CONTRACT MANUFACTURING
We provide in-house assembly services
Our 13,500 sq.ft facility includes a dedicated assembly and fabrication area that can be adapted to low-mid sized production runs as required. We can bridge the gap between ‘alpha’ build and volume production for your product.
Being in such close proximity to the assembly area means challenges can be addressed extremely quickly and efficiently!
Validated Tier 1 Automotive vendor and ISO-9001 certified with proven QMS process resulting in your product produced properly within budget and on time.
Additional assembly staff can be quickly contracted to meet the projects needs.
PRODUCTION SET UP + MANAGEMENT
Vendor sourcing + logistics
We have established a wide reaching network of qualified suppliers to meet your product’s needs. We are constantly updating the list to ensure you receive competitive pricing.
We have experience with an array of overseas and North American vendors for both fabrication and hardware. They are selected and verified by our Vendor Approval Process and re-evaluated based on tried-and-true performance.
Document controls
At Tensen Design + Manufacturing we can adhere to your company's document control system as required. Our Quality Management System (QMS) is ISO 9001:2015 certified.
Quarantine + RMA Process
Vendor defects, returns and replacements are managed by our robust RMA (Return Merchandize Authorization) process. While our proven Quarantine process can efficiently identify and resolve production line issues and perform in-house Rework changes and ECO modifications.
DESIGN DRIVEN RESULTS
QUALITY MANAGEMENT SYSTEM (QMS)
As a Tier 1 supplier with decades of design and manufacturing experience, Tensen Design + Manufacturing offers a robust, ISO 9001-certified Quality Management System that has stood the test of time across diverse market verticals, including Industrial, Consumer, Automotive, Medical, and more.
By partnering with Tensen, you can rest assured that our ISO 9001-certified QMS will ensure your product meets the highest standards of quality and compliance, no matter the industry.
QUALITY OBJECTIVES
CERTIFIED TIER-1 AUTOMOTIVE SUPPLIER
IN-HOUSE CONTRACT MANUFACTURING
FINAL ASSEMBLY:
Our commitment to seamless coordination and strategic collaboration ensures that your product is assembled in proper sequence and validated to your specifications.
ASSEMBLY TRACKING:
Critical steps and completion verification are tracked and sign off at every station. We take pride in our work and take accountability if an issue does occur.
TESTING / EOL:
We provide End Of Line (EOL) testing, Final Product Approval (FPA) services and can build your product to industry standards and restrictions.
PACKAGING:
Our design team offers custom packaging design, testing and graphic design services. We provide vendor sourcing and can co-ordinate production of shipping materials and implement sealing and shrink wrap systems.
CUSTOMIZED MATERIAL HANDLING SYSTEMS
FLOWRAIL SYSTEM
Custom Material Handling System:
We can design and build custom material handling systems to meet your production needs.
Based on timelines, quantities and budget, we can incorporate palette roller systems with speed dampeners, laneway barriers, and hard stop mechanical systems to improve loading efficiency and safer handling.
Our Palette Tracking and Inventory system allows for real time snap shot of where your parts and goods are stored.
VALIDATED NETWORK OF VENDORS + SUPPLIERS
MANUFACTURING TECHNOLOGIES + EXPERTISE
Plastics and Elastomerics:
-Injection molding (single / multi cavity)
-Reaction injection molding
-Additive manufacturing (3D printing)
-Thermoforming, including twin-sheet
-Vacuum forming
-RTV molding for soft components
-Casting / Die Casting
-CNC milling
Metal components:
-Sheet metal fabrication technologies
-CNC milling
-Casting / Sand Casting
-Extrusion
-Laser + Waterjet Cutting
INJECTION MOLDING
INJECTION MOLDING:
We bring decades of unparalleled experience and battle scars, allowing you to navigate through the sometimes costly journey (if not done correctly) of production tooling.
Injection molding melts plastic granules, and injects them into a mold under pressure.
Precision and repeatability define this process. It can produce complex geometry, and is best for large production runs.
Injection molding is ideal for electrical and medical parts, where high precision is paramount.
PLASTIC MOLDING PROCESSES
In addition to Injection molding, there are other plastic molding processes to consider.
Extrusion: Melted plastic pushed through a Die and cut to length.
Blow Molding: commonly used for bottles and containers
Compression Molding: Powdered or granulated plastic placed into a mold where heat and pressure is applied
Thermoforming: Heated plastic sheets vacuum formed over a mold.
Rotational Molding: Powdered plastic transferred to a mold which can rotate while heat is applied to melt the plastic.
Choosing the right process will depend on:
> Material requirements
> Size of the part
> Part complexity and shape
> Number of parts required
> Budgetary and timeline restraints
OVERMOLDING
Rigid base substrate is created, then put into a second mold to be covered by a softer outer layer. It is often used to produce hard plastic parts with a more pliable covering.
Since Overmolding can be done with injection molding machines, it is a more flexible process than two-shot molding.
Two-Shot Molding:
Involves two different injected materials, but one specialized, rotating mold machine.
Two-shot is best for high-volume production, due to machine complexity.
It has shorter cycle times than overmolding. The bond between materials is stronger.
THERMOFORMING
Thermoforming:
A process that heats a plastic sheet, forms it over a mold, and cools it into shape. It uses thermoplastics, like polypropylene, ABS, polystyrene, PETG, and polycarbonate.
Of the many thermoforming processes, the most common are:
Vacuum Forming:
Uses vacuum suction to pull a heated sheet of plastic over a mold. It is efficient and cost-effective, but less detailed than pressure forming
Pressure Forming:
Positive pressure is used to force a heated sheet of plastic onto a mold. It allows for tighter tolerances and more detail than vacuum forming.
SHEETMETAL FABRICATION
The process of creating three-dimensional forms (or cut shapes) out of flat metal sheets.
Working closely with our validated network of vendors, we have decades of experience in designing, testing and assembling sheet metal parts.
Whether for internal structure and shielding functions, or for external show surface enclosures, we can accurately create your parts using Solidworks 3D CAD.
Our knowledgeable and dedicated team have designed parts for many industries such as medical, automotive, aerospace, electronics and consumer goods.
Depending on your product and functional needs, sheet metal fabrication can offer an inexpensive, quick and efficient solution.