Case Study: Sliding Door Hardware
As R&D Manager at Rustica Hardware, I collaborated closely with the owner to establish and lead the Research and Development department, transforming creative concepts into tangible, sellable products. Drawing from my hands-on experience as a hardware assembly line lead, I worked directly with engineers, laser operators, machinists, metal shop teams, and logistics supervisors to refine and expand our product offerings. These efforts resulted in several innovative additions to Rustica’s lineup, pushing the boundaries of what sliding barn door hardware could be.
Expanding Sliding Barn Door Hanger Hardware
Rustica had an impressive lineup of sliding barn door hanger hardware, but there was an opportunity to bring fresh, unique materials and finishes into the mix. We introduced new designs that incorporated unconventional materials like leather, cowhide, aircraft-grade aluminum, and polished brass. To meet the high-end aesthetic, I developed processes for finishing polished aluminum hangers and tracks, utilizing buffers and media tumblers to achieve a mirror-like surface. These hangers elevated Rustica’s offerings, appealing to customers seeking distinctive, luxury hardware solutions.
Sliding Door-Pull Hardware
Understanding the importance of functionality and design, we ventured into innovative door-pull hardware for sliding barn doors. Thinking outside the box, I collaborated with metal shop teams and machinists to create custom designs using text molds, metal presses, and press brake machines. This range of door pulls brought a new level of style and personalization to Rustica’s product lineup, ensuring compatibility with a variety of door designs.
Ceiling Mount Hardware
Addressing a common architectural challenge, we designed a high-end solution for spaces lacking header clearance for traditional sliding door tracks. The ceiling mount hardware was crafted from modular, aircraft-grade aluminum, milled and turned with precision to ensure durability and an elegant finish. This design provided a sleek, functional option for mounting sliding doors in challenging spaces, reinforcing Rustica’s commitment to innovative solutions.
Bringing Concepts to Market
Each product line was developed through a seamless, collaborative process—beginning with sketches and design concepts and advancing through prototyping, testing, and production. Working with supervisors across departments, I ensured that every detail was refined, from machining and finishing to packaging and logistics. These efforts culminated in the successful launch of new products that enriched Rustica’s catalog and solidified its reputation as an industry leader in sliding barn door hardware.
By integrating creativity with engineering and leveraging my knowledge of materials and manufacturing processes, I played a pivotal role in shaping these products into sellable items that resonated with customers and expanded Rustica’s market reach.
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