About Beacon Design
Beacon Design was founded in 1976 by U.S. Navy Veteran, Richard Beaupre. Since then, Beacon Design has designed and manufactured custom and retail keepsakes for numerous industries worldwide. Our mission is to offer unique handcrafted keepsakes made in the USA that support the initiatives of the organizations they work with while delivering impeccable service. Our sales team assists with the beginning stages, helping to identify specifications based on your budget and timeline. Our creative design team helps bring your vision to life. And it’s all manufactured in our state-of-the-art 60,000 sq. ft. facility in Lincoln, RI.
The Process
Design
Because our company is fully integrated, we can control the process from a client’s initial idea or sketch all the way down to distribution. When an organization contacts us, our team of skilled account representatives will work with the client to brainstorm ideas and discuss the goals they are trying to achieve, as well as the budget and timeline for completion.
Once an idea has been formed, our experienced account manager will work closely with our talented in-house design team to bring your unique concept to life. Our designers will carefully craft a one-of-a-kind work of art that perfectly captures your vision. Using the latest technology, we will create a digital rendering of your design, which will be sent to you for approval or any changes you may want to make.
Once you have approved the digital design, our highly skilled operators will take over and turn your digital design into a tangible product.
Photo Tool
To begin the manufacturing process, we create a photo tool of the approved design to enable mass production of the product. Once the tool is complete, we prepare the solid brass sheet by polishing it to remove any imperfections. This results in a mirror-like shine, contributing to each piece’s overall elegance.
We utilize a photosensitive resistance process invented by our late Founder, Richard Beaupre, to begin the masking step. This process involves using a light-sensitive material that leaves a pattern on the surface of a brass sheet.
After masking, the sheet is moved to the exposing stage, where the image is burned onto the metal sheet, preparing it for the etching process.
Once the metal is etched to achieve fine detail and depth, it undergoes an extensive cleaning process to ensure strong adhesion.
Plating
During the electrostatic plating process, nickel plating is applied first to increase the adhesion of brass to the final finish and provide the piece with greater rigidity. After nickel plating, the sheet goes through a second cleaning process to prepare for the final finish, which is achieved through the application of gold or rhodium.
If the design calls for it, we can introduce color next.
Color
At Beacon Design, we apply color using two methods: screen printing and digital printing.
Screen printing is a spot color process where each color is added one at a time, passed through an oven to be cured, and repeated until all colors are applied.
On the other hand, digital printing allows for laying down infinite colors in one pass.
The method used to apply color depends on the complexity of the design. Once color is applied, each piece is cut from the sheet by hand or laser. Operations then inspect each piece for quality and prepare them for the next step in our process, hand assembly.
Hand Assembly
Each part is formed by hand, using 3D-printed tools created in-house by a team of talented artists and engineers. While this may seem like a time-consuming process, we utilize robotics to assist in the final stages of production, reducing operator fatigue and ensuring a consistent level of precision and quality. Afterward, the part is hand-assembled and inspected for quality assurance before being sent to packaging.
Packaging
We understand that each of our clients has unique needs, so we offer a wide variety of stock and custom packaging options to suit those needs. Every keepsake is packaged according to your preference. At Beacon Design, we recognize that packaging serves not only to protect the product inside but also to create an overall aesthetic that enhances its value to the end user. That’s why we take great care in assisting you in selecting the perfect packaging for your keepsake, ensuring that it complements the product and creates a memorable unboxing experience.
Setting Up for Success
Our commitment to excellence and attention to detail is reflected in every step of our manufacturing process, ensuring that our customers receive only the highest quality products. We rely on our fantastic team of dedicated employees to deliver hand-crafted American-made keepsakes. Over 30% of our workforce has been with the company for over ten years. The true heart of our company lies in our extraordinary employees. They work together to provide the best service, affordable pricing, short lead times, and marketing assistance. These efforts close the loop and give our clients the best chance of success.
To learn more about creating your custom keepsake, contact us today.
