New Product Creation Process

Rooted in a rich history of innovation and craftsmanship, Tough Country and its products reflect the values of quality, ingenuity, and pride that embody the spirit of American-made companies. Tough Country goes through a meticulous manufacturing process, from initial test fitting to the creation of a final product that guarantees safety, functionality, and visual appeal.

The journey of creating a truck bumper begins with diligent test fitting on multiple truck models. Leveraging the knowledge gained from previous models, Tough Country carefully analyzes mounting points and contact areas for precise measurements. These measurements serve as a foundation for the design process.

Tough Country uses these measurements in tandem with rendering software such as AutoCAD and Inventor to create computer-rendered models of the bumper. These renderings go through several rounds of modifications to seamlessly contour with the truck’s body. The objective is to ensure that the bumper looks like a natural extension of the vehicle, blending harmoniously with its lines and curves.

After finalizing the bumper’s design, the placement and orientation of additional vehicle accessories, such as sensors and front camera, are determined to ensure optimal functionality and seamless integration.

Once the prototype and test fit is completed, a specialized jig is designed. This jig serves as a manufacturing template, ensuring consistent and accurate production of each subsequent bumper. By utilizing this plug-and-play system, any potential issues during the fabrication process are alleviated, resulting in a high-quality end product.

With the first official bumper fully welded and powder coated, Tough Country conducts a final installation to verify its fit and performance. During this phase, detailed photos are taken, and comprehensive installation instructions are compiled. These serve as valuable resources for both customers and installers, ensuring a seamless experience from purchase to installation.

The creation of a truck bumper is a complex and intricate process that demands careful attention to detail, precision, and an unwavering commitment to safety and design. From the initial test fitting to the integration of cutting-edge technologies, Tough Country works tirelessly to deliver a product that not only protects lives but also enhances the truck’s appearance. The next time you admire the rugged beauty of a Tough Country bumper, remember the dedication and artistry that went into its creation.