Precision and Passion:
The Heart of Pattern Cut’s Success Story
The Introduction:
Founded in 2002 and headquartered in Buena Park California by Leigh Freedman, Pattern Cut Inc. specializes in the manufacturing of premium laser-cut products from cabinet door grille panels for your kitchen, doorway arches, or home entertainment, HVAC supply and return grille covers and so much more. Their signature offerings include surface mount and magnetic flush mount grille assemblies with the latter now outpacing traditional models in popularity due to their sleek, drywall-integrated design. Pattern Cut also handles bespoke projects across the residential, hospitality, and commercial sectors, having delivered intricate work for prominent clients including Disney, Stanford University, and The Plaza Hotel in New York City.
Behind the beauty and precision of Pattern Cut’s work lies a strategic investment in laser technology with the company finding a powerful partner in Kern Laser Systems.
The Challenge:
Leigh entered the laser cutting space with a used Kern machine he purchased from another company over 20 years ago. “At the time, Kern didn’t have anything that would work for me. I ended up purchasing a total of five machines from another company. And then they suddenly decided to stop building those machines and stopped supporting them.” said Leigh. He was then left with nearly half a million dollars of increasingly obsolete machinery. “I said if I want to keep this going, I need a new machine that’s reliable. I called you guys up and here we are.”
The Solution:
Leigh returned to Kern Laser Systems and has since relied on their equipment to scale production with confidence. Pattern Cut’s current Kern system features a 52” x 50” table and a 500-watt laser, offering the flexibility to handle larger parts and the power to cut a variety of materials, even though they currently outsource metal cutting.
The upgrade has not only boosted capacity but also transformed the team’s day-to-day experience. “The larger cutting table and more powerful laser have increased our production. Our machine operator likes it much better than our other machines and ultimately has a better software flow.” Leigh explained.
The Impact:
Pattern Cut has seen measurable operational improvements since installing their Kern system, with increased throughput and better ergonomics for their team. The user-friendly setup supported by Kern’s detailed manuals and high-quality training videos meant the laser was aligned and operational quickly.
“I watched the laser alignment video on my phone while performing setup it worked perfectly the first time.” Leigh stated.
Kern’s support doesn’t end with setup. One of the most valued aspects for Leigh and his team is Kern’s exceptional customer service: “When I call, a real live human answers the phone and a knowledgeable person is always available to solve issues. You just don’t see that anymore.”
The Outcome:
With one Kern laser already driving production, Leigh is already planning to replace the remaining machines to make room for another Kern Laser System. “If our increased production creates the need for another machine, we’ll most certainly buy another Kern Laser System.”
Leigh appreciates not only the machine’s reliability but the people behind the product. For Pattern Cut, the combination of hardware excellence and exceptional service has been critical. “Besides having a high-quality laser machine that meets our specifications, customer service and support is a must. Kern provides all of those.”
