THE BEST THINGS IN LIFE

"Helping save lives" is not the first phrase that comes to mind when people think about Dynamic Fabrication Inc.'s (DFI) capabilities. However, the full-service Orange County, CA, contract precision metalworking firm has developed a niche market in the medical industry, creating precision machine parts that help save lives and improve the quality of life, for thousands of patients worldwide.

Founded in 1981 in Santa Ana, CA, DFI specializes in custom fabrication, precision machining, certified welding, and assembly by combining state-of-the art equipment and highly-skilled journeymen to perform a wide spectrum of work that varies from small machined parts to 30 ft long, 15,000 lb weldments.

This plant's quick turnaround on short run items has been its industry niche for more than 28 years. Customers receive same day quotes with the delivery of parts within hours, or one day, of their order. The shop is certified to weld aluminum, stainless steel, 4130, carbon and nickel alloys under stringent quality control that is in accordance with AS9003.

According to Mike Kartsonis, the founder and president of the company, a streamlined shop design enables them to execute fast deliveries of prototype, research and development, and other short run production orders. "Our facility is sectioned off by process and application to ensure that each product is created with accuracy and precision," says Kartsonis. "This layout allows us to work fast and efficiently on jobs, such as missile components, blower housings, tooling fixtures and jigs."

This production timing and top-notch service has made DFI the leading resource for Baxter Healthcare's (Irvine, CA) machining and fabricating needs for nearly 20 years. When a device breaks down, the plant is contacted to conduct an on-site evaluation of the mechanical problem.

A field team of journeymen considers whether the project requires the creation of new parts, or whether the existing parts can be repaired and reused. Depending on the mechanisms involved, this evaluation can often be quickly completed within hours, or may require a slightly longer time.

Kartsonis notes that his company's long-term experience in healthcare evolved into a crew that's highly-skilled and uniquely knowledgeable in fixing devices specific to this industry, such as feeder hoppers, tooling, custom stainless steel belt rollers and guides, among others.

An example of this expertise is their recent involvement assisting Baxter Healthcare with its ambulatory infusion products and elastomeric infusion devices that facilitate forms of infusion therapy to patients across the globe. "When a machine does not work properly, production for antibiotic, chemotherapy and pain relievers is postponed, which affects patients' lives worldwide," states Kartsonis. "We must repair that machine as quickly as possible so patients can receive the critical medicine they need."

The company recently applied its machining expertise when Baxter Healthcare encountered a mechanical failure on one of its salt bath tanks used for administering infusion therapy. The journeymen conducted an on-site inspection of the equipment and possible cause of its failure. A faulty belt roller, worn with extreme wear, was identified as the cause of the belt mechanism becoming misaligned.

The field team returned to the shop to formulate a solution. The next steps included troubleshooting whether the old parts could be salvaged and fixed, or if entirely new parts were needed. Due to the excessive use of the machine and belt roller, six parts needed to be scrapped and developed from scratch out of 316 stainless steel. The new design would be tested for long-term use and the ability to sustain the repetitive motion demanded by the device.

The team measured the specifics of each precision part to create individual blueprints. Using 316 stainless steel, each component was cut, drilled, molded and welded to perfectly fit into the existing mechanism. Stainless steel was chosen specifically for its durability, longevity and compatibility with the device's other parts.

The team faced several hurdles during this process. One involved taking precise measurements from the original broken parts in order to design stronger new parts that would function within the device. The design specs that were crafted required precision tooling and welding applications so that the manufactured pieces would fit perfectly into the existing machine, in addition to being strong enough to provide longevity.

Once the parts were machined and fabricated, an inspection was done to confirm all specs were correct. The team measured each width and height one last time. The six parts were then compared to the original parts and the differences were noted. The redesign improved both the quality and strength of the metal utilized. The precision-tooled parts were also a cost effective approach to obtaining long-term production from the 40 ft long salt bath tank belt roller system.

This turnaround for Baxter's devices encompassed three days, from assessing the project and precision tooling, to final delivery. Baxter's technicians installed the parts to the existing system and production successfully resumed. Kartsonis confirmed the accuracy of the parts and continued success of the machinery by checking with his client periodically during the weeks following delivery.

"This project entailed us assessing the mechanical issues, creating detailed drawings and recording relevant specifics to the job, which eliminated and prevented any issue from occurring," recalls Kartsonis. "If any problems did occur, we would have solved it by evaluating the issue and performing functionality tests."

DFI continues to provide expert fabrication, certified welding and precision machining services to leading companies in the healthcare industry. A noteworthy roster of repeat clients in a variety of other industries includes many Fortune 500 companies and entrepreneurial ventures in the petroleum, transportation, aerospace, entertainment, medical and environmental fields.

Current and past clients include Northrop Grumman, Baxter Healthcare, Lockheed Martin, Amgen, Rockwell, General Electric, Medtronic, Johnson & Johnson, Ceradyne and Toyota Racing, as well as variety of small businesses and mid-sized companies.

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Dynamic Fabrication, Inc., 2615 South Hickory Street, Santa Ana, CA 92707, 714-662-2440, Fax: 714-662-1052, www.dynamicfab.com.