Product design – bringing yours up to date !
Sometimes we are so busy working on the next product design that we forget what has gone before. Manufacturing processes are constantly evolving and quite often there is a better and more cost effective way to produce an existing component from your product line. This could be your main bread and butter product or maybe a product where margins are little tight and a new or an alternative manufacturing process process would breath new life, save manufacturing costs and increase profit margins.
Sometines a fresh pair of eyes will have a completely different take on the way a product should be manufactured. An engineer that has has exposure to a wide range of manufacturing processes can be invaluable.
A good example of this is one that I came across some years ago whilst working for a small but highly skilled manufacturing facility in the south west. The company was heavily engaged in the Aerospace industry, manufacturing commercial and military aircraft components to a very high standard using the fluid forming process.
One of theses components was a Boeing sheet metal wing part which comprised of 13 sheet metal components plus rivets. With their special fluid forming process in mind, engineers re-designed the component and the final part comprised of just one single part, a deep drawn component.
Benefits included:
- Cost reduction – massive saving on cost due to simplicity of manufacture.
- No more kit of parts – a single component – no more assembly
- Stronger and stiffer component – the resulting component is more predictable and mechanical properties became more consistent.
- lighter
- More accurate – no accumulation of tolerances between assembled components
- Visually a much better looking component.
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In fact the Customer was so impressed, the part was nominated an won the best Flex formed part at flexor ’98.
If you have an assembly a component or product design that you would like us to look at, please contact us and see if we can help you to improve your product design and reduce cost at the same time.
We have experience in many fields, including complex Hydroforming of sheet metal, multi axis CNC milling and turning, EDM wire cutting, Composite product design, through to large test rig design.
Oh, and if you wanted to find out more about the Cheltenham tool component we talked about above, click here and see for yourself on their website. You can also find out all about Fluid forming there too
