Inside The shop 2 questions
Inside the Holster Shop: 20 Questions About How We Build Custom Kydex Holsters
At DME Holsters, customers often ask how our holsters are made, why they fit so well, and what makes them different from mass-produced options. We sat down to answer 20 common questions about our process, philosophy, and what it really takes to build a quality custom Kydex holster.
1. How did DME Holsters start?
Back in 2012, we couldn’t find a quality holster for one of our firearms. After researching, we realized we could build one ourselves using Kydex and a foam press. What started as a DIY project turned into a business when we discovered how many shooters had the same problem: not enough high-quality holster options.
2. What was the hardest part of making holsters in the beginning?
The toughest challenge was figuring out blocking and channeling—especially once lights and lasers came into the picture. Non-light holsters were straightforward, but adding accessories required careful design to maintain both clearance and retention.
3. How do you design holsters today?
Originally, we used blue guns and foam presses with clamps. Today, we use a 3D scanner to scan the firearm, light, or laser. The scan is imported into Fusion360 CAD software where we design the mold. From there, it’s exported to our industrial 3D printers for production.
4. How do you test retention and fit?
In the early days, it was trial and error with slicer settings and print tolerances. After years of experience, we now know exactly where to build retention points into the design. Testing is minimal because our molds are precise and repeatable.
5. How do you accommodate optics, threaded barrels, and extended magazines?
We design holsters with RMR/optic cuts and threaded barrel clearance by default. Extended magazines don’t affect holster design. For ambidextrous mag releases, we make sure the inside is uncovered for admin mag changes, while the outside is protected to avoid accidental drops. Everything is modular, so one mold can be adapted for IWB, OWB, right- or left-handed carry.
6. What’s the most difficult holster style to make?
Pancake holsters are by far the hardest. They require two pieces, perfectly aligned rivet holes, and extensive finishing. Level 2 retention OWB holsters come second, since spacing the retention mechanism correctly is tricky.
7. What materials do you use?
We prefer Boltaron .080 for pancake, IWB, and AIWB holsters, and .093 Kydex for standard OWB. Boltaron is stronger but limited in colors; Kydex offers more customization. Hardware is U.S.-sourced whenever possible, with stainless steel posts and screws for durability.
8. How do you balance retention and draw speed?
All of our holsters feature adjustable retention (except pancake holsters, which are pre-set for balance). Customers can tighten them until the gun won’t come out, or loosen them for a faster draw. If they need help, we walk them through adjustments over the phone.
9. What are the most common customer mistakes?
Most fit issues come from incorrect orders—like choosing an M&P 2.0 holster for a Gen 1 pistol, or selecting the wrong light. We always ask for photos, which usually reveal the problem. On rare occasions, manufacturer specs are off (Springfield and SIG have had inconsistencies), and in those cases, we issue refunds.
10. What’s your warranty policy?
We offer a guaranteed fit based on the order form. If you filled it out correctly and the holster doesn’t fit, you’re covered. We also back every holster with a lifetime warranty against defects, excluding abuse (like leaving it on a hot car dashboard).
11. Do you handle custom requests?
Most “custom” options (colors, optics cuts, handedness) are already built into our order form. We don’t do off-brand lights, but for unique setups like cross-draw or small-of-back, customers can call us for instructions on how to order.
12. How do your holsters compare to mass-produced ones?
Quality. Ours don’t rattle. They’re precision-made with attention to fit that mass-production simply can’t match.
13. Do you change designs based on feedback?
Not usually. Customers sometimes request lower sweat guards or trimmed ends, but we intentionally design with a little extra material. We’ll guide them on how to trim and sand it if they want, and this doesn’t void the warranty.
14. What shop equipment do you use?
Beyond CAD and 3D printers, we use vacuum pumps, presses, heat strips, drill presses, band saws, Dremels, and belt sanders. Every holster is hand-sanded for a smooth finished edge.
15. How do you improve comfort and reduce printing?
We’re honest: no IWB holster is truly “comfortable.” But we design sweat guards within ⅛” of the slide, extend small-gun holsters for stability, and recommend mod wings or foam wedges to reduce printing and hot spots.
16. Do you make magazine carriers?
Yes. We offer universal mag carriers for single stack, double stack (9mm and 10mm), and AR-15 magazines. They’re made with the same precision molding as our holsters.
17. How do you handle order spikes?
We’re a small business. When demand surges, we work harder and longer. Quality never takes a back seat.
18. How important are aesthetics?
We prioritize function first, then aesthetics, then customization. Customers can pick from a wide range of colors and patterns through our order form.
19. What’s the biggest misconception about holster making?
That it’s easy. People watch YouTube and think they can replicate it. What they don’t see is the hundreds of thousands of dollars invested in CAD software, 3D printers, shop equipment, and the years of trial-and-error experience.
20. What’s the future of DME Holsters?
We’re staying small. Large-scale production sacrifices quality. We’d rather build fewer holsters at the highest standard than mass-produce at the cost of fit and finish.
Final Thoughts
DME Holsters was built on necessity and has grown into a business known for precision, quality, and customer service. From CAD design to hand finishing, every holster is crafted with care. We don’t cut corners, we don’t compromise on fit, and every product comes with a lifetime warranty.
👉 Ready to order your custom Kydex holster?
Browse our collection here: Shop Holsters