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Oshkosh Designs 'Floors' the Competition
Oshkosh Designs, based in Winneconne, WI, specializes in creating intricate and standout designs for flooring, stair risers, treads, chair rails, ceilings, and backsplashes. The company prioritizes using high-quality heartwood, specifically select and better grades, to ensure the best material for its fine inlay and etching work, as lower grades with sap and knots are less suitable. Their designs incorporate a diverse range of materials, including domestic and exotic hardwoods like red and white oak, maple, black walnut, American cherry, Brazilian cherry, mahogany, santos mahogany, poplar, wenge, purpleheart, ash, ipe, bubinga, and yellowheart. Beyond wood, they also integrate natural stone, metal, and glass into their creations. Oshkosh Designs offers a variety of standard patterns for medallions, borders, and parquet designs, such as Chateau, Del Sol, Ashanti, and La Jolla, and provides customization options to resize, reshape, or change materials to match specific decor requirements. They also offer a dedicated custom design service to meet unique client needs.
The manufacturing process at Oshkosh Designs is highly integrated, with both design creation and all machining performed in-house within their 65,000-square-foot facility. The initial stage involves careful inspection of boards, followed by processing in the rough mill area. Here, a Cameron Automation OptiRip system automatically measures the length and width of boards on a conveyor. Laser lights then guide the operator to determine the optimal rip combination. The boards are subsequently sent to a Mereen-Johnson 431 gang ripsaw, which features variable feed for precise lumber sizing, typically from 4/4 to 2/4, with custom widths also available. Pistorius saws are also part of the shop floor machinery.
Central to the creation of intricate details are two LMI lasers, which are used for etching and cutting the small wood components required for inlays in medallions and borders. Wood products constitute approximately 80% of Oshkosh Designs' business. The remaining 20% involves materials like marble, granite, slate, travertine, glass, and non-ferrous metals, which are cut using a waterjet laser located in a separate area of the facility. After cutting, these small parts are meticulously hand-assembled to form the complex patterns. A water-based adhesive is used to secure the components. If necessary, the assembled pieces undergo sanding via a Cemco sander before being finished on an automated Deimco line, which utilizes water-based finishing materials.
Oshkosh Designs is committed to green manufacturing practices. The use of water-based products in their finishing process is a key aspect of this commitment. Furthermore, the company designs its hardwood inlay and parquet wear layers to be 5/16 inch thick, which helps conserve hardwood resources. Whenever feasible, Oshkosh Designs sources its lumber from certified suppliers, including those recognized by Smart Wood. The company also minimizes its environmental footprint by recycling sawdust, which is provided to local farmers for beneficial reuse. This comprehensive approach ensures both high-quality products and responsible manufacturing.
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