John DeBone, Author at Hudson Technologies

Author Archives: John DeBone

Metal Injection Molding (MIM) vs. Deep Drawn Stamping (DDS)
August 5, 2022 8:43 am Leave a Comment
Creating industry-defining metal components starts by forging raw metal into the ideal shape and size. Fortunately, there are a wide variety of techniques available to help you create high-performing metal components. It can be challenging to decide which method works best for your project. Each type of metal forming offers unique advantages and disadvantages, and no one technique is perfect for every project.

Two of the most popular metal forming techniques are metal injection molding (MIM) and deep-drawn stamping (DDS). Both of these methods can create highly complex metal parts at high throughput. So, which method makes the most sense for your project?

Metal Injection Molding (MIM) vs. Deep Drawn Stamping (DDS)

Metal forming processes shape metal components without changing their volume, allowing manufacturers and suppliers to create a variety of metal tools, instruments, and parts. Two of the most common types of metal forming — metal injection molding and deep drawn stamping — offer unique advantages and disadvantages, depending on the project.

Metal injection molding produces complex parts, often at a lower cost than metal casting or CNC machining. Once a cast is made, MIM can mold parts in seconds. Since MIM uses casts, it creates minimal production waste, and it’s capable of handling a wide variety of alloys and pre-alloy metals. Importantly, metal injection molding can create complex shapes (e.g., threads, fins, etc.) on small parts, though it’s not ideal for complex 3D dimensions. However, there are also drawbacks. MIM casts often have high mask hermiticity and larger pore sizes than some other types of metal forming. The tool life used during this process is also short, which can add costs to projects requiring high throughput.

Deep-drawing metal uses customized dies to stretch metal into shapes. This process does not require a cast, giving it some advantages in cost-effectiveness and tool lifetime. DDS is also capable of creating incredibly complex shapes using complex axisymmetric geometries at high throughput. Another advantage of deep-drawn stamping is its ability to utilize a variety of pre-alloy, alloy, and powdered metals — including modern superalloys.

Choosing Between MIM and DDS

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Both metal injection molding and deep-drawn stamping have advantages and disadvantages. The type of alloy you use, the technical requirements of your project, and your throughput requirements all play a role in deciding between these two metal forming options.

MIM is best for projects requiring:
- Small components that are not highly complex 3-dimensional shapes
- Parts that do not require uniformity due to irregularities produced during casting
- Products where thickness across features needs to be different
- Certain tight tolerances
- Straight or flat sides
MIM is not ideal for projects requiring:
- 3D products
- Identical components at high throughput
- Certain tolerances
- High repeatability
- Low porousness
DDS is best for projects requiring:
- 3D components
- Components that are taller than they are wide
- Certain tight tolerances
- High cost-effectiveness
- Part uniformity
- High throughput
- Long tool life
DDS is not ideal for projects requiring:
- Perfectly straight edges
- Low volume runs or low-cost prototyping
- Certain tolerances
Hudson Technologies’ 2022 Strategy

Hudson Technologies is a leader in deep-drawn stamping custom manufacturing. We provide end-to-end DDS solutions, and we specialize in helping you convert projects using non-ideal metal forming into deep-drawn stamping. Our range of cutting-edge machinery and technology allows us to tackle complex projects using best-of-breed deep-drawn stamping techniques. From drawing and sampling to design, we’re ready to help you accomplish your next high-volume production project.

Contact us today, and one of our in-house metal forming experts will be in touch.
2022 Deep Drawn Stamping Trends
March 15, 2022 8:15 pm Leave a Comment
In 2021, the phrase “supply chain” continued to make mainstream news just as it had done at the outset of the pandemic. Consumers have come to associate the phrase with the absence of their favorite brands from store shelves. However, for the U.S. manufacturing industry, including the deep drawn stamping industry, the supply chain challenges of the past two years have deeper implications and signal shifts that are likely to carry over into 2022 and beyond.

2022 Forecast of Manufacturing Trends for Deep Drawn Stamping

To understand how the deep-drawn stamping industry is changing, it’s first important to understand the crucial factors affecting the entire U.S. manufacturing sector. Of course, the broader industry has been beset with supply chain challenges, spanning all business and manufacturing sectors. Decades of manufacturing offshore, pandemic-driven labor shortages, and significant inflation have wreaked havoc on traditional fulfillment times.

Recently, businesses have placed larger orders for metal stamped parts to stock up and avoid shortages. However, doing so lengthens already extended lead times. A progressive die run previously might have required 10 to 18 weeks of lead time, the combination of larger orders and transportation difficulties lengthens production time substantially.

Raw material shortages have also been a significant issue, resulting in increased prices, reduced profit margins, and longer lead times. To receive their orders on schedule, clients now have to be flexible about their metal choice.

The Benefits of Reshoring

However, the current supply chain woes are forcing all firms to rethink how they source products from start to finish. Of course, reshoring is an effective solution. Leveraging domestic supply chains, U.S. manufacturers benefit from lower transportation costs, as well as faster supply and distribution times. Further, they will no longer be dependent on complex and strained international supply chains and be insulated from protectionist policies on either side of the Atlantic.

Businesses can further benefit by working with all-in-one manufacturers, which distinguish themselves by handling even the most complex jobs, all under one roof. By working with all-in-one manufacturers, businesses can reduce the number of suppliers they work with, saving them time and money while mitigating the risk of mistakes when coordinating with two or more vendors on a single component’s production.

Most Impacted Industries and Finished Goods

The current supply chain challenges have affected every sector in some way. However, several industries, which have long been more reliant on international logistics than others, play prominent roles in our everyday lives and may face continued supply and distribution problems:

Aerospace

Airplanes are sophisticated vehicles with parts sourced from multiple countries. The rising cost of metals and labor costs have increased production costs, while COVID outbreaks in many countries where critical components are manufactured have increased production times.

Medical

To treat the massive influx of new patients since the pandemic’s onset, providers have needed an immense amount of new equipment. Among other equipment needs, industry supply companies have required greater quantities of stamped metal parts for use in components such as:
- Defibrillators
- Pacemakers
- Brain Stimulation Devices
- Battery Components
- Capacitor Components
Semiconductors

More goods, from refrigerators to light bulbs, use semiconductors these days. U.S. consumers would not feel the effects of the chip shortage so acutely if the production process was not so heavily reliant on international supply chains. And while national policies that would incentivize reshoring also remain bottlenecked, demand for the services of manufacturers at every step of the semiconductor production cycle, from deep-drawn metal stamping to lithography, remains high.

Consumer goods

Many businesses have been replacing processes such as die-casting and forging with more efficient ones such as metal stamping, to take advantage of higher production volumes and lower production costs.

Hudson Technologies’ 2022 Strategy

In 2022 and the foreseeable future, U.S. businesses in need of stamped metal parts will need domestic all-in-one manufacturing suppliers who can complete and deliver high-quality projects on schedule.

Over our eight decades in business, Hudson Technologies has navigated periods of regional and national economic uncertainty, offshoring, and technological advancement. We’ve thrived by keeping our finger on the pulse of our customers’ needs and pain points. We’ve diversified our raw goods suppliers during this challenging time to ensure we can fulfill customers’ orders. We’ve examined and remediated our production processes for inefficiencies that may delay production times. And we’ve worked with new customers seeking domestic suppliers to help them establish more efficient supply chains.

We remain dedicated to manufacturing stamped metal parts of the highest quality and providing excellent customer service. Explore our capabilities, then contact us today to discuss your stamping needs.
Overview of Progressive Die Stamping
October 18, 2021 9:42 am Leave a Comment
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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:
- 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.

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.

Cost

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 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.
Short Run vs. Long Run Metal Stamping Overview
October 15, 2021 1:48 pm Leave a Comment
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A production run is the period of time in which it takes to produce a predetermined quantity of products. For custom metal stampings, 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-run 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:
- Reduced production and material costs: In addition to tooling and labor costs, other metal stamping costs include those for materials. Since a small amount of material is required for short runs, indirect costs for materials 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 stamped 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:
- 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 production volume of stamped parts required offsets the cost of tooling.
- High repeatability: Long-run stamping is ideal high volume production of 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 Precision Metal Stamping Process

There are several factors of production 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 the 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 precision 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:
- Deep draw stamping
- Shallow draw stamping
- Progressive die tooling
- Transfer press tooling
- Stage tooling
In general, short production runs are often ideal for design teams looking to perform user tests and make part adjustments, or when you’re looking to reduce tooling expenses and marginal costs. 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 of production such as your budget, 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.
Metal Diaphragm Material Selection
August 23, 2021 1:58 am Leave a Comment
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 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 Profile

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:
- 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 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.
Guide to Heat Treating Deep Drawn Stamped Components
August 9, 2021 9:57 am Leave a Comment
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:
- 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.

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.

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.
Reducing Lead Times When Manufacturing Metal Components
August 5, 2021 7:55 pm Leave a Comment
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:
- 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:
- 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:
- 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 quality standards. For more information about our services, please visit our capabilities page or contact us today.
Deep Drawn Stamped Solutions for the Medical Industry
March 4, 2021 7:16 pm Leave a Comment
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

Metal 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

All 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.
Tips for Deep Drawing Stainless Steel
March 1, 2021 8:38 am Leave a Comment
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 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 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 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.
Benefits of Titanium in the Medical Industry
February 22, 2021 8:18 pm Leave a Comment
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.