Scaled Production

At DI Labs, we specialize in manufacturing high-performance additive components for production programs. Our process is designed to ensure dimensional stability, functional performance, and repeatable surface finish/color, all while reducing risk and accelerating time to market. We apply a structured, yet flexible approach inspired by the PPAP (Production Part Approval Process), working closely with our clients every step of the way to refine designs and establish a robust production-ready process. While we do not handle final assembly, we support pre-commercialization device development through our structured approach.

Our Process: From Concept to Scaled Production

1. Regulatory & Performance Requirements Definition

• We start by understanding your specific needs, including material properties, tolerances, mechanical performance, and surface finish.

2. Feasibility & Form Fit Testing (PPAP 1)

• We manufacture an initial batch based on your existing design to establish a baseline for evaluation.

3. Engineering Review & Process Optimization

• We work closely with our clients to review initial results, addressing performance, fit, and finish concerns.
• If needed, we refine the design for better manufacturability and performance.

4. Dimensional Validation & Quality Benchmarking (PPAP 2)

• We produce refined samples with a strong focus on dimensional accuracy, consistency, and repeatability under real-world conditions.
• Clients assess these parts for compliance with their quality expectations, evaluating factors such as tolerances, mechanical performance, and surface finish consistency.

5. Design Optimization for Scale 

• Based on feedback, we collaborate on necessary refinements to enhance manufacturability while maintaining performance expectations.

6. Quality Control & Production Readiness (PPAP 3)

• We document key process parameters to ensure repeatability and traceability.
• Approval at this stage enables progression to pilot production.

7. Pre-Production Validation & Scalability Testing

• A larger batch is manufactured under controlled conditions to validate the process and confirm all requirements are met before full-scale production.
• If adjustments are needed, we revisit sample validation before proceeding.

8. Series or Batch Production

• Once the design and process are locked, we manufacture components at the required production volumes with verified consistency.
• Any design or process changes restart the validation cycle to maintain quality.

Why This Process Matters

• Efficiency & Cost Savings – Avoid costly design or production failures through iterative validation.
• Predictable Quality – Ensure components meet industry expectations before scaling.
• Process Reliability – Documented workflows ensure repeatability and traceability for regulatory and production needs.

By taking a systematic approach, we help our clients seamlessly transition from prototype to full-scale production, ensuring successful additive manufacturing for regulated industries.