Over the years, we have engineered, machined, and surfaced numerous patterns using various materials, including MDF, epoxy, and foam boards of different densities and heat resistance levels. This time, the challenge was to machine a large pattern, measuring eight feet in width by twenty feet in length, in our San Clemente shop, ship it to our facility in Tijuana for surfacing and fabrication of the vacuum form tool for production, and deliver the final product to the client’s facility in Mexico. Working under the client’s strict manufacturing guidelines, our teams at both plants collaborated to produce a production tool that is still in use in their manufacturing to this day.