Think Lightweight is an Industry 4.0 company.

There have been three distinct industry periods since the initial industrial revolution. The Industry 1.0 period was basically the addition of electricity applied to power machinery. During Industry 2.0 period, machines became more robust and able to perform at higher speeds. The Industry 3.0 period was based on the integration of computerized technology and this resulted in the automation of saw mills and development of CNC (Computer Numeric Control) machining technologies.

“We believe we have a unique advantage in the market place through the implementation of Industry 4.0 technology and best practices. This is a core part of manufacturing process philosophy and an example of our commitment to ensuring innovative state-of-the-art products.”

So, where are we at today? Think Lightweight is an “Industry 4.0” company. The concept of Industry 4.0 is predicated by integrating robotics and advanced internet technologies into the manufacturing process. Our focus is on continual innovation to the products we produce and manufacturing processes we use to create them. Another core philosophy that it’s not just about perfecting the shop floor with robotics, it also includes increasing the knowledge of the people who work within the organization and the processes they employ. We are an Industry 4.0 company and we are very proud of it. We firmly believe this is a key part of our competitive advantage.

Continuous Panel Processing

We have developed an exceptional lightweight panel processing line at Think Lightweight and we are not aware of any other hollowcore competitor that has employed technology to the extent as ours. Every aspect of our line is automated. Machine settings are integrated with automatic air drills, we employ automatic machining, and robotic stacking. The result is economies of scale and savings that are passed on to you. Using standard manufacturing technology it would take eleven workers to man one product line in order to create 14 linear foot panels. By employing computer technology and robotics, we are able to accomplish this with only two workers per line. In fact, every seventeen seconds we create a sized, machined robotically stacked lightweight component.

Lightweight Component Solutions

We can provide different product options depending upon your needs. Some of our clients want to purchase the entire product sheet and then they’ll do all the sizing and laminating necessary to create the finished product. We also offer the ability to create finished Lightweight Component Solutions for you and your end client. In essence, we can create the finished hollowcore solution based upon the specifications your client has prescribed as a complete turnkey package. This enables you to take advantage of our state of the art high volume panel processing line, PUR lamination process, and edge treatment expertise.

Edge treatment parameters such as edge bander pressure and glue temperature vary by product. By allowing us to create the end package, you can take advantage of expertise CNC (Computer Numeric Control) machining technologies, and facility hardware insertion technologies. As a package, we have the ability to provide a component through a distributor for the same or lower cost to a mill work shop. That’s an option every mill work shop wants.

Component Creation Process

There are seven steps required to create a Lightweight Component Solution.


Client Submits Drawing.

The first step is for the client to submit a drawing to Think Lightweight. We can receive drawings online in any format, ranging from a sketch to engineered drawing to a photo with notes. If you can send it, we can translate it.


Think Lightweight Research & Development Team Reviews Drawing and Provides Preliminary quote.

After we have received your drawing our R&D team will review it, make pertinent recommendations, and provide a preliminary quote.


Client Approves Recommendation and Places Order Subject to Prototype Approval.

From that your client will approve or perhaps adjust and it will go through the process again if that happens and then place order subject to prototype approval.


Prototype Creation and Customer Sign-off.

Next, we will create a product prototype so that you can review the finished product and sign-off when it is acceptable.


Production Run and Assembly Drawings Completed.

Then we start the production run and complete the assembly drawings that are needed. We provide a detailed level of information to ensure a successful installation.


The Finished Components are Shipped to the Distributor, Millworker, or directly to the End User.

After the production run is completed, we can blind ship, direct ship or ship to the distributor, mill worker, or to the end user.