Crafting Harmony in New Product Development
Ten years ago, Fern & Roby embarked on a journey driven by a passion for creation and innovation. This Virginia-based design and machine shop ventured into the realm of product design after honing its skills in high-end architectural design and interior decoration. With this shift, they began specifically focusing on items that complemented their primary offerings, like light fixtures and hardware.
The Founder, Christopher Hildebrand, whose background in design and product management at Tektonics Design Group, combined with experience in a foundry and metal fabrication, laid a strong foundation for Fern & Roby. Their early investment in CNC routers and milling equipment was not just a business decision but a leap towards fulfilling a long-held aspiration – to create their own products.
The turning point for Christopher came with the development of his own audio equipment line. The project, born out of a friend’s request to build a set of speakers, reignited a love for music that had waned in the digital age. This rekindled passion led to the creation of amplifiers, turntables, and other audio accessories, emphasizing the difference quality equipment can make, much like the distinction between a high-end camera and its less capable counterparts.
Fern & Roby’s commitment to local, U.S.-based production of exceptional quality had a dual purpose: not only did it result in superior products, but it also supported the livelihoods of their employees. This ethos became a significant part of the company identity and business model, with a focus on developing products that offered a good return on investment and set clients up for success.
Their diverse range of customers, from medical devices to consumer electronics, benefited from Christophers deep industry knowledge. The founder's background in ornamental wrought iron, casting, wood carving, and fine art, coupled with experience in creating machined hardware for government bridge projects, provided a unique perspective in product development.
It was in this context of innovation and growth that Fern & Roby’s path intersected with Mika Metal Fabricating. Seeking a collaborative partner who could augment their capabilities, Christopher visited Mika Metal during a trip to Cleveland. Mika’s integrated services and warm reception helped a partnership blossom, but Mika’s full suite of services and capabilities, including the required in-house powder coating and silk screening, made for a product development process that was not only easy for Fern & Roby, but also reduced the costs associated with managing multiple vendors.
Mika’s expertise in laser cutting, bending, hardware insertion, and powder coating brought Fern & Roby’s integrated amplifier with phono to life. Mika’s design for manufacturability (DFM)assessment played a pivotal role in refining the design, ensuring they were not only aesthetically pleasing but also manufacturable and functional.
This partnership culminated in the creation of the Amp No. 2 chassis, a beautiful example of the synergy between Fern & Roby’s innovative design and Mika Metal’s manufacturing prowess. The collaboration was marked by excellent communication and execution, with Mika providing a comprehensive solution that streamlined the process and reduced complexity. According to Fern & Roby’s founder, “[Mika’s] engagement and communications with me and my staff were excellent and the fabrication was executed flawlessly.”
Fern & Roby AMP NO. 2 - Side view, laser cut aluminum enclosure with powder coating and inserted hardware
Fern & Roby AMP NO. 2 - Back view with silk screening
The partnership between Fern & Roby and Mika Metal is a testament to the power of collaborative innovation. It highlights the importance of aligning vision, skill, and capabilities to create products that are not just market-ready but also embody the highest standards of quality and design.
To learn more about Fern & Roby visit them at AXPONA (The Audio Expo of North America), Booth 584, April 12th through 14th at Schaumburg Convention Center, Schaumburg, IL. In need of an Industrial Design firm? Contact Christopher Hildebrand at christopher@tektonics.com to discuss your next project.
Have a product idea but not sure how, or if, it can be commercialized? Mika Metal Fabricating may be able to help by partnering with you to conduct market research, develop a business case and bring your qualified ideas to life.
To submit a Product Development Idea Submission form, contact Rebecca Cole, Director of Sales & Marketing at rebecca.cole@mikametal.net. All discussions are completely confidential. If your product idea fits our initial screening, Mika agrees to sign a confidentiality agreement before discussing the specific details of your idea in further detail and/or reviewing any proprietary information, product sketches etc.
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Featured Images:
- Mika Metal Fabricating shop floor
- Tektonics Design Group exterior photo
- Fern & Roby AMP NO. 2 - Laser cut aluminum enclosure with powder coating and inserted hardware
- Fern & Roby AMP NO. 2 - Silk screening
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