Onset Engineering(949) 446-9456

From drawing to parts. Fast.

One Irvine shop for the enclosure, the overmold, the cable harness, and the box build. Design, 3D printing, molding, and 100% electrical test, from prototype to production. Pickup on the floor, or we ship. ITAR registered.

THE SHOP

An engineer at a white bench soldering a wired assembly under a task lamp, with power supplies and hand tools beside the work.
Soldering on the bench
An engineer working at a computer in the shop, with a rack of desktop 3D printers behind him.
Print cell

CAPABILITIES

02 / PROTOTYPING

Hold it in your hands

  • Large-format FDM and SLA
  • Silicone and urethane casting
  • Injection molding
Materials and build sizes

03 / PRODUCTION

Build the harness and the box

  • Cable assemblies and wire harnesses
  • Custom overmolding and box builds
  • 100% electrical test
Assembly and 100% electrical test

CABLE ASSEMBLIES

One roof, from the connector to the box.

Design the enclosure, 3D-print or mold the housing, custom-overmold the connector and strain relief, then build and 100% electrically test the harness and the electromechanical box. Prototype through production, without a high minimum.

Cable assemblies and wire harnesses
A coil of gray overmolded multi-pin circular cables with part labels, on a table in front of the Onset Engineering wall sign.
Overmolded circular cables
A multi-branch wire harness on a wood bench, with circular metal backshells, a ribbon breakout, and crimped and ferrule terminations.
Multi-branch wire harness

DESIGN

From the model.

New product development and design for manufacturing, taken through to a part the shop can mold.

Medical connectors and drawing standards
CAD render of a molded enclosure with a translucent cover, internal contacts, and a straight connector.
Molded enclosure, design model

PROTOTYPING

In hand.

Printed prototypes, fit on the bench before a casting or a mold.

Materials and build sizes
Hands assembling blue 3D-printed prototype parts on a shop bench, with more printed pieces stacked nearby.
Fitting printed prototypes

PRODUCTION

On the press.

Molded parts, harnesses, and box builds from the Irvine floor.

Print, build, and test
An inspector at a vertical molding machine checking a small molded part, with finished housings on the press table.
At the molding press
A batch of identical green terminal-block assemblies with red, black, and white wires, laid out on a workbench.
Terminal-block assemblies
Green terminal blocks mounted in a black enclosure, wired with red and black leads and marked with white labels.
In an enclosure
A wired terminal-block harness with red, black, white, and green leads.
Wired harness

3D PRINTING

3D printing, quoted the same day.

Extra-large FDM, and SLA when the part needs a finer surface. Send STL, 3MF, STEP, or SolidWorks, or a drawing or sample if that is what you have. Quotes the same day. Most prints in two business days.

Send a schematic, wire list, pinout table, BOM, PDF drawing, STEP, STL, 3MF, or SolidWorks file. A physical sample cable or part is enough to reverse-engineer and replicate.

Materials and build sizes

FDM — large format, up to 47 x 23 x 31 in

2 business days$150

SLA — up to 145 x 145 x 175 mm

2 business days$200

Casting — silicone / urethane, printed mold

2–3 weeks$500 + tooling

Injection molding — aluminum or steel mold

3–4 weeks$1,000 + tooling
A person holding a large gray 3D-printed panel. The full panel and the person are in frame, so the size of the print is clear.
Extra-large FDM panel

LARGE FORMAT

Extra-large FDM.

Panels and parts up to 1200 x 600 x 800 mm (47 x 23 x 31 in), the size of a panel you can hold in front of you.

SLA is for surface finish and detail, up to 145 x 145 x 175 mm.

PRINTED PARTS

A 3D-printed film-holder fixture with a blue geared roller, a gray frame, and two mounting brackets.
Film holder fixture
Gray 3D-printed handle parts with metal threaded inserts, laid in a row.
Handle parts
A white 3D-printed housing standing on the print bed of a 3D printer.
Printed housing
A black 3D-printed bracket formed as a curved arch.
Printed bracket
A gray 3D-printed mounting base with a circular seat, side brackets, and bolt holes.
Mounting base