Over 80 Years Of Manufacturing Excellence

B​org Design was founded in 1945 by Karl A Borg. Karl was a machinist for a shop in Waltham, MA, and left to start his own company in the basement of his house in Sudbury, MA. With one main customer, Sudbury Laboratories, the company slowly grew from the basement into the detached garage. Being the only employee, Karl was forced to become an expert in all aspects of machining and manufacturing. He would regularly work with customers to improve their designs and solve any manufacturing challenges they faced.

Over the years, Karl gradually expanded the garage to 1,600 sq. ft. In 1978, Karl Stanley joined his father in the business. Karl Stanley was a Mechanical Engineering graduate from Norwich University. Karl Stanley brought passion and the ability to grow and expand the business. The pair became known for their ability to develop effective solutions to customers’ manufacturing issues.

The family was always at the core of Borg Design. Karl A’s two grandsons worked with him from the age of 7. Teaching the kids how to run the machines, clean the floor, and deburr the parts. In 1992, Brandon joined the company full-time. Karl Andrew followed him in 1993, after graduating from UMass Amherst with a degree in Mechanical Engineering.

The Modern Machine Shop

Then in 1996, Borg Design moved for the 1st time. They moved into 3500 sq. ft location on Kane Industrial Drive in Hudson, MA. This move for the 1st time allowed the company to grow and expand freely. In 2001, now with 6 CNC Machining Centers and eight full-time employees, Borg Design moved again, to a 100-year-old mill building in Hudson, MA with 12,000 sq. ft. of manufacturing floor space. We outgrew that space as well.

In 2014, Borg Design moved into its current 58,000 sq. ft. facility at 19 Brent Drive in Hudson, MA. The move allowed a complete reorganization of the production environment housing 50+ precision CNC machines, a fleet of 20 collaborative robots for 24/7 lights-out production, and in-house 3D printing additive manufacturing. The remaining footprint supports engineering, inspection, quality, and administration. It is the infrastructure that makes Borg one of the most capable precision contract manufacturers in New England.

Whether you’re looking for prototype or production machining, 3D printing, or design and engineering consulting, you can count on us to deliver:

• Defense-grade certifications. AS9100D · ISO 9001:2015 · ITAR registered · CMMC Level 2 (C3PAO assessed). The full compliance stack, third-party verified.
• Production-scale automation. 20 collaborative robots across the production floor enable true 24/7 lights-out machining — high volume, unattended, and repeatable at scale.
• Advanced CNC capability. 50+ precision machines including 4-axis and 5-axis machining centers, large-format milling to 120″+ X-axis, and precision turning. We run what most shops consider complex geometry as a routine day.
• In-house 3D printing additive manufacturing. SLA resin printing (Formlabs Form 4) and FDM for functional prototypes, design iteration, and end-use components — from first concept to machined production under one roof.
• Engineering depth. Registered mechanical engineers on staff. SolidWorks modeling, DFM review, fixture design, tooling packages, and prototype-to-production planning — we review your model before we quote.
• Rigorous quality control. In-house CMM dimensional validation, FAI reporting, controlled documentation, and traceable process control from prototype through repeat production.

Borg Design is focused on delivering the highest-quality products and on managing projects with integrity and data clarity. We are committed to managing information at the highest levels of security and confidence.

Borg Design Certifications and Credentials:

CAGE Code: 1V3P1
UEI code: FJ5KUWG5MEQ3
DDTC/ITAR code: M32272
JCP/DD2345 Certified
ISO9001:2015 and AS9100:2016 ->Download certificate (.pdf)
CMMC Level 2 (C3PAO) -> Download certificate (.pdf)

Frequent Questions.

What is a CMMC Level 2 (C3PAO) company?
What does DDTC/ITAR registered (M32272) mean?
Why choose a AS9100D and ISO 9001:2015 certified manufacturer?

We operate in a state-of-the-art 58,000 sf CNC machine facility, staffed by engineers and associates with years of experience. Our team works together to deliver a full range of services specializing in large and small production runs, complex 3D machining, design work, machine building, assembly fixtures, prototypes, and machining and engineering consulting.

Design Capabilities & Consulting
Our Mechanical Engineers are experienced with machine and product design, as well as designing and build compression and transfer molds, assembly fixtures, and machines. Borg Design’s Engineers use SolidWorks for 3D CAD modeling and drafting. Machining consulting and design for manufacturing consulting with services ranging from programming assistance, complete programming, part fixtures, and tooling packages. We can also help reduce manufacturing costs.

Fabrication Resources
Welding and sheet metal work; including bending, stamping, water jet, and laser cutting and rivet installation. Rigorous quality control, short lead times, and quick turnarounds are what make Borg Design a leader in our field.