Reverse Engineering
We specialize in reverse engineering, leveraging advanced technology and precision tools to recreate and improve upon existing designs. Utilizing the cutting-edge Hexagon Geomagic Design X software in conjunction with the 3D Systems Geomagic Capture Desktop 3D Scanner, we ensure high accuracy and detail in all our reverse engineering projects. Additionally, we employ a variety of standard measuring instruments, including calipers, micrometers, depth gauges, and radius gauges, to guarantee precision in every aspect of our work.
Our expertise in reverse engineering spans a wide range of applications, from plastic molds for the food processing industry and firearm components to safety equipment for emergency vehicles. We also specialize in creating both small prototype and large production molds for soft fishing baits, as well as components for race cars. Our diverse experience ensures that we can meet the unique needs of any project, delivering custom solutions that are tailored to our clients’ specifications.
Product Design
We specialize in the precision design of parts, assemblies, and technical drawings, utilizing the industry-leading SOLIDWORKS 3D CAD Design Software. Our team brings decades of manufacturing experience to the table, ensuring that every project we undertake is guided by the principles of design for manufacturing (DFM) to guarantee efficiency and quality.
Our expertise spans a wide range of product designs, including custom plastic molds for the food processing industry, intricate firearm components, advanced safety equipment for emergency vehicles, innovative prototype molds for soft fishing baits, high-volume production molds for fishing baits, and specialized race car components. No matter the complexity or diversity of your project, our skilled professionals are equipped to deliver exceptional results tailored to your needs.
CNC Programming
Our expertise in CNC programming and machine simulation is anchored in our extensive use of CAMWorks software, with its advanced features including automatic feature recognition, intelligence-based machining, and the TechDB for capturing best practices, our programming time is cut dramatically, and machining cycles are optimized—helping us to achieve faster turnaround and higher productivity.
As a CAMWorks reseller and a dedicated machining facility, we possess deep knowledge in programming a wide array of CNC machinery. Our proficiency covers 2-axis lathes, 3 to 5-axis mills, 4 to 6-axis mill/turn machines, multi-task machining centers, Swiss-style lathes, and Wire EDMs. We have successfully programmed components in materials such as aluminum, brass, bronze, plastics, and stainless steel, catering to a diverse range of industries including aerospace, defense, firearms, food processing, industrial, manufacturing, recreational, and safety.
CNC Machining
For CNC machining, we use a Haas DM-2 Vertical Machining Center with Haas TRT160 5th Axis Rotary Table, and a 3-axis Haas VF2-SS Vertical Machining Center, both with optional 50,000 rpm Air Turbine Spindles. We have machined parts from aluminum, brass, bronze, plastics and stainless steel for the aerospace, defense, firearms, food, industrial, manufacturing recreational and safety sectors.
Morningstar has produced part lots as small as 1 to as large as over 20,000 items. Almost every item we use in our manufacturing processes is built and assembled in the USA from American components. We have machined parts from aluminum, brass, bronze, plastics and stainless steel for the aerospace, defense, firearms, food, industrial, manufacturing recreational and safety sectors.
Manual Machining
For manual machining, we use a Sharp LMV-50 3 HP Vertical Milling Machine with an Acu-Rite digital readout (DRO). Optional items include a Vertex right angle head attachment, Kurt DX6 and Kurt DX4 vises and a Kurt Sidewinder vise.
Part Inspection
For part inpection, we employ Renishaw probing on both of our Haas vertical milling machines, precision height stand with .0001 dial indicator, precision depth gauges, precision calipers, precision micrometers, thread gauges, gauge blocks and gauge pins.