CAD design and CNC fabrication services
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CAD design and CNC fabrications services
We pride ourselves on serving the needs of those whose only limitation is their imagination. So many of our clients searched in futility to locate a company that could work with them and provide them with a completed project. Many past projects included a combination of collaborative design, research, engineering, precise milling and fabrication, the inclusion of computer-controlled lighting, electronics, motors, linear bearings, solenoids, the use of epoxies, advanced sprayable coatings, and ease of customization over production pieces.
Examples of Past Projects
Below are just a few examples of past projects completed (please note: Some of these projects cannot include detailed descriptions and/or photos as they were completed after signing various NDA forms)
Example 1:
THE REQUIREMENTS: A client needed a project designed and engineered with the following specifications: It needed to move a device in a programmable linear fashion and be easily customized to adapt to various lengths in future similar projects. Although this project would remain indoors, at times it would be located near ocean areas where the salt content in the air would be a “harsh condition”. It had to be long-lasting and maintenance-free. It would need to be computer-controlled and not only programmable at the factory, but also remotely through both an internet connection and a local Wi-Fi connection.
THE SOLUTION: Research began determining which computer-controlled stepper motor was necessary to assure both the speed and the torque requirements were met. The size was limited so the motors size and orientation were a critical factor. Since it had to be adjustable to various lengths in future projects, any type of screw based linear system was eliminated as their sizes and lengths were limited. Instead, a cogged belt design was used so the only future modification necessary was the length of the belt, greatly reducing inventory costs, and allowing for unlimited lengths. Next, the motor had to move a linear bearing. This became the most difficult part of the project as the bearing had to be high-quality, long-lasting, able to operate in a harsh salt air environment, and be maintenance-free. Almost all linear bearings require lubrication, which must be renewed periodically. This was not acceptable. After much research a German company was contacted which produced self-lubricating linear bearings which would meet all the above criteria. This project was completed satisfactorily, met all the pre-determined requirements, and was delivered to the client.
Example 2:
THE REQUIREMENTS: A gym owner desired a 64’ long strip light and only offered two words to work with to come up with a design. He said he wanted it to be “Steam-punk and Vegas.” First, an 8’ prototype was produced. He loved the design, and approved the project.
THE SOLUTION: Eight 8-foot light sections were created using a pattern of chrome “knuckles” that imitated a chain effect to achieve the “steam-punk” look he was seeking. These were designed to interlock producing one 64’ long light. Two 64’ LED light strips were attached to clear Lexan strips set at a precise angle and distance to shine back on the chrome knuckles and reflect off the multi-curved surfaces. A special control box was fabricated to house the various power-supplies and computer equipment. The computer controller included over 200 preset moving patterns which could be controlled remotely by a cellphone app. Utilizing the reflective properties of the chrome knuckles, the number of light reflections were greatly amplified giving it a true Vegas feel (please see the Past Projects section for photos and videos of the completed project)
Example 3:
THE REQUIREMENTS: A client wanted to supply new cabinets to the pinball machine renovation industry. The new cabinets had to be identical to the old ones in every way. All sizes, channels, hole placements, interior parts, etc. had to match up exactly so any retrofit components would fit and attach as original. The new cabinet was designed by reverse engineering an old pinball machine supplied by the client. Precise measurements of every component were taken and entered into the CAD program for accurate milling.
Here was the difficulty: The majority of pinball machines were manufactured in Chicago, Illinois, starting from the 1930s. These machines had to be well-built to stand up to the physical forces which they likely would be subjected to. The original cabinets for these machines were shipped out fully assembled by skilled workers in the various Chicago factories. Because of modern shipping costs, the client required his cabinets to be shipped flat-packed, and then assembled in the field, many times by people unskilled in cabinet assembly. The assembled cabinet had to be square in all directions, easy to assemble, and extremely strong and rigid when completed to withstand all the expected physical forces likely to be exerted upon it.
THE SOLUTION: First, it was determined to use Baltic Birch plywood because of its strength and stability. Advanced, strong, self-aligning hardware was researched and offered as a possible field assembly solution, but this hardware proved to be too costly and brought the price point to an unacceptable level. Back to the drawing board, a special interlocking joint was designed which required no additional hardware and allowed all the corners to lock into place. Because of the CNC precision, these corners locked tightly and when the bottom panel was installed, the entire cabinet automatically became square and plumb, with no torsional misalignment. The client included all the tools necessary for the customer to assemble the cabinet, which was comprised of only a small bottle of high-strength wood glue and a single rachet strap.
Example 4:
THE REQUIREMENTS: A client wanted a large combination kitchen peninsula/dining room table built with a solid granite top to match the existing kitchen countertops. Most of the time this piece would act as a peninsula in the kitchen, but needed to be moved occasionally and be used as a table. The problem: This item would be extremely heavy. The floor was a cement slab covered with luxury vinyl. Any wheels would need to be of industrial strength and would be extremely unsightly and unstable. In addition, the pressure from the weight of the table pressing on the wheels would likely indent the vinyl flooring causing damage.
THE SOLUTION: This project was engineered using CAD design software, and all the components were milled by CNC machinery. The precision of the pieces allowed the entire piece to be glued and press-fit together with interlocking joints. To prevent the likely vibrations that would weaken the legs when sliding this piece, these too were interlocked into the upper structure. (Please note: not a single metal fastener was used in this entire project. Only high-strength adhesives and extremely precise interlocking joinery). The bottom of each leg allowed for 25 square inches of surface area (100 square inches total) contacting the floor, preventing any indentations. Special easy-glide, weight-bearing, non-marring pads were adhered to the bottom of each leg. The result? A peninsula that did not move if leaned against or bumped into, but could be easily relocated and used as a dining room table by lifting slightly while sliding, while never causing any floor damage.
Why Choose Us
Stronger Everyday Storage
Crooked doors, flimsy shelves, and sagging drawers make a kitchen tiring to use. Our CNC process focuses on solid materials, exact cuts, and smart support.
Design Friendly Support
Designers often worry their ideas will be watered down in the shop. We review sketches, mood boards, and finish samples carefully so the cabinet parts we cut respect the layout, style choices, and small details.
Consistent Custom Details
Hand-cutting complex layouts can lead to uneven reveals and awkward gaps. With CNC fabricated cabinets in Laguna Hills, CA, every panel, notch, and curve follows the same digital plan, so long runs, corners, and special features line up cleanly.
Rated 5 out of 5
What others thought of
The client hired Robert Sappo after interviewing three contractors from Angie’s List for a kitchen and bathroom remodel and floor replacement. They were impressed by his attentive listening, proactive suggestions, and confident approach. Initially skeptical about some of his ideas, they were convinced by his reassuring demeanor.
During the project, Robert acted not only as a contractor but also as a guide, advisor, and designer. He helped with material selection, accompanied them to suppliers, and maintained clear, punctual billing with no surprises. Described as a perfectionist with high standards and a good sense of humor, he delivered what the client calls their “dream home” after nearly eight months of work.
The client highly recommends Robert and would exclusively choose him for future projects.
Janja V.
FAQ's
Frequently Asked Questions
Traditional cabinet work often relies on repeated hand measurements and layout lines. CNC fabrication uses digital drawings and machine cutting, so each panel, shelf, and face follows the same plan, giving more consistent fits and cleaner joints.
Timing depends on project size, materials, and how quickly drawings are approved. Once designs are signed off, CNC machining and assembly usually move faster than hand-built work, because parts arrive ready to fit together with fewer surprises.
Homeowners who want CNC fabricated cabinets in Laguna Hills, CA often appreciate our mix of design support, detailed CAD work, and local follow-up, so questions, adjustments, and delivery are handled by a shop that knows the area and its homes.