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Author Archives: John DeBone

  1. Overview of Progressive Die Stamping

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    With many manufacturing methods available, it can be difficult to choose the best option for your project. In this blog, we will compare progressive die stamping to various other methods to help you determine if this technique is the most suitable choice for manufacturing your components.

    What is Progressive Die Stamping?

    Progressive die stamping is a unique metal forming process that is used to create parts for various industries and applications. This type of metal stamping incorporates various work stations, each of which carries out different operations on the part. Key benefits of progressive die stamping include:

    Progressive Die Stamping

    • Minimal scrap
    • Decreased labor costs
    • Short setup times
    • Fast production of small parts with tight tolerances
    • Saves time and money by combining multiple operations
    • Long run lengths

    Progressive die stamping offers an efficient and cost-effective method for producing parts in large volumes, making it a great choice for industry applications such as:

    • Healthcare
    • Mining
    • Food and beverage
    • Appliances
    • Electronics
    • Automotive
    • Aerospace
    • And more 

    Progressive Die Stamping Process

    Progressive die stamping uses a type of tooling called a progressive die, which contains multiple stamping stations to carry out simultaneous operations on a sheet metal strip. By combining all the necessary tools into one die set, progressive die stamping is a great solution for high-volume production runs.

    Hudson Progressive Die Stamping

    To begin the process, the die is placed into the stamping press. At Hudson Technologies, our straight side progressive presses feature a 60 to 500 ton capacity. The die opens as the stamping press moves up and closes as the stamping press moves down. While the die is open, the metal moves through the die, being precisely fed into the die with each press stroke. 

    When the die closes, it performs its work on the metal, which can include coining, bending, cutting, embossing, and more. Once the metal has moved through each station, the finished part is ejected from the die.

    When to Use Progressive Die Stamping vs. Traditional Metal Stamping

    When choosing between progressive die stamping and traditional metal stamping methods such as stage tooling and transfer press tooling, it’s important to consider factors such as cost, production volume, and lead time.

    CostCost

    When considering cost, it’s important to think about tooling setup costs as well as per-piece cost. Stage tooling boasts lower setup costs but has the highest per-piece cost. Progressive die and transfer press tooling have higher setup costs compared to stage tooling but offer lower per piece costs. 

    Production Volume

    Progressive die stamping is specifically designed for high volume production, typically exceeding 50,000 pieces per year. While transfer press tooling is also good for high volume production, it differs in that the part is separated from the metal strip during the first operation. Stage tooling, on the other hand, is ideal for small, low-volume production runs of less than 50,000 pieces per year.

    Lead TimeLead Time

    When considering the needs of your project, it’s important to think of project timelines to determine which method is best. While stage tooling features a relatively slow fabrication speed, progressive die and transfer press tooling offer medium to fast production speeds.

    Progressive Die Stamping Services from Hudson Technologies

    If you determine that progressive die stamping is the best manufacturing method for your project, let the experts at Hudson Technologies help. We offer custom progressive die-stamped components as well as progressive die tool manufacturing. With over 80 years of experience, we have the necessary equipment and knowledge to meet your progressive die stamping needs. To learn more, visit our capabilities and tooling pages or download our Turnkey Solutions Ebook. You can also contact us or request a quote to get started.

  2. Short Run vs. Long Run Metal Stamping Overview

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    The term “production run” describes manufacturing a predetermined amount of products during one time period. Production runs can be short or long, depending on the needs and goals of the application. Here, we will discuss the advantages associated with both short and long-run stamping production durations, as well as the applications each is best suited for. 

    What Is Short-Run Stamping?

    Short-run stamping is a multi-step process that produces complex metal parts in small quantities. Typically, short-run stampings describe production runs of 5,000 parts or fewer that take place over the course of six months or less. During production, a metal blank is placed between a die and a punch and formed according to the customer’s specifications. A variety of metals can be used for this process, such as aluminum, steel, brass, and more. Short-run stamping has several benefits, including:

    Metal Stamping

    • Reduced production costs: Since a small amount of material is required for short runs, costs are reduced. 
    • Less waste: Sheet metal blanks generate significantly less waste than fabricating parts using multiple pieces of metal. 
    • Reduced lead times: Short, low-volume production runs can be completed quicker than standard runs. 

    A wide variety of industries use short production runs to produce high-quality components quickly. From automotive to aerospace, the medical industry, electronics, construction, and more, there is a high demand for this service. The stamping process works best with symmetrical parts and is frequently used to produce components such as engine cylinders, fire extinguisher housings, and aluminum cans, to name a few. 

    What Is Long Run Stamping?

    Long-run stamping is used to produce large quantities of parts quickly and cost-effectively. There are several production methods that can be used, including coining, deep drawing, bending, and piercing. In most circumstances, long-run stamping productions can produce over 800 parts per minute. Long-run productions can last anywhere from six months to one year and deliver many significant benefits, such as:

    Stamping Press

    • Fast production capabilities: This type of production run creates large quantities of components at once and is ideal when speed is a concern. 
    • Cost-effective pricing: Long-run production delivers the most cost-efficient components and is typically the lowest price-per-piece manufacturing method, as long as the volume of parts required offsets the cost of tooling. 
    • High repeatability: Long-run stamping is ideal for reproducing the same part multiple times.

    Long-run stamping is used by appliance manufacturers, the lighting industry, electronics companies, and more. The process produces both large, complex components as well as small and highly detailed parts. Items such as metal washers, brackets, springs, and more are well suited to long-run stamping production.

    Choosing a Metal Stamping Process

    There are several considerations to take into account when choosing a metal stamping process. Which materials and tooling methods will be used, how much lead time is acceptable, and budget must all be determined. For short-run productions, at least one of these factors should remain fixed while the rest can remain flexible and be adapted over time. If a long-run production is selected, all of these factors are flexible and can be changed freely during the production process.

    When choosing a metal stamping process, one of the factors you should determine is if you’re planning on a short or long production run. Each metal stamping process and tooling technique require different lead times. Long production runs offer the most flexibility and the largest selection of processes. Stamping processes include: Custom Deep Drawn Stamping Services

    • Deep draw stamping
    • Shallow draw stamping
    • Progressive die tooling
    • Transfer press tooling
    • Stage tooling

    In general, short production runs are often ideal as part of a testing or design process, or when you’re aiming for minimal tooling expenses. Long production runs are best in situations where a high volume demand justifies the required tooling costs. Long-run stamping delivers the lowest price per piece.

    Custom Deep Drawn Stamping Services From Hudson Technologies

    Long and short-run metal stamping both provide numerous benefits. Determining which method is right for your application depends on factors such as your budget, production time frame, required tooling, and the number of parts you require. Hudson Technologies is a leading provider of metal stamping services, including custom tooling and deep-drawn manufacturing services. Learn more about the turnkey solutions we offer in our free eBook, or get started on your project today by submitting a request for a quote

  3. Metal Diaphragm Material Selection

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    Metal diaphragms are plates of metal built to axially deform and regulate pressure. Various systems across industries use the diaphragms to separate opposing fluids, regulate or cap pressure levels, indicate when pressure levels reach above certain thresholds, and more. For example, food processing, pharmaceutical production, and semiconductor manufacturing all rely on well-constructed metal diaphragms to control dynamic systems. But in each application, the material plays a large role in the diaphragm’s performance.

    Keep reading to learn more about the metal diaphragm production process made and choosing an ideal metal material for your specific application.

    How are Metal Diaphragms Manufactured?Metal Diaphragm

    Metal diaphragm manufacturers incorporate multiple steps into production based on the specifications of the product and details of the application. The diaphragm’s required life cycle, deflection ability, and ability to withstand pressure all influence the profile shape and material selection.

    Manufacturers will digitally design and virtually test a diaphragm model in advance of production to solve functionality and manufacturability issues. Creating a computer-aided design (CAD) file allows the design engineer to check for potential flaws before physical prototyping. Based on the specifications of the application, the design engineers will consider the following:

    Solid Centers

    There are two main types of solid center diaphragms: high-sensitivity low-pressure (HSLP) diaphragms and low-sensitivity high-pressure (LSHP) diaphragms. HSLP diaphragms are often matched with pressure sensors to detect potential fluid breaches and contamination in food, beverage, and pharmaceutical production. LSHP diaphragms typically see use as a failsafe component, as these diaphragms withstand high pressure levels and only open when pressure levels reach a predetermined range.

    Selecting a ProfileMetal Stamping

    Metal diaphragms may be domed, corrugated, or flat. Flat metal diaphragms are the easiest to mass produce, but corrugated diaphragms are popular for their linear characteristic curve and ability to deform to a greater degree without incurring damage. The linear curve gives the diaphragm extended range, high sensitivity, and better spring rates. Designers may choose to enhance or modify certain characteristics by specifying the material thickness and the depth or pitch of the corrugation. These features will influence the overall operating life of the diaphragm.

    Once the design is complete, diaphragms get produced through metal stamping. Metal stamping processes use a die (or a series of dies) that press into and deform metal stock into the preferred shape. After metal stamping, the completed diaphragms are quite delicate. Manufacturers need to carefully package the items to protect them during storage or shipping.

    Read more about our corrugated diaphragm capabilities here.

    Choosing a Diaphragm Material

    Different metals offer different characteristics and advantages. Some of the most commonly used metals include:Stainless Steel

    • Inconel®. This material resists abrasion, corrosion, and heat. It retains its characteristics in temperatures above 750°F.
    • Haynes® 242®.Haynes 242 is highly ductile and resists thermal expansion up to temperatures of 1,600°F.
    • Hastelloy®. Hastelloy features excellent corrosion resistance, tolerates exposure to most chemicals, and can operate at high temperatures for limited periods.
    • Titanium. Titanium nitride offers good resistances to abrasion and adhesion, while titanium aluminum nitride diaphragms provide excellent resistances to both.
    • Monel®. This material offers good resistance to saltwater and high resistance to corrosion under exposure to non-oxidizing acids.
    • 17-7 PH stainless steel. This stainless steel alloy features superior strength and hardness, resists deformation and fatigue, and offers good corrosion resistance.

    The appropriate material selection will depend heavily on the intended use case, including the process fluids the diaphragm may come into contact with, operating temperature ranges, and various environmental factors.

    To learn more about the materials listed above, read our Choosing Materials Guide.

    Diaphragm Manufacturing Considerations

    When designing or ordering custom metal diaphragms, pause to consider the various options at each production stage to ensure an optimal solution.Design & Engineering Process

    • Design and engineering. During this stage, make detailed CAD files and 3D mockups before physical prototyping begins so the designs can be thoroughly tested and optimized.
    • Stamping process. During the metal stamping process, manufacturers can control camber, concentricity, and other factors. Depending on your intended application, you may have unique requirements for the edge burr and tolerance threshold.
    • Tooling. Consider how different tooling processes, such as metal-to-rubber or metal-to-metal, will influence production costs, as well as the final product and its performance in the end application. We offer custom tooling, made in-house in our tool room, to all of our clients.
    • Packaging. Be sure that the packaging accounts for the fragility of metal diaphragms.

    Metal Stamped Components from Hudson Technologies

    Selecting the right material for your metal diaphragms is crucial for ensuring the proper performance of your equipment. At Hudson Technologies, we have the experience and expertise to design and create metal diaphragms for any industrial use case. To see how our capabilities can benefit your operation, please contact us today.

  4. Guide to Heat Treating Deep Drawn Stamped Components

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    For applications requiring complex parts and efficient, repeatable manufacturing processes, deep drawn stamping is one of the best processes to use. Deep drawn stamping can manufacture high volumes of parts with a combination of speed, accuracy, and consistency. It also produces parts in a single piece, which helps eliminate assembly requirements. Additionally, deep drawn components are highly durable because of the compression that parts undergo during fabrication.

     

    Deep drawn metal stamping is particularly popular among manufacturers due to the lightweight, high-strength, and conductive properties of metal materials. However, metal can occasionally require additional processes to contribute new properties or tolerances for certain applications. To achieve this, heat treating is often used in conjunction with the deep drawn stamping process for a variety of metal parts.

     

    What Is Heat Treating?

    Heat treating processes can modify the mechanical and physical properties of metal while maintaining its shape and overall integrity. It enhances the existing properties of metal while preparing it for additional processing. Depending on the application and specific parts, there are various heat treating processes available, including:Molten metal being poured

    • Entails heating metal to a designated temperature before slowly cooling it. This process is most often used for deep drawn components.
    • Involves heating parts to a specific temperature under the critical point within an inert atmosphere or vacuum. This process is used to enhance the strength of iron.
    • Used for treating medium-to-high carbon ferrous metals in an effort to produce bainite, which enhances the toughness and strength of metals while reducing distortion.

     

    What Is Annealing?

    Annealing is a type of heat treatment process that alters the physical and chemical properties of metals to reduce hardness while increasing ductility for improved workability. What specifically causes the change in properties is the dislocation of the metal’s crystalline structure. During heating, atoms migrate within the crystal lattice and there’s a reduction in the number of dislocations, which causes the metal’s ductility and hardness to change. While cooling and hardening, the heat-treated metal recrystallizes.Heat treating metal components

    To complete this process, different types of machinery are used for annealing, including:

    • Vacuum annealing furnace. This equipment is used to perform annealing and aging treatments for many types of alloy materials, stainless steel, magnetic materials, devices, copper, and much more.
    • Hump-back (belt) annealing system. This system gets its name from the “humpback” of the raised heating chamber, with entry and exit tunnels on inclines on either side. The design is ideal for applications requiring a controlled hydrogen atmosphere, as heavy air entering the entry and exit doors remains outside the elevated chambers through which hydrogen gas flows.
    • Retort heat treat furnace. These furnaces feature sealed vessels, which lay over or around products to separate them and the heat treating space from the furnaces’ heat source and insulation. They enable more control of workspaces involving hydrogen or argon atmospheres for optimum efficiency and accuracy.

     

    Applications of Annealing

    Annealing is the primary heat treatment process used for deep drawn components, and it is typically used to treat raw materials or components during formation. Annealing is commonly applied in between forming processes to help maintain the material’s strength while reducing stress and fatigue resulting from the deep draw forming process.Stainless steel alloys

    Annealing is often used for treating raw stainless steel alloys such as AM350, which is an alloy containing chromium, nickel, and molybdenum. This blend is conducive to heat treating, as it enhances the material’s strength and formability. When treated, AM350 stainless steel benefits from improved formability without any compromise in corrosion resistance or overall strength.

     

    Custom Deep Drawn Components from Hudson Technologies

    If you need dependable deep drawn metal stamping services for a particular application, Hudson Technologies has the resources required to produce top-quality, consistent results. We can produce a wide variety of custom and cost-effective metal parts for use in nearly any industry without the wastage that results from other less efficient processes.

    For more information about our deep drawn stamping capabilities, or to learn about how Hudson Technologies can meet your specific requirements, contact us today.

     

     

  5. Reducing Lead Times When Manufacturing Metal Components

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    Metal fabrication encompasses various processes that turn metal stock material into finished components and goods. Each fabrication method requires a different set of skills, training, and specialized equipment. The time it takes to complete a metal fabrication project can vary widely based on the specific provider, the process used, order volume, design complexity, and many other factors.

    Shortening project lead times—the time it takes to manufacture and deliver your order—will bring products to market faster. While it may be tempting to implement any time-saving measure that comes along, cutting corners can lower product quality. This blog post will discuss some of the methods for shortening lead times in metal fabrication without lowering your project standards.

    Lead Times and Metal Component Manufacturing

    Manufacturers may incorporate a variety of metal fabrication techniques during the production process. Typical metal fabrication processes include:A saw cutting a metal component with sparks

    • Metal stamping. The metal stamping uses a series of tools and dies to make various cuts and impressions on sheet metal, ultimately forming the metal into a specified design.
    • Deep drawing. In metal drawing, sheet metal is pulled into a die using a punch to form a hollow shape. A deep-drawing process creates a component with a depth greater than its diameter.
    • Cutting. A variety of cutting processes exist to reduce sheet metal or bars into smaller sections. Examples of cutting equipment used in manufacturing include lasers, plasma torches, and various mechanical cutters, such as saws.
    • Folding. Folding creates angles by bending the metal to a specified degree. Folding is a delicate process requiring specialized presses that can fold sheet metal without tearing it.
    • Machining. Machining is a reductive process, removing material from stock bars and blanks to form the desired component. The most common machining processes use a turning machine or a milling machine.
    • Drilling. Drilling creates holes in the metal workpiece for fitting or attaching components.

    Each of these processes offers different lead times. When engaging a provider for a metal fabrication project, ask the following questions:

    • How will your current order backlog impact lead times for my project?
    • How will the complexity and tolerance requirements of my part impact lead times?
    • Are there alternate materials, hardware, or tooling that could shorten lead times without impacting quality?
    • Is there a way to limit the need for secondary or specialized processes to reduce lead times?

     

    Tips for Reducing Metal Component Manufacturing Lead Time

    Numerous factors beyond the shop floor can have an impact on project lead times. Some tips to reduce lead times with your metal fabricator include:Two partners reducing lead time

    • Purchase standard components instead of fully custom orders when feasible.
    • Complete the prototyping and testing phases on customized parts to avoid problems and delays during the full production run.
    • Reduce communication and shipping complexity by using a domestic or nearshored manufacturer.
    • Consider adding kitting or assembly to your order to reduce lead times after order completion.
    • Streamline inventory management with Just-in-Time and Lean inventory practices.
    • Evaluate and improve internal communication processes.
    • Choose a highly skilled and reliable supplier.

     

    Other Manufacturing Timeline Considerations

    Carefully choosing your manufacturing partner is one of the most critical decisions you can make to streamline your lead times. Your choice of manufacturing partner can impact your project lead times in a variety of ways. To make sure your partner won’t contribute to longer project times, make sure that they have:Manufacturing partners working together

    • Reliable material suppliers
    • Efficient prototyping, sampling, and test run capabilities
    • Willingness to build a long-term partnership that streamlines costs and processes
    • Proximity to your location to minimize transport times
    • A comprehensive portfolio of in-house services (instead of using a variety of third-party providers)

    If your manufacturing partner has not demonstrated consistent repeatability, reliability, and conformance to tight timelines and tolerances, it is better to switch suppliers sooner rather than later.

    Metal Component Manufacturing from Hudson Technologies

    Hudson Technologies has a long history of successful partnerships, offering state-of-the-art in-house capabilities, skilled staff, and adherence to stringent standards such as AS9100D, ISO 13485:2003, ISO 14001:2004, and ISO 9001:2015. For more information about our services, please visit our capabilities page or contact us today.

  6. Deep Drawn Stamped Solutions for the Medical Industry

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    Good medical devices must satisfy three categories: they achieve tight tolerances, healthcare professionals can easily use them, and they help the patient heal. High-quality equipment and tooling ensure high-quality end parts for medical applications ranging from device pumps and motors to pacemakers, defibrillators, and surgical equipment.

    Benefits of Metal Stamping Over Other Metal Fabrication Processes

    Medical ProductsMetal stamping comes with a host of benefits that set it above other metal fabrication processes. Manufacturers can easily automate the metal stamping process, making it a great method for mass-producing parts. These mass production capabilities also make it more cost-effective for large-volume orders — after paying the initial setup costs, each individual product over a certain volume does not contribute much to overhead. Furthermore, it’s much easier to repeat processes and duplicate components with stamping than with other fabrication techniques.

    Metal Stamping Applications in the Medical Industry

    Metal components serve a vital role in the construction of medical devices, which must be highly precise, durable, and biocompatible for both internal and external use. Due to its immense versatility, metal stamping allows the medical industry to create and refine these devices quickly and efficiently.

    One of the most significant applications for metal stamping is the creation of implantable medical device components, which must retain their shape and be easy to sterilize.

    Additionally, this process provides an ideal method for fabricating customized solutions. Metal stamping contributes to an expansive range of standard and customized medical devices, such as:

    • Battery cases
    • Shields and half-shells
    • Capacitor components
    • Implantable cardioverter defibrillators
    • Stamped and machined lids, covers, and headers
    • Neuromodulation products
    • Implantable cardiac pacemakers
    • Ventricular assist devices
    • Implantable drug infusion pumps
    • Implantable loop recorders
    • Implantable hearing devices

    Hudson creates a number of products for the medical industry. A couple of our most notable offerings include:

    Device Enclosures

    Metal battery enclosuresAll permanently implanted medical devices, including pacemakers, cochlear devices, internal defibrillators, and drug pumps, are manufactured from titanium. Titanium is the only metal that the human body will not reject. Hudson has a long history of deep-drawing titanium into intricate shapes and has been manufacturing implantable titanium medical components since the early 1970s.

    Implantable Components

    Implantable components include the outer shield of the device, battery cases, and other components. By designing and building custom tooling, Hudson uses metal stamping to manufacture components for a variety of purposes affordably and quickly.

    Strategies for Manufacturing Medical Components

    To manufacture medical components of the highest caliber, the Hudson team uses the following practices:

    Using Titanium for Medical Devices

    Since the 1940s, titanium has been one of the medical industry’s preferred materials due to its ability to bind with both bone and living tissue. Titanium is incredibly strong and resistant to corrosion, making it ideal for a wide variety of medical components. At Hudson, we have experience working with titanium grades 1, 2, 4, 5, 7, 9, 11, and 23, each of which has its own unique benefits for the medical field.

    Design Assistance

    Due to the vital nature of the components created at Hudson, we are dedicated to working closely with our clients throughout the design process. From initial design development and prototyping into full production, our design team will work closely with you to turn your idea into reality while adhering to stringent medical industry guidelines. Metal stamping can incorporate part modifications, making the design process highly versatile. We can incorporate cleaning, embossing, and holes into all of our custom-manufactured medical components.

    We place particular emphasis on creating medical components that are easily manufactured and highly reliable. To ensure these qualities, we employ:

    • Failure Modes and Effects Analysis (FMEA): A thorough analysis that enables us to identify potential future failures, how serious these failures may be, and how to remedy them.
    • Finite Element Analysis (FEA): This process examines the effects of physical forces (such as vibrations or heat) that may have a negative impact on the component. By looking at the component’s individual elements, we can anticipate how well the product will withstand these forces.
    • RoHS Compliance: We comply with RoHS standards in order to ensure the quality of our products and the safety of our staff and clients.

    High Production Run Sizes

    Hudson has the capacity to produce deep-drawn prototypes, even for high-volume production runs. Thanks to the ability to automate the metal stamping process, this method is ideal for mass-producing parts.

    Metal Medical Device Components from Hudson Technologies

    Hudson Technologies provides industry-leading custom metal stamping for a wide range of medical applications. Founded in 1940, we perform precision metal stamping using state-of-the-art equipment, creating high-tolerance parts in large production volumes.

    We design all our tooling in-house to optimize the production process. Our highly trained staff operates over 130 forming presses around the clock, working with mechanical and hydraulic presses ranging from 1-500 tons. We also use a servo press with a CNC lower cushion for special orders.

    We draw our designs with reliability and manufacturability in mind, aiming to achieve the most affordable solutions through collaborative relationships with our customers. We also offer extensive modification capabilities, which allows for greater component customization. We perform in-house heat treatment as well as hydrogen and vacuum annealing to minimize lead times and optimize quality control.

    To find out how our custom medical stamping services will benefit your next project, contact us or request a quote today.

  7. Tips for Deep Drawing Stainless Steel

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    Manufacturing with stainless steel provides many of the benefits of steel without the high potential for rust and corrosion. The chemical composition of stainless steel includes at least 10.5% chromium, as well as iron, nickel, and manganese. When exposed to air, the chromium in stainless steel oxidizes, creating a protective layer that is highly resistant to moisture and corrosion. There are a wide range of stainless steel types, each categorized based on their molecular composition and structure.

    stainless steelStainless Steel Type 201/201L

    Stainless steel type 201 features a lower percentage of nickel than other stainless steel blends. This makes it less expensive, but also less corrosion-resistant. A higher manganese content makes stainless steel 201 stronger than other blends and allows it to retain strength and dimensional stability even in extremely cold environments. It is an excellent option for durable, inexpensive components in cold applications where exposure to corrosion is minimal.

    Stainless Steel Type 316/316L

    stainless steel in warehouseStainless steel type 316 is distinguished by its higher nickel and molybdenum content. Type 316 exhibits extreme resistance to corrosion and moisture in comparison with other stainless steel alloys but is also more expensive due to its high nickel content. It holds up particularly well to salt water and chlorides, which makes it useful for marine components, stainless steel floats, and medical devices.
     

    Stainless Steel Type 409

    stainless steel tubesStainless steel 409 is a temperature-resistant blend of stainless steel with a higher iron content. This ferritic stainless steel contains 11% chromium, which provides good corrosion resistance. However, its greatest benefit lies in its ability to withstand extremely high temperatures. Although Type 409 exhibits a greater level of corrosion-resistance than coated iron alloys, it is less resistant than most other stainless steels. Light rust may eventually form with extended exposure to moisture or corrosive elements.

    AM350 Stainless Steel Alloy

    AM350 is a stainless steel alloy that contains nickel, chromium, and molybdenum. Unlike other stainless steel blends, AM350 can be heat treated to enhance formability or strength, depending on the needs of the application. Heat treatment processes used to enhance AM350 include annealing, hardening, sub-zero cooling, and double aging. Annealed AM350 exhibits a higher degree of formability, while maintaining good strength and corrosion resistance.
     

    Alloy 20

    Alloy 20 is a unique blend of nickel, iron, and chromium with a niobium stabilizer. The unique chemical composition of Alloy 20 makes it especially corrosion-resistant, particularly in the face of corrosive chemicals. Its ability to withstand extreme corrosion makes it ideal for a wide variety of harsh application environments, including:

    • Chemical and petrochemical processing
    • Food, beverage, and dye production
    • Heat exchangers
    • Explosives
    • Tanks and valves
    • Synthetic rubber and plastics manufacturing
    • Pharmaceuticals
    • SO2 scrubbers and other extreme environments

     

    Deep Drawing Stainless Steel

    Stainless steel offers a number of unique benefits over other materials, but those characteristics can make it a challenge for deep drawn metal stampings. Drawing stainless steel requires a greater level of force than other common drawing materials because it work-hardens faster. In addition, the layer of oxidized chromium that gives stainless steel its characteristic corrosion resistance also creates a higher level of friction between the steel and the die, which also contributes to a need for more force.

    When performed correctly, stainless steel drawing yields products and components with high corrosion resistance, exceptional tensile strength, and superior resistance to a wide range of temperatures.
     

    Common Components and Applications of Deep Drawn Metal Stampings

    Deep drawing is a metal fabrication process that involves the use of a die and punch to create components from sheet metal. The deep drawing process is characterized by the creation of products and components that are deeper than their diameter. Repeated impacts from the punch will force the material into the shape of the die, creating durable, hollow, box-shaped or cylindrical components. Deep drawing is used to create components from a wide range of materials, including aluminum, copper, brass, steel, and stainless steel.

    The primary benefit of deep drawn stamping is the speed with which the equipment can be used. This highly versatile process can be used to create a wide variety of components, from simple cylinders to intricate shapes for specialty applications. The seamless nature of deep drawn products makes them airtight and waterproof, and the compression process creates exceptionally strong components with a hardened crystalline structure.
     

    Deep Drawn Stamping from Hudson Technologies

    At Hudson Technologies, we are committed to providing the highest quality deep drawn components in the industry. For more information on our extensive portfolio of deep drawn stamping solutions, visit our Core Capabilities page or download our Turnkey Solutions eBook. To learn about ways that Hudson Technologies can help with your next project, contact us today or request a quote.

  8. Benefits of Titanium in the Medical Industry

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    The medical industry has used titanium in surgical and dental equipment since the 1940s. Today, it can be found in a wide array of biomedical implants such as pacemakers, eye implants, and hearing aids.

    Titanium possesses a unique ability to bind with bone and living tissue, making it an ideal material for orthopedic implants such as knee and hip replacements. Because of its strength and increased resistance to corrosion, it is well-suited to many other medical instruments, as well.

    Grades of Medical Titanium

    Titanium is available in four different pure titanium grades and as many as 25 different alloys. Below is a sample of the kinds of titanium used in healthcare today:

    • Pure Titanium
      The four grades of pure titanium are numbered 1-4, with 1 being the softest and 4 being the strongest. Grades 1, 2, and 4 are most commonly found in modern medical devices. Each is distinguished by its degree of formability and ductility.

      • Grade 1
        Grade 1 titanium consists of pure, unalloyed titanium. It is prized in healthcare for its excellent formability, increased resistance to corrosion, and resilience against impact.
      • Grade 2
        Grade 2 titanium is an unalloyed form of titanium with greater strength than Grade 1.
      • Grade 4
        Grade 4 titanium is another form of unalloyed titanium. Like Grades 1 and 2, it offers enhanced resistance to corrosion, great formability, and high strength.
    • Grade 5
      Grade 5 titanium is an alloy made with 6% aluminum and 4% vanadium. Since it offers superior fracture resistance, it is the most common material used in dental implants.
    • Grade 7
      Grade 7 titanium consists of titanium alloyed with 0.12% to 0.25% palladium. It is more resistant to corrosion than any other titanium alloy.
    • Grade 9
      Grade 9 titanium is an alloy made with 3% aluminum and 2.5% vanadium. It is particularly known for its great mechanical strength.
    • Grade 11
      Grade 11 contains unalloyed titanium as well as 0.12% to 0.25% palladium, much like Grade 7 titanium. It shares many properties with Grade 1 titanium, but it offers superior resistance to corrosion.
    • Grade 23
      Grade 23 titanium is an alloy made with 6% aluminum and 4% vanadium that features extra low interstitial elements. Like Grade 5 titanium, it is also a common choice for dental implants.

    Positive Characteristics of Medical Titanium for Biomedical Implants

    Titanium has many characteristics that make it the ideal metal for medical applications. Its advantages include:

    • Durability
      Medical implants made from titanium alloys routinely last 20 or more years inside the human body.
    • Higher strength-to-weight ratio
      Titanium is stronger and lighter than stainless steel, which largely accounts for its widespread use in surgical implants.
    • Non-ferromagnetic property
      Because it isn’t magnetic, medical titanium doesn’t interfere with magnetic resonance imaging (MRI) machines. Because of this property, patients with titanium implants can still safely undergo MRI examinations.
    • Biocompatibility
      Unlike other metals, medical titanium can remain in constant contact with living tissue without adversely affecting it.
    • Biointerfacing
      Titanium implants have an engineered biointerface with biomimetic motifs that increase cell contact area by as much as 75%, enhancing the cell’s binding properties. As a result, their use further reduces the chance of implant rejection.
    • Osseointegration
      Medical titanium implants can physically bond with natural bone, eliminating the need for adhesives.

    Titanium Implantable Medical Devices

    The strength to weight ratio, hermeticity, biocompatibility and light weight makes titanium the best choice for implantable medical devices.  Examples of components made for implantable medical devices at Hudson Technologies include:

    • Defibrillators
    • Pacemakers
    • Drug Pumps
    • Bone Growth Stimulators
    • Battery Components
    • LVAD (Left Ventrical Assist Devices
    • Neurostimulation Devices

    As a leading manufacturer of precision engineered metal components for implantable medical devices, Hudson Technologies offers customized solutions for a wide range of applications. At every stage of the manufacturing process, we work closely with you to ensure that the finished product reflects your concept. Regardless of your needs, we can design a solution that helps you provide your patients with the best care possible.

    To find out more about how Hudson Technologies can meet your titanium needs, request a quote from our website today.

  9. Tips for Finding and Switching to a Better Deep Drawn Stamping Partner

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    Deep drawn stamping is a metal stamping method used to create components that are deeper than they are wide. It is suitable for producing hollow parts and products that lightweight and seamless without sacrificing strength or stability. However, manufacturers must have the right knowledge, skills, and tools to form them successfully.

    The following article outlines some of the things to look for in an ideal deep drawn component manufacturer. Additionally, it discusses how to switch suppliers if your current manufacturing partner does not meet your needs.

    Importance of Deep Drawn Components

    Deep drawn components are found in devices and equipment for a wide range of industries, such as:

    Given the important role deep drawn components play in many industrial applications and processes, it is essential to partner with an experienced and knowledgeable deep drawn stamping company to ensure the parts and products you need function and perform as intended.

    Deep Drawn Component Supplier Selection Considerations

    Tips for Finding and Switching to a Better Deep Drawn Stamping Partner

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    There are many factors to consider when choosing a deep drawn component manufacturer for a project. Some of the key considerations to keep in mind include:

    Manufacturing Capabilities

    Your deep drawn component supplier should have the skills and tools to accommodate your manufacturing needs with regard to material, design, and production volume and produce components that fully meet your specifications and standards. Additionally, if you’re looking for a long-term partnership, they should be able to adjust their operations to match increasing or decreasing demand.

    Quality Control Policies and Procedures

    One way of determining whether a deep drawn supplier is right for your project is to review their quality control policies and procedures. They should have quality standards that align with your own and the equipment and processes in place to ensure your components meet them.

    Competitive and Innovative Drive

    The manufacturing sector is highly competitive. Companies must be willing to invest in new technologies and technologies to ensure they can keep up with current demand and provide customers with the best possible products and services.

    Customer Service

    Your manufacturing partner should understand your needs. Additionally, they should be open to working with you to develop a manufacturing solution that fits them.

    Company Reputation

    Avoid working with companies with a bad reputation. While you should take negative customer reviews with a grain of salt, they can be indicative of potential issues with the company’s products and/or services.

    Certifications

    If your industry or industrial application is subject to specific standards, your manufacturing partner should be able to create components that comply with those standards. For example, if you’re doing business in the aerospace industry, they should have AS9100D certification and produce components that follow the standard’s guidelines.

    Switching Deep Drawn Stamping Partners

    If your current deep drawn stamping supplier does not match what you’re looking for in a manufacturing partner, you should consider switching to one that better suits your needs. Once you’ve decided on a new partner, you should keep in the following tips in mind to ensure a smooth transition:

    • Confirm whether you or your current partner owns your tools. If you do not own the tools, you will need to budget for the production of new tooling.
    • Verify that your new partner has a thorough understanding of your material needs, tolerance requirements, and desired applications. If they do not, you should communicate with one of their representatives or consider other options.
    • Ensure your current and future projects will be finished on time. If you have active projects with your current partner, make sure you finish them. Before switching completely to the new partner, perform a test run to verify they can finish your projects.
    • Consider reshoring, nearshoring, or diversifying to multiple suppliers. These partnerships allow you to establish a more resilient supply chain. Read more about reshoring here.

    Deep Drawn Stamping and Metal Drawing From Hudson Technologies

    At Hudson Technologies, we’ve provided custom deep drawn metal parts and products for over 80 years. This experience, combined with our broad range of manufacturing capabilities and highly skilled team, allows us to produce precise, complex, and/or high-performance components for some of the most demanding customer applications.

    For more information on our metal stamping services, visit our Capabilities page or download our eBook. To discuss your project requirements with one of our experts, contact us or request a quote today.

  10. Choosing the Right Sheet Metal for Your Manufactured Components

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    Choosing the right sheet metal for your manufactured components is crucial in ensuring that your parts will perform optimally. To make sure you choose the correct sheet metal, it is important to consider factors such as material, size, design, and tolerance requirements as well as manufacturing and fabrication processes that the material will undergo.

     

    Material and Size

    There are many metal and alloy options to choose from when selecting a sheet metal material. To ensure that you choose the appropriate material for your particular needs, it is important to ask the following questions:

    • What is the desired size of your component?
    • How strong does your component need to be?
    • Does the material need to be easy to work with in terms of weldability, ductility, tensile strength, and machinability?
    • What is the budget for your project?
    • Is your component going to be used in an application, such as automotive or aerospace, that requires an excellent strength-to-weight ratio?

     

    Design and Tolerance

    When choosing a sheet metal for your manufactured parts, it is necessary to consider design and tolerance requirements such as:

    • water jet cuttingWall thickness
    • Bend allowance
    • K-factor
    • Orientation of holes and slots

     

    Manufacturing Processes Utilized

    The sheet metal you choose needs to be capable of withstanding the manufacturing processes that your component may undergo before completion. Some common manufacturing processes include:

    • laser cuttingLaser cutting. Laser cutting is ideal for precision designs with tolerances up to +/-0.005″.
    • Waterjet cutting. Waterjet cutting uses a high-pressure jet of water containing abrasive particles to cut plates of metal up to 150mm thick.
    • Bending forms the metal by applying stress along an axis with the use of V-bend dies, goose-neck dies, U-bend dies, or others, depending on the sheet metal bending design considerations.
    • Machinists can form a hollow or curved surface by drawing the metal into a die using a mechanical punch.
    • Annealing involves heating the metal to a specific temperature for a fixed period then cooling slowly to change the microstructure. Annealing softens and improves the machinability of metal and provides enhanced electrical conductivity.

     

    Fabrication Processes

    Fabrication involves finishing corners and closing gaps to enhance or maintain the shape and integrity of the finished product. Techniques like welding, riveting, and brazing join the metal, although the process used will depend on the component’s material.

    Common welding techniques include:

    • TIG welding. Tungsten inert gas, or TIG welding, does not use filler metal. Instead, it uses a tungsten electrode in an inert atmosphere of argon or helium to achieve a strong, high-quality, precise weld that is environmentally friendly.
    • MIG welding. Metal inert gas, or MIG welding, is a cost-effective, fast, and clean option when compared to TIG welding. However, it is less reliable and more hazardous than TIG welding.
    • Brazing is a joining method used for aluminum and brass components.

    Knowing the differences between these processes is important as the one you choose will directly affect the final product as well as the cost.

     

    Designing the Optimal Solution With Hudson Technologies

    Hudson Technologies has a long history of partnering with companies to design high-performance metal components. We routinely work with design engineers to create everything from single prototypes to large-scale production runs. For more information on our capabilities, contact us today, and for more help on choosing the right sheet metal for your project, download our eBook, Choosing the Right Material.

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