Decades of Exceptional
Craftsmanship
Who We Are
Founded in Spokane Valley in 1981 by custom woodworker Ken Kaiyala, The Design Factory has produced hundreds of high-quality, handcrafted original works for residential and business clients in Washington and all over the US.
The Design Factory grew out of Ken’s passion for creating unique designs. In his more than 40 years in the trade, Ken has produced made-to-order wood products of every kind:
Handcarved, sandblasted, routed, and multilayered signs for businesses, churches, lake cabins, apartment complexes, subdivisions, special occasions, and more
Specialty cabinetry
Custom wood furniture and accessories such as wine storage and reception desks
Landscape lights and outdoor structures
Custom doors and gates
Decorative wooden boxes and cutting boards
Background
Ken's interest in making things, and woodworking in particular, showed itself in his 7th grade shop class in Portland, Oregon, where his work won a citywide craftsmanship award. Ken went on to a technical high school, Portland State College, and Oregon State University where he studied science and manufacturing engineering.
For 20 years Ken worked as a manufacturing engineer, engineering manager, and facilities manager in the foundry industry, all the while continuing woodworking and art as hobbies. He also designed and built his own family's home during this time.
In 1981 Ken started The Design Factory as a part time business designing and making custom woodwork items. In 1984 this business became his full time passion.
In 1987 Ken opened a second business to manufacture architectural millwork and high-volume wood products, and to complete large woodworking projects. Clients included Keystone Lighting, Columbia Lighting, Carver Stereo, local cabinet shops, and local residential and commercial building contractors.
In 1995 Ken left managing this big business and returned to his real love: designing and making specialty woodwork projects. The most rapid growth in this rejuvenated business has been the design and manufacture of handcarved signs and their mounting structures.
Ken in his shop in Spokane Valley, WA
Design Process
The Design Factory is happy to produce a design you already have, or work with you to come up with a new design that fits your needs and budget.
Our process is to first make sure we understand your objectives, and then propose a concept that is straightforward but with some unique touches if possible. We always try to create a product that blends in with its environment.
For signs, we may also suggest specific colors or 3D elements that ensure it is easy to see and eye-catching. Sometimes mounting structures can be used to make the sign seem larger and grab more attention. See examples on our Gallery page.
Images courtesy St. Paschal Catholic Chuch
Materials
The Design Factory does not make backlit exterior plastic signs. Our signs are made primarily from wood or high-density urethane foam.
If an exterior sign is to be made from wood for appearance or for structural reasons, we usually use clear laminated vertical-grain western red cedar. This is the preferred material for handcarved incised lettering, although sometimes domestic or imported hardwoods are used. Of course, interior signs can be made from most any type of wood, or you can specify the material for either application if you choose.
For sandblasted wood signs, we use flat-grain western red cedar.
For signs with solid painted backgrounds, the preferred material is high-density urethane foam. It carves and machines easily, paints well, and has a material lifetime guarantee. It is also used for sculptural elements attached to the sign face.
For signs with a solid painted surface, Sherwin Williams water base exterior primer is first applied and lightly sanded. Then a 30-year house paint is applied. It can be tinted to any color necessary and is easy to use. All copy and sculpture elements are also finished with exterior paint.
Some signs have decorative metal elements or are used as mounting brackets. These can be made from aluminum or steel. The aluminum can be used unfinished or painted. The steel can also be painted, powder coated, galvanized, or rusted and oiled for and antique look. Chain, bright finished, painted, or rusted is used for most hanging signs. Steel rods can also be used.
Ken cutting a letter into a cedar sign using his custom carving tools
Working With Us
If you’re interested in hiring The Design Factory for a custom project, send Ken an email at kkaiyala@comcast.net or call him directly at (509) 255-5355. Since each product is made to order, lead times are determined per project. We typically require 60% down at the beginning of the project to purchase materials, and then bill the remaining amount upon completion and delivery. Shipping costs depend on how large the item is, and where it is being sent. All custom work sales are final and non-refundable.
Contact The Design Factory today to begin your next project.