One stop manufacturing and full kit assembly for The Buddie System safety alert product for Australia

Low-volume kits are hard to source

Is a premium low-volume product hard to manufacture when it needs parts, assembly, and ready-to-ship packaging?

The Buddie System is an Australian-based company. Its TBS safety alert product is a wireless instant alarm for crane operators and riggers. It is designed for fast action in an emergency. The key problem is the full kit. Many suppliers only do one step. Some only machine metal. Some only mold plastic. Some only assemble. Large factories may also ask to increase the order quantity. The client needed one partner that can manage design to production, assembly, and packaging in one connected flow.

Small-batch kitting with complete accessories.

One flow from parts to shipment

True one-stop delivery depends on two things. Full-in-house capability across the chain, and stable control at every step. Because the customer receives a complete kit, any weak step will show up later in assembly, function, or lead time.

Mastars gets involved early, starting from prototyping. Our prototyping team quickly turns concepts into buildable samples, then iterates in short cycles until assembly is stable. We use CNC prototypes, 3D printing, or soft tooling as needed. Each round focuses on tolerance stack-up, sealing features, fastening points, and assembly sequence, and we provide practical DFM feedback. This improves development efficiency, reduces trial and error, lowers mold rework risk, and cuts total cost. Then our dedicated tooling team tailors the mold plan to the product and locks quality and schedule from the start.

On this foundation, Mastars connects the process into one closed loop. Prototype validation confirms the structure and the assembly path, then we move into tooling and production readiness, followed by CNC machining, injection molding, full assembly, and final packing. Supporting steps include manufacturability review, assembly fixtures and aids, incoming inspection, controlled fastening and torque, functional checks, final inspection, labeling and serial numbers for traceability, and complete kitting with manuals and accessories. Each unit ships as a complete kit, with fewer handoffs and less rework, making delivery easier and more predictable.

Test data logged for full traceability.

What buyers gain from one supplier

Core outcome. Stable quality. Precise build. Reliable lead time. One accountable partner.

✅ Stable fit across plastic and metal parts

✅ Fewer handoffs and fewer cross-supplier errors

✅ Repeatable assembly with clear inspection points

✅ Complete kitting and controlled packing for shipment

✅ Simpler communication with one plan and one schedule

Precision assembly with controlled torque and alignment.

Where this helps beyond this project

If your product is used in the field, reliability matters. One stop manufacturing can reduce risk even at low volume.

Industries and products that often benefit

• Industrial safety devices such as alerts and handheld tools
• Medical accessories and device sub assemblies
• Outdoor and sports electronics kits such as mounts and housings
• Robotics and automation parts such as covers and brackets
• Consumer electronics peripherals such as docks and enclosures

Do you need parts, assembly, and packaging in one flow, but your supply chain is split across multiple vendors. Share your requirements and Mastars can review your build plan.

Pre-shipment functional test, item by item.

Mastars, the most trusted and reliable one-stop services partner for low-volume digital manufacturing worldwide!