When Off-the-Shelf Isn't Enough

Many manufacturers are structured to run a low mix of product variations. That model supports high-volume efficiencies, but it also makes it difficult to introduce anything outside the standard configuration—especially lower-volume or custom builds. Customization can disrupt production flow, require separate documentation and validation, demand additional capital equipment, and consume valuable engineering and machining resources.

US Digital is structured differently. From the beginning, we have built our manufacturing model to efficiently support both high-volume production and custom projects—many of which are lower volume. Customization is not an exception to our system; it is an intentional capability aligned with our vertically integrated philosophy.

Our culture has always been open to custom requests because it aligns directly with our values. We have a relentless drive to solve customer problems and to make it easy for people to do business with us.

As a vertically integrated manufacturer, US Digital has invested many millions of dollars in advanced production infrastructure to support rapid customization across our line of encoders and accessories. Because we control critical processes in-house, we reduce reliance on outside vendors and overseas supply chains—allowing us to respond quickly, protect quality, and maintain consistency from prototype through production.

Our manufacturing capabilities include:

• Precision waterjet cutting system
• Wire EDM and sinker EDM machines
• Multiple 3-axis CNC machining centers
• Conversational and traditional mills
• Conventional and CNC lathes
• NC and CNC grinders
• Several laser cutters
• A bank of 5 and 6-axis CNC screw machines

This combination of advanced machining technologies allows us to modify housings, shafts, mounting configurations, and other mechanical features efficiently—without outsourcing critical processes.

Examples of customizations we have delivered in response to customer requirements include:
• Gear-driven encoders
• Single encoder disks up to 24 inches in diameter
• Segmented encoder disks over 36 inches in diameter
• Custom size, shape, and spacing of holes on disks
• Multiple indices
• Custom index alignment

Depending on the scope and complexity, some custom projects have been completed within weeks, while others require longer development cycles. What remains consistent is our commitment to delivering solutions efficiently from concept to production.

Your application should not be limited to stock items. If it matters to your design, it matters to us. We look forward to hearing from you.

This is the fourth post in a series demonstrating that “making it easier” at US Digital is not just a slogan; it is who we are.