Our structured development process delivers custom weighing solutions from concept through production with predictable timelines and outcomes.
Phase 1: Discovery and Requirements Definition
Application Review: We meet with your engineering team, mechanical, electrical, and controls, to understand the equipment, its intended use, and the role weighing plays in its operation. Understanding not just what you need to measure but why you need to measure it helps us engineer solutions that address your actual requirements.
Load Analysis: Define expected load range (minimum, nominal, maximum, and overload), load directions including primary and parasitic forces, and dynamic factors including impact frequency, vibration spectrum, and cycling expectations over the equipment’s service life.
Environmental Specification: Document operating environment including temperature range (both ambient and equipment surface), moisture/humidity exposure, dust and particulate characteristics, chemical exposure, vibration levels and frequencies, shock magnitudes, UV exposure for outdoor equipment, and any hazardous area classifications requiring certified equipment.
Accuracy Requirements: Define required accuracy class and verification method, resolution, linearity, repeatability, hysteresis, and temperature effects. Accuracy requirements should consider both the measurement precision needed and the operating conditions under which that precision must be maintained.
Interface Requirements: Specify electrical outputs (analog, digital, or wireless), communication protocols, connector types, cable lengths and routing, and integration with machine control systems. Define data formats, update rates, and any special requirements for your control system integration.
Physical Constraints: Review available mounting space including envelope dimensions and access clearances, structural interfaces including mating surfaces and fastener patterns, access requirements for installation and future service, and any constraints on weight or form factor.
Deliverable: Detailed OEM Requirements Specification document capturing all technical requirements in a format that drives design decisions and serves as the basis for verification testing.
Phase 2: Concept Design and Proposal
Concept Development: Our engineering team develops one or more concept designs addressing the requirements, evaluating trade-offs between cost, performance, complexity, and risk. Multiple concepts may explore different sensing approaches, materials, or configurations to identify the best balance for your application.
Preliminary Analysis: Initial FEA and engineering calculations verify that concepts will meet capacity, accuracy, and fatigue life requirements. Preliminary analysis identifies technical risks early, when design changes are inexpensive.
Concept Review: Present concepts to your team with preliminary drawings showing configuration and interfaces, specifications documenting expected performance, and cost estimates enabling business case evaluation. Gather feedback on concept direction, identify concerns, and refine approach based on your input.
Deliverable: Concept Design Package with preliminary drawings, specifications, and proposal/quotation for your review and approval before proceeding to detailed design.
Phase 3: Detailed Design and Analysis
Mechanical Design: Detailed 3D CAD modeling of load cells, mounting hardware, and mechanical interfaces. GD&T-toleranced drawings for all components define the precision required for manufacturing and enable verification through inspection.
Strain Gauge Layout: Precise positioning of strain gauges to maximize signal from the load you want to measure while minimizing sensitivity to off-axis loads and temperature effects. Gauge placement optimization is critical for achieving specified accuracy under real-world loading conditions.
FEA Validation: Detailed stress analysis under all load cases, normal operation, overload, shock events, and thermal loading. Fatigue analysis for cyclic loading applications predicts service life under expected duty cycles. FEA validation confirms that the design will meet performance requirements before committing to prototype manufacturing.
Electrical/Electronics Design: Signal conditioning circuit design optimized for your accuracy and environmental requirements. Connector and cable specification ensuring signal integrity through the measurement chain. EMC considerations preventing interference from affecting measurements or equipment affecting other systems.
Design Review: Formal design review with your engineering team before releasing for prototype manufacturing. Design review confirms that the detailed design meets your requirements and provides opportunity for refinement before building hardware.
Deliverable: Complete Design Package including drawings, specifications, FEA reports, and bill of materials documenting the design for manufacturing, testing, and future reference.
Phase 4: Prototype Manufacturing and Testing
Prototype Build: Manufacture prototype quantity (typically 1-5 units) using production-representative processes. Prototypes should represent production intent so that testing validates not just the design but the manufacturing approach.
Factory Calibration: NIST-traceable calibration of each prototype unit documenting linearity, hysteresis, repeatability, and zero/span stability. The data provides baseline performance documentation and identifies any units with anomalous characteristics.
Environmental Testing: Temperature cycling across the specified operating range verifies that compensation maintains accuracy through thermal extremes. Vibration and shock testing confirms survival of mechanical environments. Other environmental tests as required by application, humidity, salt spray, dust exposure, or chemical resistance.
Integration Testing: Install prototypes on your equipment for real-world validation. Support your team during integration with technical assistance, troubleshooting, and optimization. Integration testing reveals issues that laboratory testing alone might miss.
Deliverable: Prototype units for your evaluation, calibration certificates documenting performance, and test reports comparing results to requirements.
Phase 5: Production Release and Ongoing Supply
Design Finalization: Incorporate any changes from prototype testing and integration experience. Finalize drawings and specifications for production release. Design finalization locks the configuration for production manufacturing.
Production Documentation: Manufacturing procedures ensuring consistent production. Quality control plans defining inspection points and criteria. Inspection criteria for accepting or rejecting production units. These procedures are for production-floor calibration.
First Article Inspection: Complete inspection and documentation of first production units verifying that production processes produce conforming parts and that production units match prototype performance.
Supply Agreement: Establish pricing, lead times, minimum order quantities, blanket order options, and quality requirements. Supply agreement defines the ongoing commercial relationship for production supply.
Technical Support: Ongoing engineering support for your production and field service teams. Design updates as your equipment evolves, new variants, capacity changes, or interface modifications to support product development.
Deliverable: Production supply with documentation, certifications, and ongoing technical support throughout your product’s life cycle.