But the popularity of those keychains with the USFG logo on them led Lynch into making belt buckles — the design became part of the official Forest Service ranger uniform - and then to build a foundry in Encampment, which became the Western Heritage Co., which in turn grew into a major manufacturer of custom-made bronze, silver, gold and silver alloy cast items.When Pat's son Mike Lynch became president of the company in 2001, he moved most of the operation to Loveland, where the company has continued to expand its product line to lapel and hat pins, award plaques and knives/multi-tools. They've also progressed to embroidered patches, briefcases, desk accessories, metal coasters, clocks and mugs, all while retaining a significant number of processes in-house.
Western Heritage provides a long list of state and federal agencies with custom products, including the Forest Service, Bureau of Land Management, U.S. Fish and Wildlife Service and the National Park Service, as well as local customers including Thompson Valley High School and Colorado Youth Outdoors, all of which also sell items online.
And demand is booming, to the point where the company has been renting manufacturing space in north Loveland after outgrowing its original location. The plan is for Western Heritage to build a new, custom-designed, 7,500-square-foot plant of its own in Timnath later this year.
Question every expense
How is Western Heritage able to build a tailor-made facility in the current economy?
It's all about conserving money and resources, according to Mike Lynch, who also admits his shrewd mindset has kept the company debt-free.
"We have always treated this business as if we were in the startup phase, even though we are going into our 34th year," he said.
Lynch had the foresight two years ago to slash budgets and allow natural attrition to downsize operations to the current dozen employees. He said he has always asked three questions of every expense:
- Do we need it?
- Can we do it ourselves?
- Can we find it used somewhere?
A self-described auctionaholic, he keeps a steady eye on eBay, Craigslist, government and Colorado State University surplus and auction houses for any useful equipment. The company's telephone system first served the Grand Junction Bureau of Reclamation. Metal tumblers initially shined CSU silverware, and embroidery machines that recently arrived from Iowa were a lucky eBay purchase Lynch made on Christmas Day. He also buys used government vehicles for $600 or less — "They run great." — that he's been known to pass on to employees as perks and thank-you gifts.
"I have only bought one piece of new equipment, and maybe two out of 15 computer systems," he said.
Lynch is deeply pleased with "one of the coolest machines" he's yet acquired: a gently used 3-D printer that turns CAD files into wax forms.
"We can then take those 'prints' and cast them in metal here in our shop," he explained, kicking the company's fine metal-smithing up a notch.
The 3-D printer will soon be joined by what Lynch describes as his "dream casting machine," purchased from NASA surplus last year.
"It is the only one in the world with its melting capabilities," he said. He hopes its unique capabilities will allow the company to maneuver even more solidly in the hotly competitive small-castings world.
By late February when the machine is uncrated, calibrated and put on the production line, Western Heritage will have run it more in one day than it operated during its entire tenure at the space agency.
Lynch will not divulge what he paid for the machine which cost over $120,000 new, but says, "I got a great deal."
