Case Study

Clayton Associates

Reliable design for manufacturing (DFM) solutions are valuable for many organizations who need assistance ensuring their product design concepts can be molded repeatedly and efficiently. See how Flexcraft worked with their customer to provide a reliable end-product for Clayton Associates.


Clayton Associates is a manufacturer of HEPA vacuum systems and source capture tools used to control worker exposure to toxic metals and dust during the manufacture and maintenance of aircraft, vehicles, and watercraft. Offering an extensive line of aerospace quality DA and orbital sanders, Clayton Associates is known for dust control solutions for industries such as military and aerospace.


Clayton Associates contracted Flexcraft early in the design stage of their project to provide critical design for manufacturing (DFM) assistance. Flexcraft worked directly with Clayton Associates to help them optimize the parts for the molding process. This collaboration was critical in order to eliminate potential problems before the process of building the molds even began.


In effort to design quality components at a lower cost, the Flexcraft team worked seamlessly with Clayton Associates to conceptualize their new vacuum system until the product was ready and approved to be manufactured. The solution required various components including a thick-walled polycarbonate vacuum canister, multiple injection molded components and secondary operations including ultrasonic welding for assembly.


Since the design for manufacturing occurred early in the design process, before tooling began, the entire process went smoothly with a moldable end product. By working with Flexcraft as their single source supplier, Clayton Associates was able to take advantage of tooling, molding, decorating and assembly services, all under one roof! Plus, Flexcraft was able to include key stakeholders throughout the process from conception to production, making communication a seamless experience.

As a result, Flexcraft successfully helped another client bring their product from concept to production. Clayton Associates was pleased with the end result: The Scorpion Handheld HEPA Vacuum.

As an ISO 9001:2015 certified plastics molding company, our design for manufacturing quality assurance department and production personnel work directly with customers to ensure they consistently receive the highest quality products possible.

Are you looking for a design for manufacturing solution for your next design?

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