Engineered to enable high-volume one-off product customization through intelligent material handling, advanced laser processing, and scalable automation
A leading consumer products manufacturer sought to expand into direct-to-consumer customized products but faced significant limitations with its existing manufacturing process.
The company’s products required laser ablation of painted stainless-steel surfaces to create custom graphics, logos, and personalized designs. Existing operations relied on highly manual processes that were optimized for large production runs featuring a single design across many products. Frequent changeovers and manual handling made low-volume and one-off customization economically impractical.
To support business-to-consumer growth, the manufacturer needed a solution capable of producing thousands of uniquely customized products per shift while maintaining product quality, operational efficiency, and profitability. The system also needed to support a wide variety of product sizes and geometries while providing the flexibility to accommodate future process refinements and product expansion.
Compounding the challenge, the selected manufacturing process relied on Class IV laser technology, requiring strict safety controls and specialized engineering to protect operators while maintaining production throughput.
The client partnered with Re:Build DAPR to develop a fully automated laser etching platform capable of transforming one-off customization into a scalable manufacturing operation.
Re:Build DAPR began the project by evaluating manufacturing workflows, material handling requirements, laser processing constraints, and throughput objectives to develop a system architecture capable of supporting large-scale customization.
A major focus of the project involved optimizing product flow throughout the facility. The engineering team analyzed multiple intelligent conveyor configurations and performed vehicle traffic management studies to determine the most efficient system layout while minimizing equipment cost and floor space requirements.
Because the process relied on Class IV laser technology, Re:Build DAPR conducted extensive research into laser safety requirements and developed a comprehensive approach to operator protection, process containment, and equipment integration. Multiple concepts were evaluated, including individual laser-safe workcells and larger enclosed processing environments, ultimately resulting in a solution that balanced safety, flexibility, and cost.
The team also addressed significant uncertainty surrounding laser operating parameters. Because the selected laser technology had not yet been fully characterized for the client’s products, the system was engineered with substantial adjustability to accommodate future process optimization without requiring major equipment modifications.
Re:Build DAPR designed and delivered a fully integrated laser etching automation platform that combined intelligent conveyance, laser-safe processing environments, custom workholding solutions, and advanced motion control technologies.
At the heart of the system was an intelligent conveyor architecture capable of dynamically routing products through multiple laser processing stations. The approximately 50-meter conveyor system provided precise product tracking, efficient traffic management, and continuous material flow throughout the manufacturing process.
The automation platform incorporated four laser etching workcells housed within a laser-safe processing environment. Each workcell was designed to support both single-sided and dual-sided etching operations, allowing products to receive custom graphics on one or both sides without additional handling.
To enable dual-sided processing, Re:Build DAPR developed a custom lifting and rotation mechanism capable of raising products into position for laser processing and rotating them 180 degrees between etching operations. This innovative approach allowed both sides of a product to be processed within a single automated cycle.
The system also incorporated a custom universal nesting platform capable of securely handling more than 25 different product configurations. Extensive motion studies, timing analysis, and engineering validation ensured products remained stable throughout transport, acceleration, deceleration, and processing operations while maximizing throughput and system efficiency.
Re:Build DAPR successfully delivered an automation platform that enabled the client to launch a profitable direct-to-consumer customization business that had previously been impractical using manual methods.
The completed system exceeded the client’s throughput target of 4,000 uniquely customized products per eight-hour shift while providing the flexibility to process individualized customer designs with minimal operational disruption. The automation platform transformed customization from a labor-intensive process into a scalable manufacturing capability.
In addition to throughput improvements, the solution introduced comprehensive product digitalization and tracking capabilities that improved operational visibility and downstream manufacturing processes.
Although project schedules were impacted by broader industry supply chain delays, the completed system ultimately performed as intended and delivered a strong return on investment. According to the client, the automation platform has proven highly successful and continues to provide significant value through increased customization capabilities and expanded market opportunities.
The laser etching system included:
Let’s talk about your unique challenges and how Re:Build DAPR can help you.
