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Production-Readiness Fixtures and NPI Hardware for Defense Communications

Fathom Helps a Satellite Communications Leader Accelerate the Path from Design to Production
  • Defense Contractor

    Client

    Defense Contractor

  • Aerospace & Defense

    Industry

    Aerospace & Defense

  • CNC Machining, Quick-Turn Sheet Metal Fabrication, Prototyping, Design for Manufacturability, Kitting & Assembly

    Capability

    CNC Machining, Quick-Turn Sheet Metal Fabrication, Prototyping, Design for Manufacturability, Kitting & Assembly

Overflow Capacity
Reduced Schedule Drag
Improved Field-Install Consistency

Closing the Gap Between Design and Production for Secure Communications Hardware

A leading  was under pressure to move new secure communications and antenna system designs into production faster. But small-volume assembly aids, gauges, test stands, and line fixtures kept becoming hidden schedule blockers, even when the core electronics were otherwise ready to ship. Fathom brought four facilities and multiple manufacturing technologies together to delivesatellite communications and defense technology companyr the production-readiness hardware that kept these critical programs on track.

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The Problem

  • The company’s engineering teams were developing secure terminal, ground-station, and defense communications hardware on aggressive timelines.

  • While the electronic designs were progressing on schedule, the physical tooling needed to validate, assemble, and test those designs was not keeping pace.

  • Assembly fixtures, gauges, handling aids, and line-support equipment were being improvised or delayed, creating hidden bottlenecks that threatened delivery dates for high-visibility defense programs.

  • The challenge was compounded by the sheer variety of hardware involved. Each new product introduction required a unique set of fixtures and validation tools—from precision nests and drill guides to setup plates and protective covers.

  • Without a manufacturing partner that could deliver this breadth of NPI hardware quickly and reliably, rework rates climbed and first-pass assembly yields suffered.

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The Solution

  • Fathom deployed a coordinated, multi-site approach that matched each type of production-readiness hardware to the right manufacturing technology and facility:

  • Hartland, WI led fast-turn additive manufacturing for rapid fixture iterations, fit-check tools, and early validation hardware, getting functional tooling into engineers’ hands in days rather than weeks.

  • Ithaca, NY led CNC fixture development for durable, repeatable tooling that could withstand production-line use.

  • Denver, CO produced precision gauges, nests, and machined setup hardware with the tight tolerances required for secure communications assemblies.

  • Round Rock, TX supplied fabricated carts, panels, and line-support equipment sized for pilot builds and low-volume production runs.

  • Across all four sites, Fathom delivered documentation packages focused on repeatability and receiving-friendly inspection records, so each fixture arrived production-ready, not just prototype-ready.

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The Results

  • By combining additive speed with CNC precision and sheet metal scale, Fathom cut the company’s NPI cycle time and eliminated the tooling bottlenecks that had been delaying program milestones.

  • Rework caused by improvised or poorly fitting assembly aids dropped significantly, and first-pass assembly readiness improved across multiple product lines.

  • Rework caused by improvised or poorly fitting assembly aids dropped significantly, and first-pass assembly readiness improved across multiple product lines.

  • Just as importantly, the company avoided over-investing in expensive hard tooling during the early stages of production.

Global Satellite Network Around Earth with Digital Connectivity Lines

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