The Capabilities and Applications of Metal Diaphragms
Metal diaphragms are thin circular plates that undergo elastic deformation when subjected to pressure or axial loading. They are typically manufactured by forming a thin metal sheet into a ripple shape. At Hudson Technologies, we offer metal diaphragms that are flat or corrugated, meaning as rings or solids. These types of products have the capability to have a variety of materials and sizes and can be used in many different types of applications.
Hudson’s Metal Diaphragm Capabilities
Metal diaphragms can be used for many different purposes. It is because of this that we offer so many different variations of sizes and materials. At Hudson Technologies, we offer metal diaphragms with a diameter of anywhere between 0.200 – 18.00” and a material thickness between 0.001 – 0.018”. This type of variation allows for you to have fully custom precision metal diaphragms.
We also have a large inventory of in-house stock with other materials available upon request. You can choose from:
Applications of Metal Diaphragms
Metal diaphragms are utilized in many different industries and serve many purposes. They are sometimes used in things such as; mechanical seals, edge welded bellows, pressure transducers and medical devices.
Metal diaphragms are typically used to:
Regulate pressure
Convert movement into measurable communication with equipment
Create a physical barrier between opposing forces in gas and liquids
Act as membrane used to pump fluids
Serve as a predictable failure point to protect equipment from overpressure conditions
Provide reliable performance including:
Cycling for up to millions of strokes
Capable of working in extreme environments (temperature, corrosion, etc.)
From one piece to high volume production, we are with you every step of the way. Quick-change tooling allows for efficient production of multiple products at varying quantities and reduced lead times. This means that no matter what the application, Hudson has the tools to meet the requirements necessarily to keep time and costs lower.
Hudson Technologies is a stand alone manufacturer of precision metal diaphragms with the expertise, equipment, quality, flexibility and capacity you need to cost effectively do feasibility studies, design metal diaphragms, produce prototypes, meet production demand and expand product lines.
If you’d like a product quote, please contact us today.
At Hudson Technologies, we’re always looking for ways that we can provide improved parts and services. And although we have always designed unique solutions for the secondary processing of our precision 3D metal parts for aerospace, medical, automotive, electronic, and a variety of other industrial applications, we have recently taken that a step further.
By employing innovative tooling, punching and CNC machining, Hudson has produced secondary holes, slots and flange cuts in delicate 3D metal parts without adversely affecting the part integrity. With our newest tool, a Rofin UW1200 5-Axis Fiber Laser, we are able to improve efficiency, accuracy, flexibility and capability for secondary processing.
5-Axis Fiber Laser Provides Increased Accuracy to Manufactured Metal Parts
By using this new 5-Axis Fiber Laser, Hudson Technologies is able to:
Produce a part in one step – eliminating costly tools, multiple setups, and labor expense
Expand versatility and flexibility with the addition of laser cut copper, brass, Inconel, titanium, Hasteloy and exotic shielding alloys
Improve turnaround times
Reduce the need for tooling and punches
And more…
An example of the benefits is an aluminum rectangular enclosure. This part was processed in less than 90 seconds in a single setup, well within the accuracy requirements. Edge quality was excellent and deburring was eliminated. In the past, processing this part required 3 setups that involved costly tooling, presses and labor.
We have initially assigned 200 part numbers for processing using this new tool, but plan to expand that number with standard and custom parts. We look forward to providing you with the highest quality parts and services with laser precision. To find out more about this process or to speak with a representative, call us at (866) 241-4448 or contact us online.
When you’re searching for a manufacturer for your deep drawn products, cost is a very important part of the equation. However, getting a deep drawn supplier is about more than just looking at the bottom line in terms of parts cost. Don’t underestimate the value and importance in having quality materials, workmanship and quality control.
Cutting costs on parts up front can end up costing you more in the long run in time and money. Avoid these unforeseen costs by finding a deep drawn manufacturer with these traits:
Knowledge and Experience
Quality is a word that is used frequently these days, but in order to make quality deep drawn parts for your company, the manufacturer you choose needs to have the knowledge and experience to ensure your part meets your exact specifications and the role that part must play.
For more than 75 years, Hudson Technologies has been partnering with some of the world’s most recognizable companies to manufacture products to meet their specific needs. We have the experience needed to get each and every part perfect, each and every time.
Workmanship
Creating perfect deep drawn parts takes more than just a machine. It is the fusion of operator and machine that creates the quality deep drawn part for your company. We treat every part we create as if they were being made for our company; something that can’t be said of all manufacturers.
Cost is always part of the equation, but quality of materials (such as stainless steel and titanium, along with aluminum, cold rolled steel, brass, copper, HY-MU 80 (other shielding alloys available), nickel, cupro nickel and more), workmanship and experience are what makes a great product.
Deep drawn metal stamping is a manufacturing process that competes with several other processes that create the same or similar products. However, the deep draw process has several significant differences that set it apart from those other methods. Without being an expert on manufacturing, you could fall victim to hearing false myths about deep draw, so we’re going to be debunking a few of them today.
The cost is too high. Simpler methods are cheaper.
False. Deep draw is a continuous process, making it one of the fastest and most cost effective available. Using the deep draw process, the cost per unit decreases as the number of parts produced increases.
Deep drawn stamping can only create simple parts.
False. Deep drawn metal stamping is capable of creating highly complex geometries to very tight tolerances. Multi-station stamping presses are capable of forming axisymmetric parts that are seamless, strong, and light.
High tech = high cost.
False again. From an operational standpoint, deep drawn metal stamping is one of the simplest and most robust processes available. Low technical labor costs and high production time combine to make the deep drawn process easy and profitable to manage.
Materials are weakened by deep drawing.
While understandable, this myth is still false. A common misconception is that deep drawing stretches the material and therefore damages it. The reality is that the force but on the material only increases the overall strength through a process known as cold working. While some elongation may occur, actual stretching of the base material is very slight. In the end, the finished part is actually stronger than the original material.
While there are more misconceptions out there, these are the top four myths about deep drawn metal stamping and the deep draw process. For more Hudson Technologies FAQs, check out our Ask Farley section, where our all-around deep draw guru, Farley Fitzpatrick answers questions sent into us.
When it comes to choosing the right manufacturer for your deep drawn metal enclosures, cases, stampings, and metal diaphragms needs there is a lot that can factor into your decision. Beware of lost cost, international manufacturers who may not provide a quality product, could deliver late, and could have hidden fees.
Here are some things to look for when selecting your manufacturer:
Experience
When considering different manufacturers, it’s important to take into account their overall experience and reputation. The more experienced the manufacturer, the better your odds of them being able to meet your specific requirements.
For more than 75 years, Hudson Technologies has been partnering with some of the world’s most recognizable companies to manufacture products to meet their specific needs.
Product Offering
One of the most important aspects of choosing a manufacturer is ensuring they have the capability of doing the work that you need and using materials you require.
Our catalog has over 15,000 standard deep drawn shapes and sizes available with little to no tooling charges. And our engineered products offer custom components designed to customers’ specifications.
Values
Believe it or not, the values of a company can really mean a lot when working with them for your manufacturing needs. If building a green supply chain and creating more sustainable products are important to you and your customers, Hudson Technologies is the right manufacturer for you.
We are a leader in green manufacturing because it is the right thing to do – for our customers, our team members and the community. We are leading the way in our industry. The majority of stamping companies today continue to use chlorinated lubricants and hazardous solvents.
We’re also open to questions and communication throughout the design, deep draw process and delivery. Communication is very important because this is your product, and you certainly should be up to speed on its progress.
Regardless of your project size, it is important to choose the right manufacturer for the job. That means choosing someone with the experience to create what you need, the supplies and technology to get it done, and the values that make you proud to present your products to your customers.
To find out more about our products, contact Hudson Technologies online or call (866) 241-4448.
When technology depends on a battery case to perform reliably, even in the most demanding environments, it’s time to look towards deep drawn metal battery enclosures. At Hudson Technologies, we manufacture deep drawn metal battery cases for implantable medical devices, aerospace, aviation, military, hybrid electric vehicles and other industrial and commercial applications worldwide.
Hudson Technologies offers many things when it comes to battery enclosures including:
Little to no tooling charges on over 15,000 standard shapes and sizes in our catalog.
Custom Battery Enclosures: Built to your specifications and requirements
Cylindrical deep drawn enclosures – standard and custom
Expertise manufacturing prismatic (rectangle) deep drawn enclosures – including stainless steel and titanium
Covers and headers with secondary machining operations
Manufacturability and design solutions
Project management works with you every step of the way to ensure new programs launch smoothly
Finite Element Analysis (FEA)
Prototypes to high-volume production
Global sourcing
Covers/headers with secondary machining operations
At Hudson Technologies, you also have the assurance of working with a green manufacturer. Our environmentally superior products are made using biodegradable lubricants and an aqueous cleaning system. No chlorinated lubricants or solvents are ever used to manufacture our products. Our manufacturing process produces no hazardous waste.
To find out more about our deep drawn metal battery enclosures, contact Hudson Technologies online or call (866) 241-4448.
Titanium Alloy 3-2.5 (Grade 9) is a medium strength alloy with good weldability and fabricability for mildly reducing to mildly oxidizing media. For years, people in our industry said it was “impossible” to deep draw Grade 9 titanium alloy. Through many years of research and testing, Hudson Technologies has proven that it CAN be done. So what does that mean for you?
The Perfect Compromise
Grade 9 titanium alloy is the perfect compromise between the facility of welding and manufacturing of the “pure” grades and the high strength of Grade 5 or 23. It has excellent corrosion resistance and can be used extensively in the aerospace, chemical processing, medical, marine and automotive industries.
For years, Medical OEM’s have been asking for deep drawn Grade 9 titanium, especially for neuro devices. Grade 9 titanium offers better telemetry than commercially pure titanium, better electrical properties (allowing devices to be charged remotely), and better MRI performance.
Deep Drawing
Deep draw manufacturing forms metal into a seamless round, square or rectangular shape called an enclosure, or case. Deep drawn cases are used to enclose technology, especially in demanding environments or whenever tight tolerances and reliability are important.
Many factors, including material type and thickness, corner and bottom radii, and shape, determine the number of reductions required to make an enclosure.
To find out more about deep drawing Grade 9 Titanium capabilities and what that can mean for your company, contact Hudson Technologies today.
Deep drawing is the process of using metal dies to form blank sheets of metal into a desired shape. Specifically, if the item depth is greater than its radius, the metal forming process is called deep drawing.
This popular metal forming method has many benefits over other methods and by using the deep drawing process, you can maximize your money and get more for your business.
Deep drawing from Hudson Technologies is a great solution for any manufacturing process that requires one or more of the following:
Seamless parts: deep drawn parts are created from a single sheet of metal.
Rapid cycle times: large quantities of products are easily manufactured through deep drawing
Deep drawing delivers exceptional detailing and accuracy
Reduced technical labor: precision deep drawing can deliver similar results as technical labor in quicker time frames
Deep drawing is especially beneficial when producing high volumes, since unit cost decreases considerably as unit count increases. Once the tooling and dies have been created, the process can continue with very little downtime or upkeep.
Another money saving aspect of deep drawing is that tool construction costs are lower in comparison to similar manufacturing processes, such as progressive die stamping, even in smaller volumes.
Factors That Could Affect Cost-Effectiveness of Deep Drawing
As with most things, more complex products will increase maintenance costs, labor costs, and production costs. When considering the costs of deep drawing, these are the types of factors that will influence cost:
Hudson Technologies is an industry-leading manufacturer of high-quality standard and custom deep drawn metal enclosures and stampings. Because of our 79 years of stamping experience, vast knowledge of stamping technologies, and broad manufacturing capabilities—including a variety of shapes, sizes, and metals, —companies around the world turn to us for their metal enclosure and stamping needs.
The following eBook outlines our manufacturing capabilities and highlights some of the additional benefits of partnering with us for your next project.
Tooling and Equipment
At Hudson Technologies, we employ a wide selection of tooling and equipment to ensure every product is a perfect fit for its application.
Our Tooling
For our deep drawn and stamped catalog products, we offer little or no tooling charges on over 15,000 standard shapes and sizes of enclosures. For more unique parts, our highly skilled team of toolmakers design and build all of our custom tooling in our in-house tool room that is fully equipped with state-of-the-art tool making equipment.
Our Equipment
In addition to our tool making equipment, our facility is equipped with a variety of manufacturing and finishing equipment, such as:
130 deep drawing presses. We employ several types of presses—including hydraulic, pneumatic, servo, and double-action mechanical—that generate forces ranging from 1 to 500 tons. This large variety of presses gives us the flexibility to make sure out customer’s parts are manufactured on the most efficient equipment.
Annealing and heat treating furnaces. Our vacuum and hydrogen humpback furnaces allow us to perform in-house annealing and heat treating.
Green manufacturing. None of our production processes use chlorinated lubricants or solvents, allowing us to manufacture safer, greener products. All lubricants used are water soluble, and we employ state-of-the-art aqueous cleaning equipment.
Deep Drawing Capabilities
Our deep drawn products are available in a wide range of sizes, materials, tolerances, and shapes.
Size
Regarding size, we offer manufacturing capabilities for:
⅛ to 12 inches (3.1 mm to 305 mm) in diameter
Up to 12 inches (305 mm) in length
.002 to .187 inches (.05 to 6.35 mm) in thickness
Material
We can source and work with a variety of metals and metal alloys to create finished deep drawn parts. Some of the materials we typically employ include:
Aluminum
Brass
Copper
Nickel and nickel alloys (e.g., Kovar®, Mu METAL®, nickel silver, cupro-nickel, and other nickel alloys)
Steel and steel alloys, including aluminized steel, cold rolled steel, and stainless steel
Titanium
Precision/Tolerance
The tolerances we achieve on deep drawn parts are largely dependent on the part’s material and other design specifications. For example:
For custom cases: tolerances are as low as ±0.002 inches (0.05 mm)
For precision headers: tolerances are as low as ±0.0005 inches (0.0127 mm)
For drawn corner radii: tolerances are as small as 0.005 inches (0.127 mm)
Shape
We offer deep drawing capabilities for standard and custom shapes, such as:
Rounds
Squares
Rectangles
Asymmetrical forms
Flanges
Value-Added Services
To support our manufacturing operations, we offer additional services to ensure the delivery of a complete, high-quality deep drawn part. Our value-added services include:
Modification, Finishing, and Assembly
Surface treating and finishing, such as aqueous cleaning, anodizing, bead blasting, deburring, heat treating, painting, passivation, plating, polishing, and powder coating
Part modification, such as bulging, coining, extruding, machining, piercing, and tapping
Components assembly
PEM®, stud, and standoff insertion
Welding, including brazing to MIL specs and laser, resistance spot, and TIG welding
Assistance With Manufacturing and Reliability
Engineering design assistance
Finite element analysis (FEA)
Lean and Six Sigma compliance
Program management
Product design and metal forming simulations prior to manufacturing
Smart Scope and metallurgical analysis services
Trade compliance
Stocking Programs and Supply Chain Management
Our stocking and supply chain management services include Kanban, logistics support, and LTL truckload and export services.
High-Quality Service
At Hudson Technologies, we strive for excellence in everything we do. Some of the key factors that contribute to us consistently delivering high-quality products and services include:
Highly Skilled Staff of Engineers and Tool & Die Makers
Our expert team has the skills and knowledge to serve customers in a wide range of industries, such as:
Aerospace and Aviation
Automotive
Commercial Battery
Electrical
Industrial
Irrigation
Medical
Semiconductors
With years of experience producing deep drawn products for both prototype and high volume production runs, they can handle projects of any size.
Finite Element Analysis (FEA)
Before the actual manufacturing process, our team of engineers can prepare a Finite Element Analysis (FEA). This simulation uses the Finite Element Method (FEM) to simulate and test designs before they move forward in production. By using this technique, our team reduces the number of physical prototype stages required, streamlining the product creation process.
Green Manufacturing
We take pride in operating as environmentally friendly as possible. We replaced the traditionally used chlorinated lubricants with biodegradable lubricants and employed an aqueous cleaning system that uses agitation and ultrasonics instead of chemicals to clean parts. Additionally, all cleaned parts are dried in a HEPA-filtered recirculating dryer for complete product control.
These changes allowed us to minimize our environmental footprint by eliminating the production of hazardous waste.
Cost Efficiency with Hudson
By partnering with Hudson Technologies, you get cost-effective solutions without sacrificing product or service quality. Maintaining the quality of our products and services relies on the following:
Process repeatability. The deep drawing process is highly repeatable, which minimizes the need to run additional production operations to resolve delivery or quality issues.
Our extensive product catalog. While we do accommodate custom orders, we maintain an extensive catalog of tooling for over 15,000 standard shapes and sizes. If a custom part is required, there will be a one-time tooling charge assessed. The tooling then will be maintained by Hudson for the life of the product at no additional tooling charges.
Material conservation. Our deep drawing operations produce minimal material waste.
Faster production. The deep drawing produces finished parts in fewer steps than some other manufacturing processes, which increases production efficiency.
To learn more about our standard and custom product and service offerings,contact us orrequest a quote today.
When manufacturing medical components, every care must be taken to ensure the medical component is hygienic, safe and suitable for performing the task it was designed to do. As part of this process, Hudson Technologies, a leading U.S. green manufacturer of deep drawn metal enclosures, or cases, and stampings, including metal diaphragms, has implemented a rigorous quality management system that ensures all manufactured parts comply with all standards.
Here are the top 3 priorities when manufacturing deep drawn medical components. Always ensure your deep drawn manufacturer can supply these things.
Keeping Medical Components Clean
During the process, it is essential that components are kept clean and hygienic. No chlorinated lubricants or solvents are used in our TCE-free manufacturing process, producing no hazardous waste. Still, to ensure proper cleanliness, all fluids used must be safe and special cleaning processes used to remove all traces of fluids and manufacturing debris that remain after manufacture. After thorough cleaning, components will be carefully packaged to prevent contamination.
Having Precision Equipment
Whether parts are to be used in medical equipment or for implanting, manufacturing tolerances must be maintained to ensure the components will fit exactly and work as intended. To ensure precision, we have:
OGP Smart Scopes – touch, laser and optical measuring capabilities
Material and process traceability
Obtaining a Quality Surface Finish
One of the best methods of ensuring a medical component is hygienic is to specify a very high-quality surface finish. Highly polished surfaces with no defects can be readily sterilized and it gives infections nowhere to take hold. It is important to ensure tools and dies being used have a good surface finish and are well maintained. This way, parts coming off the press have high-quality internal and external finishes. From there, subsequent finishing processes can achieve the specified finish.
