US Robotics Startup: 5-Axis CNC Brackets in 6 Weeks, Zero Rejects

The challenge

A Boston-based Series B robotics startup needed 50 functional 5-axis CNC brackets for a Series C investor demo in 6 weeks, then ramp to 800 pieces/month for pilot deployments. Their previous US supplier quoted 14 weeks for first articles and 18 weeks for production capacity.

Critical: no design changes allowed after prototype sign-off (would require re-validation of the robot's safety-rated subsystem).

Our approach

We ran a 4-hour video-call DFM review with the customer's mechanical lead within 48 hours of receiving the STEP file. Identified 2 design changes that would eliminate tool-change delays:

• Eliminated one undercut → switched to 5-axis-accessible geometry (no EDM)
• Standardized 3 thread callouts to off-the-shelf helical inserts (vs custom thread-milling which required a slower spindle)

Customer approved both changes. We started prototype machining on day 5.

Results after 8 months of production

• Week 3: 50 functional prototypes delivered & accepted (DFM changes caught the would-be tooling issues)
• Week 6: Pilot batch of 100 pieces delivered, customer signed off
• Week 8: Production at 800 pieces/month running smoothly, no design changes
• 6,400 parts delivered across 8 batches: zero defects
• Cpk: > 1.67 on all 5 critical dimensions (vs customer's minimum requirement of 1.33)
• Outcome: Customer hit Series C milestone, raised $45M, now on 2,000 pieces/month volume with us

Why the timeline worked

1. DFM review was synchronous, not async — a 4-hour video call, not 6 rounds of email comments on a PDF
2. 5-axis capacity in-house — no need to subcontract complex feature operations, no wait time on a partner shop's schedule
3. English-speaking project engineer assigned full-time — same person from RFQ through production ramp