Consult an Engineer ↗
From process kinematics and 3D simulation to turnkey robotic cells, precision BIW tooling, and in-house CNC sheet metal manufacturing, Draftdu builds high-throughput production systems engineered to perform on the factory floor.
Trusted by Tier-1 automotive and global industrial leaders for serial manufacturing programs
01 / AUTOMATION
Turnkey robotic assembly cells, high-speed rotary indexing dial tables, and continuous linear transfer systems engineered for high-volume serial manufacturing.
02 / TOOLING
Automotive body-in-white geo framing pallets, tabletop hemming tools, robotic gripper assemblies, and CMM dimensional checking fixtures.
03 / MANUFACTURING
6,000 sq. ft. dedicated manufacturing facility (expandable to 12,000 sq. ft.) housing 3kW CNC fiber laser cutting, 3 Meter CNC Press Brake, certified robotic welding, surface treatment and Painting/Finishing.
Electric Vehicles & Clean Mobility
A leading electric powertrain manufacturer required a multi-station automated line to assemble stator cores and insert pre-formed hairpin copper windings under a strict 45-second takt time.
The process demanded zero manual handling deformation, ±12 µm radial insertion clearance, and 100% inline electrical insulation resistance (dielectric) testing before downstream varnishing.
Draftdu engineered a synchronized 6-station rotary indexing assembly cell featuring servo-driven precision insertion tooling, a 6-axis robotic arm with custom vision-guided EOAT for hairpin alignment, and an automated high-potential (Hi-Pot) electrical test station.
We implemented closed-loop force-displacement monitoring on every insertion press and programmed custom safety interlocks with Omron light curtains and Siemens S7-1500 PLC control.
Cycle time was reduced from 68 seconds to 43 seconds (36% improvement), achieving consistent ±10 µm radial concentricity. Over 150,000 stator assemblies have been manufactured with zero field dielectric failures.
Automotive & Body-in-White (BIW)
A tier-1 automotive supplier needed flexible geo-framing and table-top hemming fixtures capable of handling driver, passenger, and rear door assemblies across two vehicle platforms.
Key constraints included maintaining ±0.15 mm spatial tolerance on class-A surface flanges, achieving model changeover in under 2 minutes, and providing complete weld-gun accessibility for 14 robotic spot welds.
Draftdu developed modular geo-framing pallets and multi-point down-holder hemming fixtures built with hardened D2 steel locating blocks, pneumatic toggle clamps with inductive position sensors, and pneumatic quick-connect couplings.
We conducted comprehensive 3D robotic kinematic simulation (OLP) to validate weld gun approach vectors and optimize clamp opening envelopes, eliminating all potential collision zones.
Delivered continuous serial production repeatability within ±0.12 mm across 120,000 cycles. Changeover duration dropped to 90 seconds, and robotic weld reach was 100% verified with zero prototype rework.
We eliminate the costly disconnect between engineering consultants and contract fabricators. By keeping kinematic simulation, detailed CAD modeling, CNC manufacturing, and commissioning within one experienced team, we guarantee accountability at every stage.
Whether you are planning a greenfield automated assembly line, upgrading BIW framing tooling, or requiring high-precision contract sheet metal manufacturing, our engineering team is ready to review your specifications.
