Custom Workstations
When your process, footprint, or combination of requirements doesn't match any standard workstation category, our engineers design from scratch. We start with your workflow, your operator, your tools, and your facility constraints — and build a workstation that solves the actual problem rather than adapting you to an off-the-shelf solution.
Key Features
Engineered around the specific requirements of your process, operator, and facility.
Process-First Engineering
Every custom workstation starts with a review of your process steps, tool inventory, material flow, and operator ergonomics — so the structure is designed around how work actually happens, not around a standard frame size.
Any Footprint, Any Height
No standard size limits — modular aluminum framing accommodates any plan dimension, height, and surface configuration without special tooling or long fabrication lead times.
Mixed Configuration Support
A single custom workstation can combine assembly surfaces, inspection zones, storage columns, flow lane inbounds, and screen mounting provisions — consolidating multiple standard workstations into one engineered station.
Utility Integration at Design Stage
Power, data, compressed air, lighting, and exhaust provisions are designed into the frame structure — not added as afterthoughts with clamps and cable ties.
Regulatory & Standard Compliance
Custom stations are designed with awareness of OSHA 1910 ergonomics, NIOSH lifting guidelines, ISO 9241 display placement, and IEC 61340 ESD requirements as applicable to the specific process.
Reusable & Reconfigurable
Aluminum T-slot construction means custom stations can be relocated, modified, or repurposed when processes change — protecting the investment beyond the original application.
Applications
Common applications across manufacturing, laboratory, and professional environments.
- Multi-Process Combination Stations — Single stations consolidating assembly, inspection, and documentation steps that would otherwise require three separate standard workstations.
- Non-Standard Part Size Stations — Oversized or unusually shaped parts that require custom surface dimensions, fixture provisions, and overhead clearances not available in standard configurations.
- Specialty Environment Workstations — Stations for hazardous material handling, radiation-adjacent environments, food-safe production, or other specialty environments with specific material and design requirements.
- Integrated Fixture & Tooling Stations — Workstation structures built around specific assembly fixtures, with datum locators, clamping provisions, and torque tool integration designed into the frame.
- Phased Expansion Stations — Initial workstations designed for planned future expansion — with structural provisions, electrical rough-in, and accessory provisions for equipment and process steps not yet in place.
- Replacement of Legacy Equipment — Custom stations designed as drop-in replacements for aging welded steel workbenches and fabricated tables — matching existing footprints and utility connections while delivering modular flexibility.
Specifications & Capabilities
Standard specifications — all dimensions and configurations are available custom.
- Frame: 30 mm, 45 mm, or 90 mm T-slot aluminum; structural analysis for large or loaded configurations.
- Surfaces: Any combination of laminate, hardboard, stainless, ESD, phenolic, aluminum plate, or glass.
- Footprint: No standard limits; any plan dimension, height, or surface configuration.
- Utilities: Power, data, compressed air, exhaust, lighting — integrated at design stage.
- Compliance: OSHA, NIOSH, ISO 9241, IEC 61340 design awareness included in engineering review.
- Ordering Options: Fully assembled, kit with drawings, or component bulk purchase.
- Lead Time: 4–8 weeks from approved drawings.
Frequently Asked Questions
What information do I need to provide to get a custom workstation quote?
The most useful starting point is a description of the process performed at the station, the operator posture (seated, standing, or both), the primary tools or equipment used, approximate work surface dimensions, and any specific storage or utility requirements. A rough sketch, photo of an existing station, or CAD layout is helpful but not required. Modular Solutions will ask follow-up questions to fill in any missing details before generating a layout proposal.
Can Modular Solutions design a workstation to match an existing line layout?
Yes. Custom workstations are frequently designed to integrate with existing equipment, conveyor heights, aisle widths, and facility column grids. If you provide the key interface dimensions (conveyor height, column spacing, aisle clearance), Modular Solutions will design the station to fit precisely. CAD files in DWG or STEP format can be provided for customer review and approval before manufacture.
What surface materials are available for custom workstations?
Available work surface materials include 3/4 inch hardboard (general assembly), phenolic laminate (cleanroom and food-safe), stainless steel (washdown and pharmaceutical), ESD mat laminate (electronics assembly), and aluminum plate (heavy load and welding prep). Surface thickness, edge treatment, and cutouts for fixtures or cable pass-throughs are specified at the time of order. Multiple surface materials can be used on the same station if the process requires it.
How many workstations can be ordered at once, and is there a volume discount?
Modular Solutions handles both single-station orders and multi-station production runs. Volume pricing is available for orders of 5 or more identical or similar stations. For large rollouts (10 or more stations), Modular Solutions typically produces a first-article station for customer approval before manufacturing the full quantity. This allows any dimensional or layout adjustments to be made before the full production run begins.
Can custom workstations be modified after delivery?
Yes. T-slot aluminum frames are designed for reconfiguration. Accessories, shelves, and uprights can be repositioned without tools. Work surfaces can be swapped by removing the surface fasteners and sliding in a new panel. If the frame itself needs to be extended or shortened, standard T-slot hardware is available to do so. Modular Solutions keeps the original BOM on file, making it straightforward to order matching components for field modifications.
Start Your Workstation Project
Send us your process requirements, sketch, or CAD layout — and we'll return a quote with layout options.
Email Us for a Quote Contact FormModular Solutions — 4280 Giddings Rd, Auburn Hills, MI 48326 | 248-625-1864