Precision in Partnership: HollyFab and Trinity Stairs Collaborate on 250+ Custom Balusters and Knuckles

At HollyFab, every project tells a story—not just about metal, machines, and measurements, but about people, trust, and craftsmanship. Our latest collaboration with long-time customer Trinity Stairs brought all of that together in one high-paced, high-detail job that tested both our precision and our speed.

This project involved the fabrication of over 250 individual components, combining steel balusters with custom aluminum knuckles—a mix of strength, style, and attention to detail that perfectly represents what we strive for on every job.

The Background: A Trusted Partnership Revisited

We’ve had the pleasure of working with Trinity Stairs on several previous projects, and that relationship gave us a strong foundation to build on. They know our standards, and we understand their vision, workflows, and expectations.

So when they reached out with this new project, we didn’t need a long back-and-forth—we were able to dive straight into the planning phase and quickly align on specs, materials, timelines, and logistics.

The Scope: Over 250 Custom-Fabricated Parts

The scale of this project required both volume and consistency. Trinity needed more than 250 stair components, all fabricated to tight tolerances and with distinct material requirements:

• Balusters: Made from durable mild steel, each baluster needed to be cut to exact lengths and turned on our CNC lathe to achieve a clean, symmetrical profile with smooth transitions.
• Knuckles: These decorative accents were crafted from aluminum, which required a completely different fabrication process. Aluminum is lighter and more malleable than steel, so we used specific forming tools and machining setups to ensure the knuckles matched the aesthetic and dimensional needs of the overall design.

Mixed Materials, Matched Quality

Working with both steel and aluminum in the same project adds a level of complexity. The two metals behave very differently in terms of machining, finishing, and handling. We carefully managed:

• Tooling changes to accommodate the unique characteristics of each metal
• Precision fits between aluminum knuckles and steel balusters to ensure proper alignment and secure installation
• Surface protection, keeping aluminum components free from scratches or contamination that could affect final appearance or finishing

The result? A seamless integration of the two materials that looked uniform and professional when fully assembled.

Communication: Staying in Sync from Day One

With a project of this scale and complexity, clear and constant communication is everything. We made it a priority to keep our point of contact at Trinity Stairs updated at every key stage—when materials were received, when cutting began, when parts moved to the lathe, and when the knuckles were being formed.

These updates weren’t just a courtesy—they helped Trinity stay aligned with their own deadlines and installation plans. And by catching small questions or adjustments early, we avoided costly delays or rework down the line.

Turnaround Time: Fast, Focused, and On Point

Despite the job’s size, we completed everything in a tight turnaround window. Thanks to our in-house capabilities and flexible production scheduling, we were able to move fast without cutting corners.

Every part was inspected to ensure dimensional accuracy and surface quality before final packing and delivery. In the end, we hit the deadline and delivered a full batch of components ready to install—something both teams could be proud of.

Final Results: Form, Function, and Fit

When installed, these balusters and knuckles will be part of a standout staircase—strong, elegant, and built to last. And because we matched form with function from the start, Trinity didn’t have to worry about fitment issues or aesthetic inconsistencies.

Whether it’s a high-end residential build or a large-scale commercial project, these kinds of details matter—and they’re exactly what we aim to get right every time.

What Makes It Work? Long-Term Collaboration

This wasn’t just another one-and-done job. It was a reflection of the partnership we’ve built over time with Trinity Stairs. Repeat customers don’t happen by accident—they’re earned through trust, performance, and consistency.

At HollyFab, we take pride in building those relationships just as carefully as we build the parts themselves.

Ready to Build Something Great?

Have a custom metal fabrication project on the horizon? Whether you need a few unique pieces or a few hundred high-precision components, HollyFab is ready to help. From design assistance and material selection to machining, forming, and finishing—we deliver quality, fast.

📞 Reach out today and let’s talk about your next project.