Concepts to hardware — Unshared and Onshore.
DFM specialist in concentrate vaporization, ceramic heaters, and complete device architecture with rapid prototyping and multi-material expertise. Pre-prototype through Production.
- DFM — Geometry simplification & cost hotspots.
- Materials — Metals, ceramics & advanded plastics.
- Ceramics — Porous bodies, heater integration & reliability.
- Vapor — Atomizers, cartridges & full devices.
- Pilot Builds — Prototype runs, fixture design, DOE, CTQs.
- Regulatory — Traceability, contact rules, doc controls.
Concentrates & Ceramic-based Vaporization
We optimize parts and assemblies touching concentrates: heater substrates, contact pins, insulators, seals, housings, and precision machined components. Target: robust yield at scale with rigorous CTQs.
Heater stacks
Ceramic substrate geometry, vias, metallurgy, resistive patterning interfaces.
Flavor & Safety
Material compatibility at temperature, surface prep, and cleanability.
Sealing
O-ring & press-fit design, leak paths, and capillary control.
Our Process
- Discovery — objectives, constraints, compliance.
- DFM deep-dive — geometry, tolerances, materials, risk/cost map.
- Prototype & fixtures — iterate quickly with measurable CTQs.
- Pilot → production — yield tuning, documentation, transfer.
CAD/CAM: SolidWorks • Mastercam • GD&T • DOE • SPC • PPAP-style docs
Services
DFM Consulting
Part consolidation, datum strategy, tolerance allocation, and cycle-time drivers.
Device Architecture
Thermal path, airflow, wicking, and assembly sequence design.
Ceramics
Compression molding, green machining, sintering allowances, QA strategy.
Precision Machining
3- to 5-axis, electrode graphite, stainless, aluminum; fixtures & tooling.
Pilot & Ramp
DOE, CTQs, yield tuning, incoming inspection, and documentation.
Supply Transfer
Bid packs, drawings, tolerances, control plans, and supplier onboarding.
Start a DFM review
Email contact@dfmskunkworks.com with a brief on current challenges and target volumes. Optional: include STEP + PDF prints.