Engineering Equipment & Processes
Over the last 18 months, Paranoid have made significant investment in super-high-end engineering equipment, resulting in 95″ of components being made in house at our Warwickshire manufacturing facility, with the exception of drawer sliders, handles and some fixings. This resulted from third parties not being able to manufacture to the tolerances and timescales we insist on, meaning we couldn’t supply products we deemed of sufficient quality to wear the Paranoid name.
This all changed when we make the decision to invest heavily in the best equipment money can buy, securing our future, and meaning we can have absolute control over any Paranoid branded product.
There are a number of stages every product goes through, whether it’s development of an off-the-shelf item, or a bespoke project to suit a customer’s needs. We use the same equipment and take the same pride in every single product we manufactuer, and, unlike competitors, who reverse engineer their products from others, we create all of ours from scratch.:
Stage 1: 3D Scanning
Before even thinking about designing a product, we 3D scan every surface and area that the product will fit around or come into contact with, meaning we know every variable, contour and mounting point, guaranteeing perfect fit of Paranoid products every time.
From the start of the process we will only use the best equipment; our mobile arm, manufactured by world leaders Hexagon, is their flagship Absolute Arm 7-Axis. Capturing 752,000 data points per second, our highly trained scanners work effeciently and quickly, meaning necessary data can be sent over to the design team within just a few hours of project commencement.
Stage 2: CAD Development
Once the scan is complete, the file, containing billions of data points, is sent to the Design Team.
Using Siemens Solid Edge and NX, undoubtedly the best CAD (Computer Aided Design) programmes available, they will create a useable model of the section of vehicle the product is being designed around.
Once this model is created, the team will start work on the product. This is by far the most time consuming part of the process, with designs sometimes taking days to put together.
Once the finished model is fully rendered, it will go through a number of virtual “tests”. For example, our roof rack CAD models were subjected to numerous FEA (Finite Element Analysis) simulations, ensuring wind noise and aerodynamics were at their optimum levels, whilst maintaing maximum load space and strength. The result is that our racks have the lowest drag coefficent in their class.
Once all tests are complete and the product is signed off by the Chief Engineer, it will move on to the Manufacturing Team.
Stage 3: Manufacture
This is the part of the process where the majority of our investment sits.
Once with the Manufacturing Team, the CAM file is loaded into the first, and largest, part of the manufacturing process; the fiber laser.
Manufactured by industry pioneers Trumpf, our TruLaser3030 is accurate to within 0.01mm, and capable of cutting steel and aluminium up to 35mm in thickness. It is the backbone of Paranoid, and means we can manufacture all our products with absolute confidence, knowing each and every one will be perfect. Any products that require etching will be done at the same time as being cut, giving optimum efficiency and flawless results.
Once components are cut and etched, they’re moved onto the press brake, again manufactured by Trumpf.
This is where the flat pieces begin to take shape, as they’re pressed and bent and formed using specialist tools and dyes to achieve the perfect result we insist on.
With our drawers, roof racks and Sleep Base system, the main contact surfaces are made from our own ultra-rugged board. Constructed from recycled plastic and aluminium, it’s proven to be the perfect substitute to normal woods, which degrade in the extreme conditions our products are often subjected to.
Stage 4: Finishing
After bending, the now shaped components move over to our Finishing Team. This is where the trademark Paranoid look really comes to fruition; any stainless components will go through our special brush and polish process, leaving them super durable, and meaning they’ll hold their finish for many years to come.
Other components are finished in our incredibly hardwearing black coat, which is our our own unique powdercoat blend, meaning bumps and scrapes just bounce off.
Stage 5: Assembly
The final stage, and where the components come together to form the Paranoid product you recognise. All products that are built in house are 100% built by hand. Our Assembly Team take so much pride, in fact, in the work they do, that they asked to be able to put their name on every drawer system they make. So, on every one, you’ll see a small plaque, signed by the team member that built it.
It’s at this point that the customer’s finished product is ready to go. Whether they’re having it fitted at our Warwickshire base, which is free to all customers, or having it shipped to them in one of our famous steel crates, it’s guaranteed that every product will fit flawlessly.