Production of our wallets

13 steps to perfection

Each DajuWood wallet passes through several stations from material preparation to final quality control. The production includes 13 different steps. The pursuit of perfection is of utmost importance at DajuWood and influences not only all production processes, but also the design. Each wallet undergoes intensive quality control and is only delivered in perfect condition. The products are designed and manufactured in the workshops in Kastelbell (South Tyrol). Well-thought-out planning, modern and noble design as well as high quality standards distinguish DajuWood.

Material preparation

Even before we start on the material preparation, we put considerable emphasis on the quality of the wood. The wood is chosen under the strictest criteria and then cut and calibrated with millimetre precision. The aim of the material preparation process is to create a sound, high-quality basis for a unique final product.

Pocket milling

The precision-cut pieces of wood are initially clamped and shaped on a CNC milling machine. This is how the interiors and sections for bank cards and notes are formed. To obtain a perfect result conforming to the desired pattern, the cutting machine is set to operate to tolerances of 0.05mm.

Adhesive

The adhesive is applied by hand and requires great skill. The adhesive layers must be applied evenly and in exact quantities. The skill of applying the adhesive involves ensuring that no air bubbles or particles of dust appear on the surfaces to be glued. Provided there is no dust, dirt or air bubbles, the end product is flawless.

Programming

Programming = Optimising. The programming for the CNC milling operation is seen as a kind of investment. The better and the more accurate the programming, the more rapidly and the more precisely the milling machine can perform the necessary preparatory work. The skilful use of the right workpieces and the correct control of the milling process form the basis for this sophisticated procedure and for the constant optimization of the final product.

Final milling

The now pre-milled and glued pieces of wood are now finally clamped up on the CNC for the last stage, the final milling. What emerges from this operation are the blanks for the designer wooden wallets. It is at this stage that the major part of the production of our unique pieces starts ... and this work is carried out entirely by hand.

Grinding

The wallets' blanks must now be ground by hand and then finished down to the last detail. Should there be any imperfections at this stage, the wood is immediately discarded and replaced with a flawless component. After the surface has been sanded smooth, the sharp edges are abraded and 3mm curves cut into the wallets with a router.

Painting (primer)

When applying the primer, a thin layer is sprayed evenly on to the wood to close up the pores. The purpose of this stage is to make the wood more resistant and smoother.

Paint sanding

Paint sanding is a tricky business. No blemishes can be tolerated here, as this is the final step in the treatment of the wood. When paint sanding, once again a thin layer of the base coat is removed to smooth out any unevenness. After the paint sanding stage, the wood surface should be perfect.

Intermediate inspection

During the course of the intermediate inspection, all products are repeatedly subjected to close scrutiny. If an imperfection or some uneven flaw is found, it will be sanded down again, painted or in the worst cases discarded.

Topcoat

To apply the topcoat we use a special preparation, which ensures that wood keeps its natural look, while at the same time preserving it. The topcoat is applied at a thickness of 0.5mm and then hardened for a day at a controlled temperature. This final layer, which has a protective function, is scratchproof and will keep the wood looking stunning for many years.

Polishing

As soon as the topcoat has fully hardened, our wooden wallets are polished again. This is another step which perfects the finish of our designer wallets. They are buffed up with two different thicknesses of polishing paper. A coarse paper is used for the pre-polish, while the fine paper gives these unique wooden items a distinctive glossy finish.

Fitting elastic bands

Fitting the elastic bands is another painstaking task. The elastic has to be inserted with millimetre precision into the fixings in the pre-milled wooden parts. The task of fitting the elastic bands on a wallet takes about 15 minutes, following the principle of the “magic wallet”. As our wallets are made entirely of wood, the insertion of the elastic bands can be quite complicated.

Lasering

The laser cut in the top right-hand corner of every wallet is a 15mm diameter hole, into which a gold badge is inserted. The laser runs at 3 metres per second and is accurate to 0.05mm. Every wallet can be finished with a personalised laser engraving, so each one of our products becomes something quite unique.

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