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Fathom operates seven facilities in North America with a focus on four core technologies:
In addition, we offer engineering design and support and a variety of post-processing services.
Fathom delivers value to customers across multiple industries, including:
Yes, rapid prototyping is one of Fathom’s specialties. We can help you iterate your part designs quickly to accelerate your new product development. Rapid prototyping is frequently used to produce visual prototypes and concept models, to validate the form, fit and function of part designs and to create marketing models.
Our services also include bridge manufacturing. Producing an initial lower quantity of parts can help you solve several common problems, including side-stepping tooling delays, meeting regulatory requirements and conducting market research (if you’re unsure of demand for your new product).
Fathom offers deep engineering and design expertise for all your prototyping and production needs. We conduct DFM analyses that help to identify issues that could affect production. Our experienced engineers are also highly skilled at uncovering more subtle issues – often part geometry-related – that could derail your project. They will make detailed recommendations on optimizing the design of your part and selecting the right material, processes and post-processing steps to help make your project a success.
We operate seven facilities throughout North America. They are:
With 25+ manufacturing solutions, Fathom is one of the largest contract manufacturers in the U.S. While most of our competitors are focused on fast, automated quoting and DFM analyzes, we take a refreshingly different approach:
We call it white glove service.
It’s a hands-on, engineering driven approach that delivers significantly more value to you and results in consistently better project outcomes.
For each project, an experienced engineer will help you to optimize your part designs for manufacturability. We will also recommend processes, materials and finishing options that will meet your cost, timing and performance requirements.
Our extensive U.S. manufacturing base plus our global sourcing network enables you to get more of your part procurement needs met through a single supplier. Our technology-agnostic approach enables us to recommend the most cost-effective manufacturing methods, materials and processes that will help you meet your sourcing objectives.
Yes, Fathom Edgeworks is a strategic sourcing and manufacturing solution that gives our customers the Fathom Edge in navigating supply chain volatility through smarter sourcing and global manufacturing agility. It combines Fathom’s domestic and international manufacturing network with U.S.-based engineering, compliance support and delivery duty paid (DDP) logistics, all under a single, strategic offering.
ICOMold is our overseas partner that provides injection molding, urethane casting and CNC machining services. It has been serving the needs of blue-chip customers for over 20 years. During that time it has built a reputation as a cost-effective source for high-quality injection molded parts.
Fathom Edgeworks provides smarter sourcing and stronger supply chains through:
Our experienced sourcing engineers are experts at helping our customers optimize their part designs for production, manage overseas part production projects and manage all supply chain logistics so they don’t have to.
Fathom has a strong track record of significantly reducing tariff costs on behalf of our customers.
Fathom has been involved in additive manufacturing for over 40 years and continues to be a leader in this space. Our Hartland, WI location is one of the largest additive manufacturing facilities in the U.S. We support six additive technologies:
We also have extensive expertise in post processing and finishing additive parts to enhance their surface finish, performance and aesthetics.
When you award your part-production project to Fathom, you’ll have immediate access to an engineer, who will help you select the right technologies, materials and processes that meet your needs. Using our detailed DfAM process, we’ll help you optimize your part designs for the best results. We’ll work with you from prototyping to production.
The materials available for 3D printing vary by technology. For a complete list, please visit our 3D Printing Materials web page.
Yes, we do. Fathom offers Direct Metal Laser Sintering (DMLS), a popular powder bed-based metal additive manufacturing method. It produces high-quality parts that don’t require sintering and have the mechanical characteristics of cast metal parts.
There are many variables involved in producing affordable 3D-printed parts. They include part design, manufacturing method, material selection, manufacturability and designing efficient manufacturing processes.
Our experienced engineering team can help you optimize all these elements to improve your part quality. We do so using a comprehensive DFAM (Design for Additive Manufacturing) methodology, plus decades of experience solving geometry- and process-related challenges. We know what challenges to watch for based on the geometry of your part.
We can help you achieve the perfect balance of options to produce parts that meet all your requirements. We can also help you avoid headaches that could delay your project.
Most additively manufactured parts, whether they are plastic or metal, need additional post processing before they are ready for use. Some of them come off the printer with a rough or porous surface that isn’t optimal for paint, coating or plating. Other parts require support structures during 3D printing. Once they are removed, they may leave burrs or witness marks that need to be sanded out.
Fully finished parts can include the following:
For more details, visit our Additive Post-Processing web page.
CNC machining is perfect for a wide range of applications. For customers in demanding industries like defense, aerospace, medical and automotive, it meets their need for precision, repeatability and accuracy. For others, it provides a cost-effective way to get the parts they need at a reasonable cost.
Fathom offers a variety of precision CNC machining services, including:
A surprising variety of materials can be milled using CNC machining. The most common is metal, but these other materials can also be machined:
CNC machined parts are used in nearly every industry you can think of. The high level of precision that this manufacturing technology makes possible makes it ideal for high performance applications like aerospace, defense, robotics, medical, automotive and semiconductor equipment manufacturing.
Hiring a contract manufacturer for CNC machining provides cost savings by eliminating the need for expensive equipment, staff and associated facility costs. It gives you the flexibility to scale production up or down as needed, access to specialized expertise and advanced technology and a simplified supply chain and quality control process.
Whether you need small, complex parts like brackets, wire guides, clips and springs, perfectly flat washers, shims and precise filters or large quantities of formed sheet metal panels, housings and enclosures, Fathom does it all.
Our precision sheet metal cutting capabilities include:
Our metal-forming capabilities include:
Our experts have decades of expertise and bring unmatched ingenuity to help you move your sheet metal fabrication projects from prototype to production quickly and cost-effectively.
The most common types produced by Fathom are steel, stainless steel, aluminum and brass. Other types of metals used for sheet metal fabrication include copper, nickel, tin and zinc.
Yes. Several Fathom facilities offer wire EDM cutting as part of their metal fabrication services. We also offer sinker and hole popper EDM. Learn more about these precision cutting technologies on our Wire EDM Cutting web page.
Using a contract manufacturer for sheet metal fabrication offers cost savings, access to specialized technology,and increased flexibility. Companies can avoid the significant capital investment required for in-house production, like machinery and skilled labor, and instead focus on their core competencies.
It also allows businesses to scale production up or down as needed and often leads to faster production times and higher quality through specialized processes and quality control.
Finally, utilizing an experienced outside partner for sheet metal fabrication gives you access to deep expertise that can help you improve the quality of your product.
Injection molding enables the production of many parts, quickly. Family molds or multi-cavity molds can make multiple parts in a single shot, increasing the production rate. This makes it possible to produce large numbers of parts from a single tool. In contrast, 3D printed parts are made one at a time, making it hard to scale up production.
With additive manufacturing, there are strict limits on part build size, based on the size of the build platforms of the 3D printer. With injection molding, there are fewer limits on part size.
A wide variety of plastic materials can be injection molded. Common injection molding materials include a variety of thermoplastics like polyethylene (PE), polypropylene (PP) and acrylonitrile butadiene styrene (ABS), as well as engineering plastics such as polycarbonate (PC) and nylon (PA).
Tools are designed and engineered based on the material they will be molding and the number of shots they will be required to perform. A tool that will be used to create several thousand parts can be built using a less expensive material such as aluminum. One that will be used to make 100,000 parts needs to be made of hardened steel that can withstand the higher number of molding cycles.
Fathom offers a number of options that can enhance your injection molding experience:
Multi-Cavity Molds: These tools can produce multiple copies of the same part in a single shot. They contain multiple runners in cavities that are filled with molten plastic at the same time.
Family Molds: A single tool contains multiple cavities to produce parts that will be used together in an assembly. Each cavity is not identical. A good example is a consumer product that has a clamshell housing that consists of two parts. The family mold contains cavities for the right and left sides of the housing, which will be joined together during the product manufacturing process. Molding them at the same time ensures that they are produced from the same lot of resin and will therefore have exactly the same color.
Insert Molding: During or after the molding process, threaded inserts, pins and other metal pieces are embedded in the plastic part. This makes it easy to assemble it with other components.
Overmolding: During the molding process, two different materials are injection molded adjacent to each other. An excellent example is a screwdriver with a hard plastic handle that has a softer grip molded on top of it.
Yes, we offer urethane casting via our global sourcing network. It’s an ideal way to produce small quantities of parts quickly for functional and cosmetic testing. It’s also commonly used for overmolding to provide a soft surface over a rigid part.
Post-processing services vary by location and technology. But as a whole, Fathom adds value by helping our customers with secondary operations that may include:
In many cases, we perform finishing steps that tailor parts to specific applications and working conditions, such as providing corrosion resistance, wear resistance and IR shielding.
By having Fathom handle these steps, we save you time, money and factory floor space.
There are many variables involved in painting, dying or coating parts to match a specific color or finish. We’ll explore all available options to ensure that the parts we produce will meet your cosmetic and functional expectations.
Yes, many of our facilities assemble parts as part of the post-processing services we provide to our customers.
As an advanced technology-driven manufacturer, Fathom has an established quality policy. It sets a defined framework for overall quality objectives. These objectives outline our commitment to customer satisfaction through Fathom’s comprehensive capabilities, expertise and continuous improvement initiatives.
Learn more about Fathom’s commitment to quality on our Quality Assurance web page.
Fathom maintains several certifications across our nationwide manufacturing network to ensure all parts are produced to exacting specifications and requirements. Fathom’s extensive certifications include ISO 9001:2015, ISO 9001:2015 Design, ISO 13485:2016, AS9100:2016, NIST 800-171 and ITAR.
Our certifications vary by facility. Visit our Certifications web page to view a list of the certifications held by each of our locations.
A growing number of contract manufacturers utilize algorithms and automated approaches to respond to quote requests. But while they may excel at processing standard configurations, they tend to falter when handling complex, customized requirements.
At Fathom, we’re committed to a more human approach. We don’t just manufacture parts, we deliver white glove, expert-driven support that helps you navigate every stage of product development with precision and confidence. From concept to production, our team of seasoned engineers works closely with you to solve problems early, accelerate your timeline and ensure every part meets your exacting standards.
At Fathom, your project won’t be handled by an algorithm or automated system. Instead, you’ll receive hands-on guidance from real experts, starting with a personalized design for manufacturability (DFM) review to identify opportunities for optimization. We’ll help refine part designs, recommend ideal materials and processes, and align production strategies to hit your goals on time and on budget.
When you work with Fathom, you gain a proactive digital manufacturing partner who’s committed to getting every detail right, because we know the difference that true collaboration makes.
When you’re developing a new part, the biggest challenges often aren’t just what to make, but how to make it. Choosing the right process, material or production method can feel overwhelming, especially when speed, cost and quality are all on the line.
Our engineers work alongside you to evaluate your part design, uncover opportunities for improvement and guide you toward the most efficient, cost-effective manufacturing path, whether you’re prototyping, scaling up or somewhere in between.
Our broad portfolio of advanced manufacturing technologies and in-house experts allow us to recommend “best-fit,” solutions for each part, balancing performance, lead time and budget.
White glove service means more than just good customer support. It’s our commitment to delivering expert guidance, proactive communication and hands-on partnership throughout your entire project lifecycle.
In an industry increasingly dominated by automated quoting systems and algorithm-driven design tools, Fathom takes a different approach. Our human-first approach to engineering means every project is reviewed by real experts. They collaborate closely with your team to solve problems early, recommend smarter alternatives and guide design decisions that improve manufacturability, reduce cost and accelerate time to market.
We don’t just produce parts, we help you innovate with greater confidence.
