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Prototype & Design

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Prototype and Design Collaboration

Thaler Defense Systems supports early-stage product realization through collaborative prototyping and advanced manufacturing process development. While we are not a design authority, we specialize in transforming customer concepts into manufacturable, production-ready components with speed, precision, and confidence.

We work closely with customer engineering teams to develop prototype parts, offering design-for-manufacturability (DFM) input and process optimization to ensure a seamless transition to production. Our process entails engaging early with the aerospace component design team to assist with material selection while focusing on manufacturability and mission success. We have the flexibility to onboard complex projects while emphasizing the advanced manufacturing technologies that ensure a successful outcome.

Effective project management is a crucial step in aerospace component prototyping. At Thaler Defense Systems, we implement a robust project and process management approach combining early collaboration, unparalleled material expertise and targeted turnkey solutions to be certain our customers get their prototypes on time and to the desired specs. We also ensure the work meets industry standards from prototyping to production.

In the aerospace industry, cross-functional collaboration is essential for optimizing New Product Introduction (NPI) efforts and getting them to market quickly. We manage NPI with a comprehensive, structured end-to-end process that seamlessly integrates key areas, including design, prototyping, manufacturability analysis and production escalation. Our cross-functional teams synchronize their efforts by utilizing advanced digital project management and collaboration tools to facilitate the process.

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Programming Capabilities

Thaler Defense Systems utilizes advanced CAM software platforms—including Siemens NX (Unigraphics), ESPRIT and FeatureCAM—to support complex multi-axis machining and optimize toolpaths for precision, efficiency and repeatability.

Our experienced programming team works directly from customer-supplied models and engineering data, supporting a wide range of file types and CAD formats. We ensure seamless integration between design intent and manufacturing execution, with capabilities including:

  • Multi-axis toolpath programming for 3-, 4- and 5-axis machining

  • Optimization for high-speed machining, tight tolerances and critical surface finishes

  • Support for most native CAD/CAM file formats, including STEP, IGES, Parasolid and native SolidWorks, NX, and CATIA files

  • Close collaboration with engineering teams to enhance manufacturability and reduce lead times

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Partner with Thaler Defense Systems for Superior Defense Solutions

The benefits of choosing Thaler Defense Systems for manufacturing prototyping for the aerospace and defense industry include:

  • Reputable partner: We are an authoritative industry leader that is more than just a machine shop. We’re also a major defense contractor that serves as a trusted strategic partner for OEMs.
  • Unrivaled expertise: Our superior material and process expertise ensures optimal performance for your most demanding programs. Count on us to provide informed recommendations that help you make educated decisions.
  • Turnkey solutions: We offer end-to-end solutions — from prototyping to full-scale production — providing a seamless process that removes the burden from your shoulders.
  • Flexibility: Our ability to onboard complex parts enables us to offer volume-based discounts and scale rapidly from prototype to production.
  • Focus on innovation: Our combination of innovative technology and superior process management enables us to support the Defense Industrial Base and all applicable national security objectives.

How Our Aerospace Prototyping Services Work

Our process begins with coordination between your team and ours to gather any technical data or documentation you have to assist us with prototype development. We can also schedule an optional meeting in person or virtually to review your project requirements. Our business development and engineering teams will then prepare a detailed quote for your review. 

We ensure our process remains confidential and secure. We won’t share your information with anyone.

Reach out today

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We’re always interested in new projects, big or small. Please don’t hesitate to get in touch with us regarding your project. Submit the online contact form or call us at 937-887-4328 to discuss your prototype ideas with our team today.

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