global Shipping

Every batch undergoes final QC. Components are professionally packaged, serialized for traceability, and shipped via your preferred logistics partner with complete documentation.

  • Final Dimensional Audit
  • Material Certs (Mill Reports)
  • Climate-Controlled Packaging
  • Customs & Tracking Docs

Quality at Every Phase

Inspection isn't an afterthought. It's embedded into our workflow to prevent defects before they occur.

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CMM Verification

3-axis to 7-axis coordinate measuring machines validate complex geometries against GD&T specifications.

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Metrology Lab

Optical comparators, laser scanners, and surface roughness testers ensure micron-level accuracy.

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Full Traceability

Every part is logged with lot numbers, heat treatments, and operator sign-offs for complete audit readiness.

What Clients Ask About Our Process

Typical engineering prototypes are delivered within 5-10 business days, depending on material availability and complexity. Emergency fast-track options are available with 48-72 hour turnarounds for critical projects.
We strongly recommend finalizing designs during the DFM phase to avoid retooling costs. However, minor adjustments can be accommodated with updated CNC programs. Major geometry changes require a formal engineering change order (ECO) and may impact timelines.
Every shipment includes a packing list, certificate of conformance, material mill reports, heat treatment records (if applicable), and full FAI/dimensional inspection reports. Digital archives are also stored in your client portal for easy retrieval.
We operate under strict NDAs and ISO 27001 information security protocols. Your CAD files and specifications are stored on encrypted, access-controlled servers. We never share your designs with third parties or use them for other clients.
MetalCore specializes in low-to-high volume manufacturing. Our MOQ starts at just 10 pieces for CNC machining and sheet metal. Injection molding and die casting typically have higher initial tooling costs but become highly economical at 500+ units.

Ready to Streamline Your Production?

Upload your prints or CAD files today and receive a detailed engineering assessment within 24 hours.