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Author Archives: John DeBone

  1. 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.

  2. 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.

  3. 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.

  4. 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.

    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.

  5. 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.

  6. 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.

  7. 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
  8. 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.

  9. 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.

  10. 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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