Working with a manufacturer that understands the differences between various metal fabrication manufacturing processes helps ensure component production is cost-effective and efficient. At Hudson Technologies, we offer machining component design and redesign services to help our customers optimize their components for full production-run manufacturing.
We can also make recommendations on preexisting component designs intended for other manufacturing methods – such as traditional machining processes or metal injection molding (MIM) – and help convert these designs for deep drawn stamped tooling and manufacturing. We do this by carefully considering our customers’ needs; our goal is always to produce custom deep drawn metal enclosures and stamped components to unique specifications.
Component Design for Manufacturing
The metal fabrication process utilized for component manufacturing influences metal component design. Our in-house engineering team employs multiple technologies and techniques to design and manufacture components that meet any required criteria.
Instead of simply filling orders for standard deep drawn parts, we take pride in working collaboratively with customers to design or re-design, prototype, and manufacture customized components. We offer custom stamping capabilities using standard, deep drawn, and shallow drawn stamping. To complete stamping operations, we use several types of stamping tooling, including stage, progressive die, metal-to-rubber/metal-to-metal, and transfer tooling. In addition, we utilize a wide array of presses with varying tonnage capacities to best meet individual customer needs.
Our customers also benefit from working with a team of engineers and designers to actively share concepts and product data for a cohesive component design. We use the following design methods to provide reliable design services:
- CAD/CAM software
- CAD Key
- Finite element analysis (FEA) for deep drawn and diaphragm design
- COMSOL Multiphysics®
Converting or Redesigning for Deep Drawn Stamping
We can also custom-design or redesign parts to make them suitable for deep drawn stamping; this is especially relevant for parts that are currently being manufactured or were designed to be manufactured by other metal fabrication processes like CNC machining and metal injection molding (MIM).
Typically, the new design version of deep drawn stamping resembles the visual design of the original casting in part and offers the same form, function, and fit in its intended system. This “design conversion” process can also offer long-term component benefits such as:
- Lighter end component weight
- Less expensive to manufacture
- Higher production volume capabilities
- Enables component to be manufactured with a different material
- Removes some porosity concerns
Conversion from machining or metal injection molding to deep drawn stamping design can enable higher volumes of production along with the reduction of costs associated with injection molding. As for altering castings, our team can accomplish this as well, depending on the project. Casting is ideal for projects with fewer budgetary concerns, and for small production runs of parts with varying wall thicknesses or those requiring precise vertical geometries.
Manufacturing Processes for Deep Drawn Stamped Components
To manufacture components with a deep drawn stamped design, we use a variety of manufacturing processes.
Custom Designing, Engineering, and Tooling
Our custom design and fabrication services allow us to manufacture components of all types. We use tooling forms such as hold-downs, punches, knockouts, and dies, and tooling types like stage, progressive die, and transfer press tooling. We offer multiple metal forming options in our catalog of over 15,000 standardized enclosure shapes and sizes. Also, our team does metal diaphragm tooling and modification tooling for existing designs.
Deep Drawn Stamping
Parts may benefit from deep drawn stamping processes, which involve using a punch to draw sheet metal into a die. The die forms the metal surrounding the punch, slowly turning the blank into a seamless 3D shape with a drawn part that has a height greater than or equal to the part width. This process works for both symmetrical and asymmetrical components to form strong metal components.
Annealing and Heat Treating
Some parts use annealing and heat treating processes to improve certain physical and chemical properties. While heat treating retains a part’s integrity and shape, annealing softens the crystalline structure within metals and boosts ductility for better workability.
CNC Machining and Finishing
Components of all types, particularly those in the aerospace industry, use the CNC machining process to manufacture high-quality parts for aircraft and other applications. CNC machining equipment helps minimize the risk of human error and prevents potential flaws from negatively affecting products. Finishing services often include painting, powder coating, plating, and anodizing.
Industrial Component Design and Manufacturing From Hudson Technologies
To provide our clients with top-quality custom parts, Hudson Technologies works with many types of materials, shapes, and sizes to meet customer specifications and AS9100D certification requirements through standard and custom tooling. Regardless of the project or the production run size, we’ll help produce it with consistently reliable results.