Key Considerations for Fabrication

Wide-format printers are already creating stunning graphics and visuals for immersive experiences for their clients — why not help build them, too? Because, let’s face it, in this industry, standing out is key, and one way you do so is by adding fabrication to your list of services.

It’s All About Being a ‘One-Stop-Shop’

Even if you’re tired of hearing the phrase “one-stop-shop,” the reality is, it’s not going away anytime soon. Jason Ahart, vice president of production operations for Franklin Park, Illinois-based Moss, explains that customers today really need that “one person” they can go to for everything they need — and if you can do that, it will set you apart from your competitors.

You can work with a variety of materials like wood (pictured here) to achieve these jobs. | Credit: Moss

“Customers, now more than ever, need more of that one-stop-shop,” Ahart says. “They need that all-in-one solution, and for the printers to be able to provide the solution in the shortened lead times that we have. They really need to be able to provide anything and everything [that may be requested].”

Currently, Moss utilizes a variety of different fabrication materials, including aluminum, wood, sign foam, and acrylic.

Connor Miller, the director of sales for Print Wisconsin in Stanley, Wisconsin, echoes a similar sentiment.

“In the world of ever-changing demands, as far as retail goes, you know you don’t want your retail clients going to look elsewhere for other parts of the job,” he says. “So, we’re trying to be that one-stop-shop to be able to handle all the requests and demands from our clients to give them what they need to fulfill their retail scene.”

Miller adds that when you’re not outsourcing, you have a better time managing tight deadlines and not waiting for others to make sure all aspects of the job are finished. He explains that was part of the reason Print Wisconsin decided to bring its fabrication projects in-house: They were tired of relying on other people to get the job done on time.

Today, Print Wisconsin works with a variety of different fabrication materials, including wood, acrylic, and occasionally metal.

Quality Control is Key

For anyone considering fabrication, Miller urges you to keep in mind that fabrication is different than typical wide-format jobs, and it comes with its own unique set of challenges.

“Our biggest challenge is quality control. With typical wide-format jobs, there’s a lot less human interaction. We print it and then it’s out the door,” Miller says. “Whereas fabrication is kind of the opposite. There are a lot of different moving aspects in a fabrication project, whether it be sanding, assembly, or painting. There are a lot more things that can go wrong, and a lot more human touches that can drive your costs up if something doesn’t quite work the way it should the first time, or it has to go to rework, etc.”

Ahart agrees, saying that although on the outside, the act of assembling structures with aluminum and fabric may not seem that complex, there are hiccups and errors you can run into along the way without proper training — especially for new hires.

For projects like this, Moss uses a "buddy system" for new employees to maintain quality control. | Credit: Moss

To get his people up to speed and comfortable, Ahart says Moss has a “buddy system” for new employees.

“When a new hire comes in, they’re working with an established person who already knows that area, and they kind of work as the buddy for them. So, they’re not allowed to do certain things until they’ve received certain training in the sign-offs. So, the buddy system works best,” Ahart says.

Conversely, Miller says Print Wisconsin has adopted robotics to help eliminate human errors. “We’ve tried to automate as much as possible,” he shares. “So, we do have a couple of robotics systems that are integrated into our fabrication side of things.”

In addition to automation, Miller says Print Wisconsin works to retain veteran employees. That way, they’re not constantly restarting the training process with new hires. He admits that thanks to COVID, it has been a bit of a challenge, but overall, he says the company aims to give its employees the tools they need to excel.

“We really try to maintain and keep employees that have been with us, that have seen the wide variety of projects that come through, where they learn every job and they learn something that they can kind of grow their knowledge, versus trying to start fresh with new employees,” Miller says.

Beyond employee considerations, wide-format servicers should also be aware that they need to maintain quality even through hurdles like art arriving at the eleventh hour. Ahart says this is common across all segments, whether it’s retail, trade shows, or outdoor events.

“Art is typically always the last thing we receive, and it doesn’t matter which region we’re in,” he says. “So, then it becomes up to us to figure out how to turn it around as fast and as accurately as possible, and as color-accurate as possible. Because it all still matters, even though the art is late, color, quality, and fit matter the most.”

Have the Space and the Staff

If you’re considering adding fabrication to your company’s offerings, both Ahart and Miller advise you to assess your own resources — specifically, your space and staff.

“Obviously, you have got to have the space for the machinery for assembly,” Miller says. “All of those aspects that you bring in-house, you must have the space, or else it’s not going to work.”

Ahart touches on the employee aspect and shares that PSPs should make sure they have the right team before embarking on the fabrication journey. “You need to consider,” he says, “what staffing you need to bring fabrication in-house? What is the level of staffing that you need to bring in-house? Because many people think, falsely, ‘I can just bring this in-house and make it.’ But if you don’t have the right staffing, that’s what’s key. That’s what makes the system run.”

Don’t Be Afraid to Make Mistakes

As with any project, there are going to be bumps in the road. However, when it comes to fabrication, don’t let the fear of striking out keep you from playing the game.

“You can kind of grow as you learn,” Miller says. “There’s going to be mistakes when you’re starting out. We weren’t experts in any of the fabrications when we first started out, but obviously our demand was there to the point where we were like, ‘Hey, let’s bring it in-house and we’ll figure it out to keep our clients happy.’”