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D8, Inc.

From its 15,000 square foot facility, D8, Inc. — a 17 year-old mold shop based 90 minutes south of Spokane, Washington — not only designs and models molds, but pours metal and does the machining as well. The company has a design department, model and pattern shop, foundry, and machine shop all under the same roof.

Recently, Kurt spoke with SolidWorks Express about D8's decision to use SURFCAM and SolidWorks products.

What challenges led to your decision to use SURFCAM software?

"We have a lot of customers who come to us for protective packaging, and about five years ago we recognized a growing need for organic, 3D shapes. In order to produce these shapes, we moved the company into the world of 3D CAD/CAM by purchasing seats of SURFCAM The part programs produced by SURFCAM are used to drive two Haas machining centers."

How are you using the software?

"SURFCAM has become an integral part of our operation. It has done amazing things for our production schedules. We use it on a daily basis, and so far we haven’t run across a part that we can’t cut. Most importantly, we’re also able to cut parts in the manner that we like. That gives us a lot of confidence when bidding on new work.

What is the benefit of SURFCAM being tightly integrated with SolidWorks?

"We can actually launch SURFCAM right from the SolidWorks environment – that saves us a lot of time and enables us to freely move between the design and manufacturing environment.”

What are the results of using SURFCAM and SolidWorks?
"We're cutting molds and patterns in 50% less time – and more. The difference that this 3-axis machining software has had on our company and its competitiveness has been profound. Our customers’ product development cycles have gotten much shorter and as a result we have less time to produce our molds and patterns. Where we had twelve weeks to work on a job five years ago, today we have just four to six weeks. SURFCAM has played a major role in making that possible.”

Describe the opportunities made possible using SURFCAM and SolidWorks?
"Constantly changing mix of customers, industries demands flexibility, agility. Honestly, we wouldn’t be doing a lot of the jobs that we’re doing today without SURFCAM. It allows us to take on more complicated geometry. One of the major challenges facing D8, beyond foreign competition, is the constantly changing complexion of its customers and work. We used to do a lot of work in the bicycle and motor sports industry. At one time, 40% of our work was creating the molds for the molded foam liners that go inside bicycle and motorcycle helmets. Today, that has dropped to perhaps 5% of our business. However, where one segment of D8’s business has declined, others have grown to replace it. Today, a large portion of our work comes from the personal computer industry. Pick a major brand and there’s a good chance that D8 developed the molds for the molded foam packaging that’s in the box. While most people rifle through the boxes to get to the product inside, we spend our time looking at the protective packaging. We have a huge interest – and expertise – in protective packaging."

What other industries are you exploring thanks to SURFCAM and SolidWorks?
"The shop also does a lot of work in consumer electronics, the marine industry, and, surprisingly, playground equipment. Kids’ playgrounds are home to a lot of complex, 3D shapes these days. Just look at the twisting and turning slides that are on virtually every playground. We do the molds that turn these slide and toys into reality.

Any final thoughts about SURFCAM?
" Advanced technology gives D8 an edge in the marketplace. We’re actually producing molds faster and delivering them at the same price that we did ten years ago. Alot of that is driven by technology. SURFCAM, in particular, has helped us to maintain our prices, despite other rising costs in the industry. We’re under intense pressure from both domestic and overseas competition, but so far we’ve been able to find a way to win.”

Interview with SURFCAM user:

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