One hanger for many ornaments, in any wardrobe
Ornaments and accessories tend to end up scattered across drawers, boxes and shelves, where they are hard to find and easy to damage.
Our client wanted a better way to organize them: a single hanger that holds multiple ornaments and fits into any wardrobe.
They came to CADLETE Designs to design the product, prove it with a working prototype, and take it through to volume production in aluminum.
The goal
A practical, durable, space-saving storage product that works in any wardrobe, produced in aluminum at volume and delivered to the client’s market.
Prove a metal product before paying for its molds
Die casting molds are a significant investment, so the hanger had to work in metal first.
One hanger, many ornaments
The design had to hold multiple ornaments on one unit while keeping them organized and easy to reach.
Fitting any wardrobe
Wardrobes vary in size, so the hanger needed a telescopic design that adjusts to different spaces.
Proving it before tooling
Die casting molds are a significant investment, so the design had to be validated in metal before committing to them.
Volume production for export
The final product had to be produced consistently at volume and shipped to the USA.
From CAD to die-cast hangers on their way to the USA
Five stages, shown with the real CAD, metal prototypes, castings and the hanger in use.
Stage 01 · Product design
A hanger with a telescopic arm and a panel for ornaments
We developed the complete hanger design to the client’s requirements, including the telescopic function and the layout for storing multiple ornaments.
A telescopic arm mounts in the wardrobe and carries a panel with holes, hooks and bars for hanging pieces.
- Product design
- Mechanism design
- 3D CAD
The hanger in 3D CAD. Stage 02 · Functional prototyping
A working metal prototype: sheet metal and VMC machining
We built a fully functional prototype using sheet metal fabrication and VMC machining.
That let the telescopic mechanism, the fit and the ornament storage be tested on real metal parts before any tooling was made.
- Sheet metal fabrication
- VMC machining
- Functional prototype
The telescopic arm prototype. 
A prototype panel. 
A VMC machined panel. Stage 03 · Aluminum die casting
Molds developed, panels and arms die cast in aluminum
With the design validated, we developed the molds for aluminum die casting.
The photos show a panel straight out of the mold, with its runners still attached, and stacks of castings during production.
- Die casting mold development
- Aluminum die casting
A raw casting, runners still attached. 
Castings in production. Stage 04 · Volume production and finishing
Volume production, finished parts
We carried out volume production of the hangers, both the panels and the telescopic arms.
Finishing included PVD coating, one of the services on this project.
- Volume production
- Finishing
- PVD coating
A finished panel. 
Arms from a production run. Stage 05 · Export to the USA
Shipped to the USA, in use in the wardrobe
We shipped the finished products to the client in the USA.
In use, the hanger sits among the clothes in the wardrobe and keeps watches, belts and ties together on one panel.
- Export to USA
- Space-saving storage
In use in a wardrobe.
Proven in metal, then die cast at volume
The hanger went from the client’s requirements to a working metal prototype, aluminum die casting molds, volume production and delivery in the USA.
What we delivered
- A telescopic aluminum hanger designed to hold multiple ornaments
- An adjustable design that fits into any wardrobe
- A fully functional prototype built with sheet metal fabrication and VMC machining
- Aluminum die casting molds developed
- Volume production completed
- Finished products shipped to the USA
Questions about this project
Why build a metal prototype before die casting?
Die casting molds are a significant investment and hard to change. A metal prototype made by sheet metal fabrication and VMC machining let this hanger’s telescopic mechanism, fit and storage be tested on real metal parts first.
What is VMC machining?
VMC stands for vertical machining center, a CNC milling machine with a vertical spindle. It cuts metal parts directly from a CAD model, which makes it a fast way to produce working prototypes before tooling.
When is aluminum die casting the right process?
When a metal part with a detailed shape is needed in volume. Once the mold exists, die casting repeats the same part quickly and consistently, which is why it suited this hanger’s panels and arms.
Can CADLETE produce metal products and export them to the USA?
Yes. For this hanger CADLETE handled design, prototyping, die casting molds and volume production, then shipped the finished products to the client in the USA.
Will my product idea stay confidential?
Yes. CADLETE signs a non-disclosure agreement before any technical information is shared, so your design files and IP stay yours. It is also why this story does not name the client.
