Prototype to Production: How Sterling Accelerates Product Development Cycles

Ralph RhysonFebruary 29, 20240 comments

In today’s fast-paced manufacturing landscape, getting from concept to production isn’t just about capability — it’s about speed, precision, and strategic collaboration.

At Sterling Industries, we help OEMs and Tier 1 suppliers bring complex parts to market faster by offering a vertically integrated, engineering-driven approach. From initial design support to full-scale machining and final assembly, we streamline your product development process without sacrificing quality.

Here’s how we help our customers move quickly from prototype to production — and stay competitive in the process.

🧠 It Starts with Engineering Partnership

Early engagement is key. Our engineering team supports your part from day one — reviewing geometry, materials, and tolerance stack-ups to ensure manufacturability and cost-efficiency.

Our Engineering Capabilities:

  • CAD/CAM Integration (SolidWorks, Esprit, MasterCAM, Fusion 360)
  • Design for Manufacturability (DFM) Consultation
  • Prototype Validation and Fixturing
  • Custom Toolpath Optimization for Precision Features

We don’t just machine to spec — we help you refine your spec, reduce risk, and eliminate unnecessary complexity before chips hit the floor.

🛠️ Rapid Prototyping in Action

Sterling’s in-house tool room is equipped for quick-turn prototypes, custom fixturing, and one-off test builds.

Tool Room Equipment:

  • Proto-Trak M2 Mill
  • Manual Lathe
  • OD & Surface Grinders
  • Custom Fixtures and Gauging Builds

Whether you’re testing a single housing, a fluid fitting, or a powertrain coupling, we can deliver a working prototype in as little as 24–72 hours, complete with balance, inspection, and tolerance validation.

🔁 Seamless Transition to Production

Once your prototype is approved, we transition it directly into our production machining environment. Because the fixturing, CAM data, and inspection plans are already developed in-house, there’s no knowledge transfer delay or need for outsourcing.

We operate:

  • 6 Vertical and 6 Horizontal CNC Mills (Up to 1000 mm cube)
  • 24 CNC Lathes (Up to 800 mm diameter)
  • 5 Swiss Turning Machines (Up to Ø32 mm)

This allows us to go from a single prototype to hundreds or thousands of parts per month with minimal lead time.

🔍 Quality You Can Scale

Speed means nothing without quality — that’s why every prototype and production run is backed by our ISO 9001:2015-certified process, digital inspection systems, and traceable documentation.

Quality Systems Include:

  • Dual CMMs for Coordinate Inspection
  • Oasis Vision System
  • OGP QL-30 Optical Comparator
  • Balance and Runout Validation
  • Digital Correction Logs (on request)

We also offer full PPAP documentation and prototype review packages when required.

📈 Real-World Example: Fuel Rail Prototype

One of our OEM customers needed a high-pressure aluminum fuel rail prototype — fast. Within 48 hours, Sterling delivered:

  • CNC-machined prototype to ±0.0005” tolerance
  • Full CMM inspection report
  • 3D CAM validation of bore integrity
  • On-site design feedback

This allowed the customer to complete bench testing the same week — accelerating their development schedule by more than two weeks and securing early supplier approval.

📦 From 1 to 3,000 Parts — We’ve Got You Covered

Volume TierRangeUse Case
Prototype1–10 unitsDesign validation, testing, R&D
Low Volume10–500 unitsPilot builds, product launch
Production500–3,000+ unitsLong-term supply, integrated delivery

With flexible scheduling and a responsive team, we can adjust batch sizes based on your product lifecycle — from EV platforms to aftermarket engine kits.

🏁 Final Thoughts

Accelerating your development cycle means more than just machining fast — it’s about having the right people, equipment, and mindset to move with purpose. At Sterling Industries, we’re proud to be a trusted partner in helping innovators bring new components to life — with speed, confidence, and control.

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Travis Watson

Travis Watson is a results-driven business executive with a strong background in strategic growth, operational excellence, and servant leadership. He has led engineering and manufacturing teams across industries such as aerospace, clean energy, and high-performance vehicles, delivering significant improvements in performance, sales, and quality systems. With experience in roles ranging from Account Manager, Plant Manager to Director of Sales and Operations, Travis has overseen ERP implementations, contract negotiations, and cross-functional team development. His leadership has consistently driven efficiency, employee engagement, and profitability. Travis holds dual Bachelor of Science degrees in Marketing and Distribution Management from Indiana University’s Kelley School of Business. He is a Six Sigma Green Belt, CAPM certified, and holds a CPIM designation. Known for developing people and driving strategic execution, he has been a key contributor to multiple high-performing teams.

Joe Johnson

Joe is a highly accomplished engineering and business leader with decades of experience in mechanical engineering, manufacturing, aerospace, and business development. His career began at Delta Faucet Co., where he honed his skills before moving on to Cummins Engine Co. as a Fuel Systems Product Engineer. He further advanced his expertise as an afterburner specialist for Pratt & Whitney Aircraft.

As a seasoned entrepreneur, Joe co-founded ReGin Manufacturing, successfully growing the company into a $10 million enterprise before its acquisition. He later served as the Engineering Manager at Advance Aero Inc..

Recently, Joe transitioned from his role as Director of Operations at Paramount Industrial and Sterling Industries to become the Director of Business Development and Engineering. In this role he is focused on supporting strategic growth and leveraging his extensive background to drive innovation and success in the industry.

Joe Hetzer

Joe Hetzer brings over three decades of extensive experience in the manufacturing sector, with a specialized focus on the aerospace and automotive industries. Throughout his career, Joe has demonstrated a profound commitment to engineering and manufacturing excellence, making significant contributions to various projects and initiatives.

As a team builder, Joe employs a servant leadership approach, fostering an environment where collaboration and growth are paramount. His ability to inspire and empower teams has made him a respected leader in his field, driving innovation and operational improvements.
A recognized change agent, Joe is dedicated to maximizing productivity and efficiency within organizations. His strategic mindset and hands-on experience enable him to implement effective processes that not only enhance performance but also promote sustainability in manufacturing practices.

With a passion for developing talent and a keen eye for industry trends, Joe Hetzer continues to make a meaningful impact in the manufacturing landscape, ensuring that teams are well-equipped to meet the challenges of today and tomorrow.

Peter C. Ariens

Peter C. Ariens is the Chief Executive Officer of NuMA Group, Inc., a private holding company engaged in the automotive, aerospace, defense, recreational, and heavy-duty industries. Under his leadership, NuMA encompasses several companies that manufacture and distribute critical components for some of the world's largest enterprises, with four manufacturing facilities located in Indiana.Before his role at NuMA Group, Peter served as President of Stens Corporation for 18 years, where he led the international parts manufacturing and distribution company until its acquisition by private equity in 2016.In addition to his executive role at NuMA, Peter actively contributes to various for-profit and non-profit boards, including:Two Ladders, Tell City, Indiana
South Central Inc., Evansville, Indiana
Toolsey, Inc., Indianapolis
He is also a member of professional organizations such as Vistage International and the Alliance of Indiana, affiliated with the IU Kelley School of Business. Previously, Peter held the position of Treasurer on the Trieste board.
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Shelia Rossmann

Shelia Rossmann is the Owner and President of Sterling Industries, Inc. and Paramount Industrial, Inc., where she has established herself as an accomplished and results-oriented businesswoman in the manufacturing sector. As a Senior Manufacturing Executive, Shelia leads her woman-owned businesses with a commitment to excellence and innovation.
Her remarkable achievements in the industry were recognized when she won the prestigious Entrepreneur of the Year award in 2013 for Manufacturing in Michigan and North West Ohio, presented by Ernst & Young. This accolade highlights her dedication to driving growth and operational success in her companies, making significant contributions to the manufacturing landscape.
Shelia’s leadership continues to inspire others in the industry, showcasing the impact of women in business and the importance of resilience and strategic vision in achieving success.

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