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Author Archives: John DeBone

  1. Metal Stamping Custom Components

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    When you partner with an experienced, industry-leading parts manufacturer, you’ll gain access to a wealth of standard tooling options from which to choose. Occasionally, however, standard offerings may not be enough. If you are considering one or more custom components, it is helpful to understand when you should seek custom manufacturing as opposed to standard, and what to keep in mind to make the most beneficial selection.

     

    Custom vs. Standard Deep Drawn Manufacturing

    Most projects can be accomplished with standard deep drawing dies, even if they include complex geometries. But when you use standard components instead of designing new components from scratch, your options will necessarily be limited and might not suit your needs. If you want an angle, depth, or shape that is uncommon, for example, you might need to engineer and commission prototypes to build a part that’s fully customized.

    However, this process is expensive and takes more time than using standard parts. To reap the benefits of both custom and standard solutions, look for a manufacturer who can modify existing components to fit your specifications. This process is called a “custom-standard” solution, and if these changes are minor, it will usually be faster and more affordable than developing a new component from scratch. Cans, cases, enclosures, covers, and headers are all relatively easy to modify with deep draw manufacturing. For example, if you have a standard can with a welded or brazed bracket, a manufacturer can replace the can with a custom version that has a drawn flange. In this scenario, the manufacturer will have provided a custom-standard solution that’s more effective than the standard option but faster and less expensive than building the part from scratch.

     

    Common Deep Drawn Modifications

    Many changes can be incorporated into standard deep-drawn components. For example, beads, ribs, holes, inserts, notches, slots, trimming, embossing, dimpling, and marks can all be added during the deep draw tooling process to create a near-custom component. Brackets can also be attached, and paint, powder coating, silk-screened graphics, and various plating types are available as well. These secondary standard modifications, when integrated into the deep draw manufacturing process, can reduce the production length and cost, as well as improve the product’s overall quality.

     

    Benefits of Custom Finishes

    Custom finishes can be applied at the end of the deep draw metal stampings process. Many options provide unique capabilities or attributes for specific applications. Operations like marking, for example, adds identifying numbers, letters, or graphics to a part. Embossing engraves shallow characters into the metal or raises the surface to create punctuated characters. Notches and threading are two processes that facilitate an appropriate fit.

    Further efficiencies can often be gained by having a custom deep-drawn part delivered that’s already prefinished with paint or a chemical film to provide corrosion-resistance (a process called passivation). Electro-polishing, plating, brazing, laser drilling, and laser etching are all finishing services that alter the material’s surface and can serve a practical or aesthetic purpose.

     

    What Is “Part Complete?”

    If a system is part complete, it means all the necessary operations are performed in one process. This approach provides many advantages over traditional, multi-level assembly; in general, it offers better accuracy, efficiency, and turnaround time, as long as all the technical requirements can still be met.

    If you need to execute secondary operations after receiving a part, talk with a manufacturer to determine if some of these operations can be addressed during the deep draw process. By consolidating these steps, you might be able to make assembly more cost-efficient and eliminate opportunities for human error.

    Click here to download our Catalog vs. Custom Deep Draw Metal Stamping eBook →

    Hudson’s Standard Tooling Library

    Before requesting a quote from a deep-draw manufacturer, look at their tooling library. The manufacturer should have a catalog of standard products without additional tooling charges, which will help to control your overall costs and lead time. Even if some tooling is required, a manufacturer with an extensive standard library can often use their existing components to provide a cost-effective solution.

    Hudson Technologies’ standard tooling library contains over 15,000 unique components. We make it easy to find precisely what you need by allowing users to search by the part number, keyword, size, diameter, shape, application, or material. Thanks to our extensive catalog, we can modify existing components to let you decide which properties you want to have in your final component. Whether you want a nonstandard finish or an improved assembly process, Hudson Technologies can provide a standard, custom, or custom-standard solution that suits all your needs.

    Click here to browse our standard catalog→

     

    Custom Component Solutions from Hudson Technologies

    Hudson Technologies is an AS9100D-certified company that has been designing and manufacturing the highest-quality metal stamping solutions since 1940. In 2007, we also converted our 115,000-square-foot facility to 100% green manufacturing. If you need to create custom components, Hudson Technologies can offer deep drawn stamping services that will improve your product quality and optimize lead time. To get started on your next custom component solution, or discuss which stamping service is right for you, contact Hudson Technologies today.

  2. Metal Stamping for the Aerospace Industry

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    When it comes to the aerospace industry, there is no room for manufacturing error. The tight tolerances and precision measurements required doesn’t allow for “good enough,” it must be perfect. Whether you need a small, precise connector, a stamped metal clip part, spring, complex gearhead, or steel airframe component, metal stamping can allow you to create a multitude of parts small and large.

    Deep-Drawn Stamping for Precise Tolerances

    The deep drawing process itself is not too complicated. Through the action of a punch, a sheet metal blank is drawn into a die. As the die forms the metal around the punch, the blank is formed into a specified three-dimensional shape little by little. It’s considered a “deep draw” when the depth of the drawn part is greater than its diameter.

    This type of process can produce both symmetrical and asymmetrical parts. Deep drawn metal stamping (DDS) is versatile and produces strong metal parts. The drawing process leads to a finished deep-drawn part stronger than the original raw material used to manufacture it. This is critical when manufacturing aerospace parts, for example.

    Aerospace Components Manufactured with Deep-Drawn Stamping

    Because deep drawing creates strong, exacting parts within tight tolerances, they are ideal for producing components that interact with other configurations. Our metal stampings are often used in the following equipment for Aerospace applications:

    • Instrumentation
    • Oxygen generating systems
    • Military aircraft housings and enclosures
    • Relays, switches and lighting systems
  3. Standard vs. Custom Metal Stamping

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    Metal stamping is a process that transforms flat sheets of metal into different shapes. It is done through a process called cold forming, using dies and stamping presses. A high volume of identical components can be produced with metal stamping, and it is generally faster and more affordable than other metal fabrication processes.

    While many tooling processes can be accomplished with speed, economy, and a high degree of quality and reliability, there are times when custom metal stamping will offer superior results. The challenge for customers attempting to choose between custom and standard metal stamping hinges on their budgetary and time restrictions. Custom tooling necessitates investing in the product research, development, and testing, whereas standard metal stamping products have already been vetted for defined applications.

    Benefits of Standard Metal Stamping

    When the word “custom” is used to describe a part, particularly within a highly specialized field, it can be perceived as preferable to a standard line of products. However, many components that are now standard started as custom projects. Even though custom parts are tailored to the user’s exact specifications, they may not necessarily be the best choice when you consider the time and cost that it takes to produce them. Standard components take advantage of economies of scale in production, and they also benefit from years of testing and retooling to make designs as efficient as possible.

    Hudson Technologies has an extensive catalog of metal stamping options that can give quality results that rival custom metal stamping. Over our history, we have developed our own standard tolerances, which we adhere to stringently. We can also modify our standard offerings to include even stricter tolerances or modifications with little to no custom tooling.

    The benefits of choosing from our standard tools and parts offerings include:

    • Choice: A vast array of over 15,000 available shapes & sizes.
    • Flexibility: Easily modifiable components with brackets, holes, slots, thread inserts, and more optional features.
    • Finish: You can choose the finishing options that best fit your application.
    • Assembled-to-Order: We offer subassembly of other components into the enclosure.

    Benefits of Custom Metal Stamping

    Standard vs. Custom Metal Stamping

    There are also times, however, when the specification for your product requires customized tooling. For these situations, Hudson Technologies has years of experience designing, manufacturing, and finishing custom metal parts using metal stamping. We can engineer a solution that meets your budgetary and performance requirements, and our customers retain full ownership of the proprietary component after the project is finished.

    Our 15,000-sq.-ft., AS9100D-certified facility can produce parts of any shape or size. For our customers, that means we can meet or exceed market standards and ensure products are created consistently with the highest-quality materials, even when parts are fabricated to tight tolerances.

    Choosing Hudson Technologies for your custom-made metal stamping products provides many advantages, including:

    • Accuracy: The technical capability to adhere to exact client specifications.
    • Reliability: Design and engineering teams that leverage their expertise to meet performance, cost, and manufacturability requirements.
    • Customization: In-house custom tooling to fit unique applications.
    • Proprietary Ownership: Complete customer ownership of tooling upon product completion.

    Metal Stamping Services From Hudson Technologies

    All of Hudson Technologies’ tooling is performed in-house with quality, reliability, and manufacturability in mind. We take great pride in our creative collaborations with our customers to ensure they get exactly what they need, whether it is adjusting standard metal stamping components or creating custom ones. Our teams run a total of 130 forming presses around the clock.

    To learn more about our metal stamping services, contact us today. You may also submit a request for a quote online.

  4. Corrugated Metal Diaphragms

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    The team at Hudson Technologies is proud to specialize in custom metal diaphragms, which we create using advanced tool designs and sophisticated power press technology.

    Put simply, metal diaphragms are thin, circular plates that elastically deform when subjected to axial loading or pressure. These mechanical seals are typically manufactured by forming a thin metal sheet into a ripple shape. Depending on their intended use, metal diaphragms can be corrugated, domed, or flat; corrugated types are the most versatile and widely used. Flat diaphragms can usually be mass produced, but corrugated diaphragms require a proprietary tool for the manufacturing process. They have greater deformability and a linear characteristic curve.

    Metal diaphragms are available in a variety of materials and sizes, and can be used in many different applications. Hudson offers metal diaphragms made of Inconel®, Haynes® 242®, Hastelloy®, titanium, Monel®, and 17-7 PH stainless steel. The ideal profile shape will depend on specific pressure, cycle life, and deflection requirements.

    Hudson offers a wide selection of standard-catalog corrugated diaphragms, ranging in size from 1” to 3” in diameter.

    The Benefits of Using Corrugated Metal Diaphragms

    There are a number of advantages to using corrugated metal diaphragms. First, they achieve a larger linear range with improved mechanical sensitivity. Next, the corrugations can greatly improve pressure regulation and deflection. And finally, corrugated diaphragms provide accurate spring rates and long cycle life.

    Corrugated diaphragms allow for higher deflection than flat diaphragms, at the same working pressure. Studies have also shown that the sensitivity of corrugated diaphragms can be easily controlled by changing parameters such as the thickness of sheet, the depth of corrugation, and the pitch of corrugation.

    Common Applications for Corrugated Metal Diaphragms

    Corrugated metal diaphragms are ideal for high-pressure applications and high-temperature applications, such as mechanical seals, edge-welded bellows, pressure transducers, pneumatic modular instruments, electronic control instruments, and medical devices.

    These diaphragms can be used to achieve various goals, including:

    • Regulating pressure systems
    • Converting movement into measurable communication with machinery
    • Creating a physical barrier between opposing forces in liquids and gases
    • Acting as a membrane for the pumping of fluids
    • Serving as a highly reliable failure point, protecting equipment from hazardous overpressure conditions
    • Ensuring reliable performance for every job, allowing for cycling of up to millions of strokes
    • Working in extreme environments (e.g., those involving high temperatures and corrosion)

    Learn More

    Hudson Technologies has been an industry-leading metal diaphragm designer and manufacturer since our founding in 1940. With a reputation for high precision and unparalleled quality, we provide ultimate peace of mind to our customers through our stringent quality control protocol, AS9100D certification, and 13485:2003 and 14001:2004 compliance.

    From one-piece orders to high-volume production, our team is with you every step of the way. To learn more about Hudson Technologies’ manufacturing practices and custom metal diaphragm capabilities, reach out to our experts today. We’re on hand to answer any questions you may have, and will guide you through every step of the process to ensure you receive a solution that meets your exact needs.

  5. Choosing the Right Metal Stamping & Drawing Supplier

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    At Hudson Technologies, we are an industry-leading manufacturer of custom deep drawn metal parts and products. Equipped with decades of manufacturing experience and a broad range of standard and custom production capabilities, our team creates stampings for applications requiring precise, complex, and/or high-performance components. We accommodate customer projects involving a variety of metals (e.g., aluminum, brass, copper, nickel, cold rolled steel, etc.) and prototype to high-volume production quantities.

    Metal stamping is a metalworking process that employs a tool and die set within a stamping press to form metal into the desired shape. Deep drawing is a metal stamping technique that “draws” (i.e., pulls) the workpiece material into the die cavity during operations, resulting in a part whose depth equals or exceeds its width. Compared to other forming processes, it allows for the creation of seamless and lightweight parts without sacrificing strength or structural stability. However, successfully producing these parts necessitates having the proper manufacturing experience, production capabilities and capacities, and certifications.

    The following article outlines the qualities to look for when choosing a metal stamping and drawing supplier and how Hudson Technologies is the ideal partner.

    Commitment to Quality

    While cost is an important consideration when vetting potential deep drawn stamping suppliers, there are many other factors to keep in mind to ensure you receive the greatest value from your chosen manufacturing partner. One of the primary ones is the company’s commitment to quality—i.e., what measures they take to ensure the parts and products they produce meet high quality standards. This can encompass a variety of aspects of a company, such as:

    • Material quality. The ideal deep drawn stamping supplier should invest in the highest quality materials for the production of the desired parts and products, regardless of whether you require aluminum, brass, copper, HY-MU 80, nickel, stainless steel, steel, titanium, or another specialty material.
    • Product quality. Your partner should maintain a comprehensive quality control program to ensure every product fully meets your specifications and standards before it is packaged and shipped to your facility.
    • Employee quality. The manufacturing partner you choose should have the knowledge skills to accommodate your exact part/product requirements, which necessitates employing designers, engineers, and machine operators who have the proper experience and workmanship.

    Choosing a partner that emphasizes quality in everything they do—such as Hudson Technologies—ensures the quality of your products and business.

    Production Capabilities & Capacity

    As indicated above, the manufacturing partner you select should be able to accommodate your part and production requirements, meaning they should have the stamping capabilities and capacities to produce the designs you require to the specifications and standards you require in the volumes you require. Some of the qualities indicative of such a company include:

    • Comprehensive standard product catalog. A sizable standard product catalog saves you time and money, as you are less likely to require investment in custom tooling.
    • Extensive industry experience. An experienced team is more effective and efficient at tackling any challenges that may arise during the project.
    • Vast material sourcing network. A big sourcing network makes it easier to source any materials required for the project.
    • Broad flexibility. A flexible stamping partner is better able to accommodate changes in the part design, customer demand, and more. In addition to their standard product capabilities, they may offer custom solutions for highly specific or unique requirements.
    • Fast response time. A responsive partner ensures the initial consultation and all other communications occur swiftly and smoothly.

    Industry Certifications

    In addition to their experience, another indicator of a quality stamping partner is their certifications. Certifications indicate a company complies with the requirements and restrictions set forth by the industry and industry organizations. For stamping operations, the relevant certifications include:

    • ISO AS9100D. This certification targets companies that create products or provide services for the aerospace industry. It indicates, among other things, a company implements sufficient measures to prevent the production of flawed or faked parts, maintain flexibility in the face of fluctuating demands, and address safety concerns.

    Contact Hudson Technologies For Your Next Deep Draw & Metal Stamping Project Today

    At Hudson Technologies, we are the ideal partner for any deep draw metal stamping project. By choosing us, you benefit from our complete commitment to quality, comprehensive production capabilities and capacities, and numerous industry certifications. To learn more about our metal stamping solutions or partner with us, contact us or request a quote today.

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