Diamond Billiard Products Replaces Wood Table Legs with Molded Composite, Cutting Labor and Installation Time

Diamond Billiard Products, a manufacturer of high-performance pool tables used in professional tournaments worldwide, has replaced the traditional wood legs on its tables with a high-performance molded composite solution, resulting in significant reductions in labor, improved durability, and faster tournament setup. The change, developed in partnership with custom plastic injection molder Manar, represents a structural and operational transformation for the company.

For decades, Diamond’s table legs were made of wood, requiring cutting, shaping, sanding, finishing, and pre-assembly across multiple departments. The process involved eight employees and 10 to 12 individual components per leg, with production taking up to three months from raw material to finished product. Brent Lykins, mechanical engineer at Diamond, said, ‘I’m here to find better ways of doing things, approaches to reduce manufacturing time and enhance performance. The wood legs were very labor intensive. We wanted to streamline it.’

Installation was also inefficient. At tournaments, installers had to access leveling nuts near the floor, often lying on their backs to make adjustments. With tables set up across uneven venues, this process was slow and physically demanding. The new design uses a side-access panel and battery-powered tool, allowing installers to adjust legs up to 1.5 inches while seated. Installation is now three to four times faster, with improved ergonomics without sacrificing precision. At large tournaments with hundreds of tables, the time savings are substantial.

Diamond spent several years developing concepts and 3D-printed prototypes before moving forward. To make the design manufacturable at scale, they partnered with Manar. Together, the teams refined the design for injection molding while ensuring it could meet tournament-level demands. The final material, 40% long-glass polypropylene, provided the strength required for structural performance. FEA validation confirmed the legs could support a 1,200- to 1,300-pound table with minimal deflection. Diamond also conducted real-world stress testing, lifting and dropping tables to confirm durability.

The operational impact was dramatic. The wood legs that once required months of multi-step handling were replaced with a molded structural component produced in a fraction of the time. Part consolidation reduced 10 to 12 wood components to a primary molded body with a foot block and shaft. Anthony Neeley, new business development and director of operations at Manar, explained, ‘This wasn’t just about molding a part. It was about applying a design for manufacturability approach to meet the structural demands of tournament-level use and deliver measurable operational improvements.’

Following the success of the legs, Diamond partnered with Manar to manufacture its table pockets. Previously, pocket components were molded domestically, shipped to Taiwan for leather wrapping and returned, resulting in long lead times of up to three months, freight delays, quality fallout of up to 50% and risk exposure. The new pocket consolidates parts, eliminates a production step, removes dependency on overseas finishing, uses automated molding with robotic insert placement, and offers improved durability with a modern matte black textured finish. The redesign mitigates risk, reduces scrap, and improves supply reliability.

By converting a core structural component from wood to composite, Diamond reduced labor and manufacturing time, improved installation ergonomics, increased durability, strengthened supply chain reliability, and maintained tournament-level performance. Through its partnership with Manar, Diamond successfully modernized a legacy product without compromising the quality players expect.

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