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Cliffmark Industries

From patent-pending sketch to 100,000 units on a shelf.

A patented golf divot tool, tooled in steel, cut twice, and delivered in two air-freight shipments. 170 days, beginning to end.

Client
Cliffmark Industries
Timeline
170 days · Apr–Dec 2025
Product
Affix Pitch Mark Repair
Scope
Tooling · Mfg · Packaging
Affix Pitch Mark Repair Tool — matte nylon, debossed wordmark, patent-pending geometry
Affix · Pitch Mark Repair Nylon, 4-cavity steel mold. Matte black + matte white. Patent-pending geometry.
Affix Pitch Mark Repair Tool — 3-quarter render, matte nylon, debossed brand
Matte black + matte white nylon · Debossed AFFIX wordmark · Embossed patent mark within
Matte Black
AFX-BK · 4-cavity tool
50,000
Matte White
AFX-WH · same tool, second run
50,000
100Kunits
Mass production run, split across two color SKUs.
170days
Engagement to final delivery in Vero Beach.
3rounds
T0, T1, and new mold cores for T2.
500Kwarranty
Steel tooling warranted for half a million cycles.
The Challenge

A patent-pending prototype, ready to grow up.

Cliffmark Industries came to Jaycon with a printed ABS prototype, a patent filing in flight, and a clear sense of what the tool had to do on a green. They needed a manufacturing partner who could carry it from a hand-printed sample to a retail-packed consumer product, at scale.

The brief was specific. Nylon, not ABS. Matte body with a debossed brand on the outer face. Patent mark and website embossed inside the part itself. Custom kraft packaging, sized to the product, one-color print, color-indicator dot for fulfillment. Two SKUs, black and white. Built so that every unit out of the mold reads identical to the last.

Affix Pitch Mark Repair Tool sliding out of its kraft cardboard packaging with debossed wordmark and color-indicator dot
Close-up detail of the debossed AFFIX wordmark on the matte nylon body
Close-up of the embossed patent mark inside the matte black Affix tool
The Tip Problem

The T0 samples were close. Then the client tested them.

Our tooling team cut the four-cavity steel mold over four weeks and produced the first trial shots. When Cliffmark put them next to the printed prototype, the prongs were noticeably blunter — exactly the geometry that determines how cleanly the tool engages a green.

The tip geometry sits across the mold's parting line, the most technically constrained region of any injection mold. Reworking it meant rebuilding the CAD model and translating that change into steel through precision machining. We assigned a mechanical engineer, returned a revised STEP file within a day, and waited while the client 3D-printed and tested it themselves before approving.

4-cavity steel mold, lower half, showing tool cavities and cores
CNC machining of revised tip geometry on the 4-cavity steel mold core
The Decision

New cores. Cost absorbed.

T1 samples came back sharper. They still missed the mark. Rather than continue grinding away at modified steel, we chose to cut entirely new mold cores so the tip geometry could be built fresh from the approved CAD, not negotiated around prior modifications.

We absorbed the cost. On September 23, 2025, Cliffmark approved T2 and authorized mass production. The kraft boxes were printed, the line ran, and 100,000 units left our Vietnam facility for QC and packing in China before two air-freight shipments arrived in Vero Beach by December 1.

"

What matters is how a manufacturing partner responds when the first parts come out of the mold. Jaycon's answer was to cut new cores and absorb the cost.

Notes from the project close, December 2025

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