Rockwell Razor Case Study

The Six Hour Part – “The Rockwell Razor Story”

The Six Hour Part - “The Rockwell Razor Story”

When the savvy pair of 20-something-year-old engineering students behind Rockwell Razors start-up set out to launch a $12,000 kick-starter campaign for their signature Rockwell 6S safety razor, neither one expected to raise nearly $150,000. When these same co-founders partnered with Thuro Metal Products to design and manufacture the handle for this classic but innovative razor, neither one expected to receive a flawless prototype of the finished product within six hours . In both cases, that’s exactly what happened…and thus, the historic Rockwell Razor story was born.

“The Razor That Adjusts To Any and Every Man”

The Rockwell 6S is a re-engineered safety razor, aspiring to be the best razor in the world. Manufactured with stainless steel, it’s durable, hefty and far more precise than anything to be found on the shelf at CVS.  Best of all, the Rockwell 6S was engineered to survive the wear and tear of everyday use, saving men more than $500 per year on replacement razor cartridges.

Innovation is at the heart of the Rockwell 6S, but in order to build something innovative, the co-founders needed an innovative manufacturing process. That’s when the dynamic duo discovered the expert engineers and World Class facilities of Thuro Metal Products.

Rockwell Razor Handle

Rockwell Razor partnered with Thuro to design and manufacture the handle for the Rockwell Razor 6s model.

The Story

The story – which began in late 2014 – unfolded just like any other business collaboration. Morgan Nordstrom, co-founder of Rockwell Razors, undertook the task of developing a U.S.-based supply chain and he needed a partner to produce the critical razor handle. After speaking with David Thuro, a plant visit was scheduled. The evening prior to Morgan’s visit, David visited a local shave store to gain a better understanding of  the hardware presently available.  David stated, “After speaking to Morgan and seeing the kick-starter campaign, I saw that Thuro had the opportunity to collaborate in the development and production of the world’s greatest shaving utensil.” On October 9th, 2014 Morgan visited Thuro’s State-of-the-art facilities for a plant tour and a sit down.

At the close of the design meeting at 11 A.M., with the goal in mind of launching the product by Christmas,  the million-dollar-question was asked: “Can you produce the 1st prototype today?” To Rockwell’s surprise, the answer was, “Yes!”   What unfolded next was a symphony of precision and collaboration.

Using AutoCAD software, the initial handle design was converted to a working blueprint with dimensions and tolerances. At this point, using MasterCam software which is a CAM package, the code for the Mazak multi-tasking CNC lathe was created. This software also allows for machine simulation which speeds the set up process by allowing the programmer to de-bug and optimize the program offline. While the design and programming was being finalized, a master tool maker was at work manufacturing a custom holder for the most critical area of the razor’s handle, the knurl, which needs to not only provide the right grip but is also the most aesthetically important part of the handle. Form and function must perfectly meld, and the right tool for the job is everything.

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Testimonial email sent from Rockwell Razor Co-Founder, Morgan Nordstrom on working with Thuro.

At 2:00 P.M, Thuro’s team began cutting parts. Two hours later, they had the 1st part in hand!

The project had been launched at 11:30 A.M., and by 5 P.M. Morgan was holding the approved prototype. The part was manufactured complete in one operation, or “one and done” as we like to say.

Fast-forward 8 weeks, by which time, Thuro had completed the first 5,000 pieces.

As a result of Thuro’s extraordinary precision and machining technology, Rockwell Razors made its first shipment in early December – just in time for Christmas.

A Bright Future Together

The historic Rockwell Razor Story is only the beginning for Thuro and Rockwell. Today, the two are collaborating to launch an exciting new product, sure to gather a similar following in the crowd-funding community.

Want to check out the latest on the Thuro/Rockwell collaboration? Visit their YouTube page.

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Production Machining of a Brass Fitting for the Air Conditioning, Heating and Refrigeration (AHR) Industry

Production Machining of a Brass Fitting for the Air Conditioning, Heating and Refrigeration (AHR) Industry

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Project Description

Thuro Metal Products has been manufacturing Fittings and Adapters for the AHR Industry for over 25 years. This Coil Hose Adapter is used in Hydronic Balancing Systems. Thuro Metal Products supplies both small and high volume components and several different families of parts used in Institutional Heating and Cooling Systems.

This Brass Adapter has a flat sealing surface which must be smooth and free of sharp edges. Thuro also supplies this Adapter with a Cone Seat. We only use Domestic Thread Rolling quality brass for your brass requirements, which is essential because this fitting connects using two threads. One side has a ½-14 N.P.T. thread while the other is a ½-14 N.P.S.M. (National Pipe Straight Male) thread. Both threads are Thread Rolled. Thread rolling provides superior strength and finish which is especially critical as the N.P.T. thread must provide a water-tight seal. Our brass components are washed in a state-of- the-art cleaning system, which eliminates all chips and oil residue.

Now, since the market often requires the use of low lead and no lead brass, Thuro has developed and refined the machining of these low lead and no lead brasses, to help our customers develop and deliver safer systems which are in accordance with standard AB1953.

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CNC Milling and Turning of a Spherical Band for the Bearing and Linear Motion Industry

CNC Milling and Turning of a Spherical Band for the Bearing and Linear Motion Industry

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Project Description

As an industry leading supplier of precision components to the bearing and linear motion industries, Thuro Metal Products, Inc. was contracted to manufacture a family of spherical bands used in pillow blocks for an industrial automation application. The open-style item pictured is one of twelve variants, which ranged in size from Ø 1 1/8″- 3 1/2″ and band width of 7/8″ to 2 3/8″.

Our engineers determined that utilizing our multi-tasking CNC mill/turn machinery equipped with live tooling would be a high-value method of fabricating these steel components to within tight ±.001″ tolerances. We used a secondary operation to form the slots, and developed a special mass finishing process to efficiently deburr and polish the components without deforming the thin walled sections.

As a strategic supplier for this family of components, we were able to offer the customer attractive pricing and the convenience of consolidating their sourcing to ensure timely delivery to their facility in Mexico, ready for final assembly.

Thuro has extensive experience in supplying components including sleeves, guide rings, end rings, trunnions, and pillow blocks to the bearing and linear motion Industry. If you would like more information about this project or our expert range of services, contact us today.

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CNC Swiss Machining of a Fitting for the Pharmaceutical Industry

CNC Swiss Machining of a Fitting for the Pharmaceutical Industry

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Project Description

Thuro Metal Products utilizes innovative manufacturing technologies to fabricate precision components that meet the stringent laboratory test standards of the pharmaceutical industry. We machined the fitting shown here for use in long duration, small animal drug studies, where the outcome depends on the accurate and reliable dispensing of water and nutrition to the costly, genetically identical specimens used in pharmaceutical testing.

Our automated CNC Swiss machining centers are capable of accurate and repeatable production of complex parts using simultaneous multi-axis operations. We used them to fabricate this component, which featured dimensions of 1.100” in length and Ø 0.359”, from 360 brass. Machined to a 64 RMS finish, we maintained tolerances of ± 0.003” on the length, +0.0°/-0.5° angular, and precision ± 0.0005” on all other dimensions.

We executed a special deburring step and a controlled cleaning process to meet the aesthetic requirements necessary to deliver a part that was absolutely free of any residue. Every step of the process, from material selection to production and final inspection, was carefully controlled and supervised to ensure the integrity of the product for its reliable use in these vital experiments.

For more information about this project, or if you have a similar need and would like to discuss the details, contact us today.

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Production Precision Machining for the Oil Services Industry

Production Precision Machining for the Oil Services Industry

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Project Description

Thuro Metal Products’ exceptional quality and expedited turnaround times have enabled us to sustain long term partnerships with industry-leading companies in a diverse range of markets. Our continual investment in new manufacturing technologies enables us to produce the Charge Case shown here with extreme agility and efficiency.

As specialists in meeting the unique requirements of machining Stress Proof Steel, we invested into a highly automated manufacturing cell for the production of these Perforating Components used in the Oil and Gas Services Industries. Utilizing 1 9/16” bar stock and specially designed tooling, we are able to precision machine all the features of this 1.563” x 1.527” O.D. component from a single set up, which provides a high-throughput solution for fabricating 800 units on a daily basis with minimal operator intervention. The stability of the process enables us to maintain a critical web thickness of .009” (±.002”) with outstanding repeatability throughout each production run.

In addition to providing higher throughput of finished parts, this automated machining technology dramatically reduces the occurrence of processing errors, minimizes labor requirements, and optimizes material usage, all of which provide unsurpassed value in terms of delivery time from receipt of the order, quality parts and reduction in costs by eliminating non-value added handling. Please contact us today to learn more.

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Automatic Multi-Spindle Screw Machining of a Fitting for the Agricultural Industry

Automatic Multi-Spindle Screw Machining of a Fitting for the Agricultural Industry

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Project Description

With more than 40 years of precision metal component machining experience, Thuro Metal Products has developed expertise in all facets of manufacturing for many industries, including industrial equipment. We manufactured the fitting highlighted here for an automated livestock feeding system using a multiple spindle automatic screw machine with tapping, thread rolling, part marking and pick-off for back-working operations.

Our skilled technicians understand how to maximize equipment capabilities to efficiently machine a small part using .812” hexagon type 303 stainless steel with overall part dimensions of 1.812 long x .812” hexagonal. We performed dimensional inspections at critical points in the manufacturing process, to ensure that we maintain ±.003” tolerances called for in the customer specification. This was followed by washing and packaging in preparation for final inspection before shipment to our customer’s Midwest facility.

By offering a complete manufacturing package, executed by an experienced labor force, state-of-the-art equipment and technical expertise, we are able to cost-effectively produce this fitting and respond to ever shortening lead times. We have the capability to deliver between 2,000 and 40,000 units monthly. Total annual demand for this item is 100,000 parts. We maintain 7,500 of these fittings in our safety stock so parts can be at our customer’s facility within three days standard freight. We maintain safety stock for the raw material so we can produce finished product at the rate of 10,000 pieces per week when necessary. This part is managed under our “readiness program”. For more information about this project, or how our manufacturing expertise can help your next project, please contact us today.