Metal forming promotes repeatability across scale and provides OEMs with the streamlined manufacturing process they need in order to turn around parts and products to their customer bases. With lower per-unit costs in comparison to machining, metal forming creates products that OEMs can rely on.

Industrial Support Inc. provides key points why industrial metal forming for complex OEM components and assemblies makes sense.

Why Complexity is Welcomed

Industrial metal forming not only makes sense for complex OEM components and assemblies, but complexity is welcomed. There are essential characteristics of both program values and component/assembly aspects where complexity isn’t an issue for manufacturers.

No matter the complexity of a part, strength-to-weight efficiency and ratios are supported by industrial metal forming because features like ribs, flanges, and closed profiles can be formed to increase part stiffness without adding wall thickness. This in turn supports lightweight components or assemblies that are durable and structurally sound.

When designs feature complex shapes and geometry, industrial metal forming operations allow for reducing part count through stamping, deep drawing, bending, and more. With a reduced part count, it takes a bulky component into a more simplified version while maintaining the complex features.

Even when components or assemblies are complex, there is an avenue for high repeatability through industrial metal forming – particularly at volume. Tooling and process windows are the most cost-impactful aspects of the manufacturing program, and when those have been established, repeatability in manufacturing becomes achievable as there aren’t design or material changes to consider.

Metal forming also utilizes a better material usage as it reshapes a material selection as opposed to machining it away. While there is still scrap as a result of nesting, skeletons, trim, and draw allowances, forming operations are more adept for complex components and assemblies.

When it Economically Makes Sense

While industrial metal forming can handle complex components and assemblies, it has to also make sense from an economic perspective as there are best-case scenarios for complex parts and metal forming operations.

If you know your components or assemblies are going to be a high enough volume where it can offset the initial tooling costs, then forming is the solution for your manufacturing operations. In the design scope, if there are benefits of formed stiffness, thin-wall construction, or repeatable geometry, metal forming is another likely solution.

When assemblies feature enough complexity where supplier consolidation removes coordination costs, metal forming is a palpable solution. And as a targeted comment on OEMs, if the value in costs is lifecycle costs instead of piece price, metal forming solutions should be considered.

Partner with Industrial Support Inc. for Your Complex Components and Assemblies

Industrial Support Inc. is the contract metal manufacturer that other manufacturers have known and trusted since 1995, creating the components they and their customers need for successful operations. While our home is in Buffalo, New York, we serve OEMs and other customer bases across the United States with our metal manufacturing capabilities and thorough quality management and control protocols.

Metal forming is one of the many capabilities our team can perform in our facility. We work with your team to understand the part application to begin material sourcing, design practices, and ultimately, setting up for manufacturing. With experienced engineers and technicians part of the Industrial Support Inc. team, our metal fabrication services follow specific processes and steps to completion in creating the high-quality components and assemblies needed.

Quality is critical at ISI, and we’ve repeatedly been acknowledged for our commitment to ensuring quality. Our ISO 9001and AS9100D certifications and ITAR-compliance capabilities allows us to handle all types of projects from numerous customers with classified work achievable at ISI.

Contact our team today for more information on our industrial metal forming capabilities and how Industrial Support Inc. can help your team.

The post Why Industrial Metal Forming for Complex OEM Components and Assemblies Makes Sense appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

But Industrial Support Inc. is here to highlight that there are ways to simplify the design process and sourcing of sheet metal assemblies for industrial equipment. By focusing on a few key pillars of sheet metal assemblies, programs can move faster with more focus and direction.

List Out the Sheet Metal Assemblies

When starting the process for designing and sourcing sheet metal assemblies, rather than looking at the assembly as a whole, break down the equipment into its individual parts and functional modules and use consistent guidelines across these individual pieces.

A common starting point can be consolidating cosmetic covers, guards, and small brackets into a single formed part. Maintain a limited material selection to not only keep costs in check, but also to promote a consistent assembly mechanically, physically, and visually.

Material thickness is going to be a discussion point throughout the design process and pre-manufacturing timeline. A way to streamline the conversation is by establishing a standardized thickness by function as opposed to differing thicknesses across components.

Lead times can shorten when reusable design aspects such as hole patterns are followed. This could be panel mounts, access doors, and lifting features.

Incorporate Design for Manufacturability

A general guideline to live by no matter if it’s sheet metal assemblies for industrial equipment, PCBs, or simple metal fabrication is to have your manufacturing program backed by design for manufacturability practices and principles.

Specifically for sheet metal assemblies, this means designing parts toward the process such as cutting, stamping, insertion, welding, grinding, finishing, and final assembly. To start, value common inside bend radius in relation to material thickness in order to reduce cracking risks. Maintain hole sizes on par with material thickness unless your manufacturer can support smaller sizes in your assembly.

Bend angles and orient bends should be standardized consistently to reduce setup times and complex inspections. When welding joints, consider using locating features such as tabs, slots, or formed self-fixturing feature to reduce variation.

And lastly, if any hardware is going to be featured in your assemblies, adhere to fastener supplier rules for host thickness along with edge and bend clearance. When this practice is followed, it prevents PEM insertion failures and distorted panels.

Value Whole Assembly Over Parts

Sourcing is one of most vital aspects for OEMs, supplier programs, and other customer bases Industrial Support Inc. partners with and for sheet metal assemblies, it’s critical to know that sourcing for the assembly itself – rather than the individual parts – can place onus of the manufacturing process.

When a manufacturer is responsible for the entirety of the process including: cutting and form, hardware insertion, welding, finishing, and any mechanical or electromechanical assembly, that’s going to lead to faster lead times and fewer handoffs, which in turn, gets metal assemblies into the market faster.

A critical note in this turnkey ability is that cross-supplier tolerance stack-up in components is eliminated and there is far fewer part variation and consistency is vastly improved. During the manufacturer discovery process, keep some of these parameters in mind either as a mental note or as a legitimate checklist.

• Manufacturers can provide proper documentation for material sourcing and traceability throughout a manufacturing program.
• Vet that capabilities advertised are performed in-house rather than with a third-party vendor to avoid costly handoffs, stalled lead times, and inconsistencies and part variations.
• Inquire about testing and inspection capabilities to ensure part functionality is accurate.
• Relevant industry experience in your field and market is an added bonus to discover as it demonstrates the chosen manufacturing company knows the ins-and-outs of your industry and what it takes to produce a successful sheet metal assembly.

Contact Industrial Support Inc. for High-Quality Sheet Metal Assemblies

Industrial Support Inc. has been the contract metal manufacturer that other manufacturers trust to fulfill a need they don’t have the means or capabilities to fulfil. Since 1995, the team at ISI has championed efforts to streamline manufacturing operations for OEMs, supplier programs, and other customer bases as well.

That includes providing solutions for sheet metal assemblies for industrial equipment. Designing and sourcing sheet metal assemblies can be difficult for OEMs, especially finding high-quality parts that are going to serve as intended. No matter the industrial application, components manufactured by ISI are backed by numerous quality management and control metrics, highlighted by quality certifications such as ISO 9001, AS9100D, and ITAR compliance standards.

Simplify your design and sourcing of sheet metal assemblies for industrial equipment and contact Industrial Support Inc. today.

The post How to Simplify Designing and Sourcing Sheet Metal Assemblies for Industrial Equipment appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

But how to tell which option is right for both your team and your project? These two manufacturing methods entail different roles in manufacturing and are vastly different processes. While they both are important in the creation of metal parts, their differences make for noticeably different components and their subsequent applications. 

Industrial Support Inc. compares and contrasts metal stamping services with CNC machining and ultimately, how to select the right option for the creation of your industrial metal parts. 

Manufacturing Decision Points for Industrial Metal Parts 

Industrial metal parts is quite a broad term to define hundreds, even thousands of different parts and components. Ultimately if your team knows that it’s between metal stamping services and CNC machining operations, there are some decision points to weigh before making a choice. 

If the part you need manufacturing services for are in a family of repeatable, sheet-metal parts where unit cost matters especially at scale, metal stamping should be your selection. Common parts include brackets, clips, shields, terminals, and covers. 

For parts where the design isn’t fully ironed out, requiring a prototype, a pilot build, features sophisticated 3D geometry, thicker stock, threaded features, frequent engineering changes, or deep pockets, CNC machining is the route to go down. 

Volume and Cost 

Not only do metal stamping and CNC machining vary in their respective processes, but they also vary in costs. Both manufacturing operations have cost tradeoffs that make it difficult to decide which is more cost-effective. 

The largest cost-impact aspect about metal stamping is the upfront tooling investments associated with production. This requires material sourcing, extensive design reviews, and if a manufacturer doesn’t perform the tooling services in-house it’s then sent to an outside vendor which further increases costs. The flip side of that equation is that the per-part cost drops significantly as volume increases, essentially offsetting the tooling costs. 

Whereas, CNC machining for industrial metal parts features minimal, if any, tooling operations. The costs associated with CNC machining stem from constant machine time and the labor that goes with machining. As volume rises, so do costs with CNC machining. 

Part Geometry and Tolerance 

Selecting a manufacturing method is also driven by the part’s design with an emphasis on geometry and tolerance. Specifically looking at metal stamping, there are multiple variations of stamping such as transfer die stamping that can perform similar actions as CNC machining such as handling complex geometry or precision features, but the costs again associated with stamping may serve as a deterrence for decision makers. Stamping is better suited for consistent sheet-metal shapes that feature normal tolerances and limited complexity. 

The safer route for manufacturing excellence if your part features tight tolerances, interfaces, precision features, and complex geometry is machining. 

Lead Times and Program Flexibility 

The last consideration to make while deciding between metal stamping vs CNC machining for industrial metal parts is time and scalability or flexibility. Because tooling isn’t associated with machining, programs can start much faster compared to stamping operations. The drawback there is that, machining is better for parts that feature constant design or engineering changes because how quick the process is. Stamping will take longer to start due to the tooling that takes place first, but if your design is locked in and the part will remain consistent, the long lead times are worth electing stamping. 

Contact Industrial Support Inc. for Your Industrial Metal Parts Manufacturing Operations 

Industrial Support Inc. has served as the contract manufacturer that manufacturers trust with their most complex and difficult operations. Located in Buffalo, New York, since 1995 we’ve served countless OEMs and other manufacturers performing the supplemental manufacturing operations they need. 

Manufacturing industrial metal parts incorporates numerous part types, design considerations, and manufacturing methods – including metal stamping and CNC machining. Those two operations play a specific role depending on customer need, part type, material selection, and much more. Either way, the ISI team has capabilities in both operations and expertise in creating the components your team needs. 

Quality management systems at ISI have routinely passed the mark highlighted by our ISO 9001 certification, ITAR compliance standards, and our AS9100 certification. Our team can handle the most advanced projects, including military-grade applications because of these quality management systems and subsequent certifications. 

Not sure if metal stamping or CNC machining is the better option for your industrial metal parts manufacturing operation? Contact the experts at ISI today.

The post Metal Stamping Services vs CNC Machining: Choosing the Right Process for Industrial Metal Parts Manufacturing appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

CNC machining and spot welding are two of the manufacturing methods used to create EV battery pack components, but what is their role in the overall manufacturing process and what pieces do they create? 

Industrial Support Inc. makes the case for both CNC machining and spot welding, their impact on manufacturing, and how they work together. 

CNC Machining Role 

When looking at EV battery pack components manufacturing, there are different lenses to look through. CNC machining is looking through the mechanical lens of battery packs. When tight flatness, sealing, alignment, and dimensional repeatability are a premium, CNC machining is the operation that should be performed. 

A common example of a component that fits this description is an aluminum battery housing or a precision interface that handles thermal management, sensor readings, and fasteners. CNC machining of these types of components helps control tolerance stack-up while improving pack-level fit, sealing, and structural reliability. 

From an engineering perspective, CNC machining operations are able to hold vital features to automotive-grade accuracy.  

Spot Welding Role 

Referring back to the lenses point, when discussing spot welding operations, that should be viewed through an electrical interconnection role which takes place inside the pack. Spot welding is used to join thin metals at tabs and busbars using centralized heat to promote fast, automation, and cost-effective battery assembly practices. When teams face high-volume programs, spot welding’s biggest strengths – speed and repeatability – shine. It creates strong joints by using minimal heat input and that helps protect heat-sensitive battery cells and maintain efficient production schedules. 

How they Work Together for EV Battery Pack Components 

It’s time to put the pieces together, how CNC machining and spot welding work together in EV battery pack components manufacturing. CNC machining essentially builds the physical, hard structure that holds all the items in place whereas spot welding creates the internal electrical network used to connect to cells. 

These two processes aren’t in competition with one another, rather, they are paired together to create a singular part that contains multiple different aspects. 

Partner with Industrial Support Inc. for EV Battery Pack Components Manufacturing Today

Since 1995, Industrial Support Inc. has served as the contract metal manufacturing company that OEMs and other manufacturers throughout the country rely on to manufacture the components they need. We’re located in Buffalo, New York, but our manufacturing capabilities reach all parts of the country, and in some applications, around the globe. 

As more sustainable pushes in power are becoming a mainstay, ISI has a proven capability in manufacturing the essential EV battery pack components that keep equipment, vehicles, and other applications powered. Through numerous manufacturing capabilities, including CNC machining and spot welding, our team takes your design and part application as guides to create the components your project needs. 

And at ISI, quality always comes first. We hold multiple certifications in quality management indicated by our ISO 9001 certification and our AS9100D certification. Additionally, we are also ITAR-certified, allowing us to handle some of the most information-sensitive projects. 

Contact us today for more information on how you can offload your EV battery pack components manufacturing to a trusted and reliable contract metal manufacturer in ISI. 

The post The Role of CNC Machining and Spot Welding in EV Battery Pack Components Manufacturing appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

Understanding the product application and having detailed knowledge of the intended environment that enclosures, brackets, and structural components may serve in is an advantage during the discovery process with a custom sheet metal manufacturing company. 

Industrial Support Inc. walks through key considerations to make prior to production. 

Commonly Used Materials 

Custom sheet metal manufacturing relies on numerous different metals to create the products needed in harsh environments. While every material is different, they all have certain characteristics that make them advantageous in harsh environments. 

Stainless steel, specifically grades 304 and 316, provide superior corrosion resistance and strength, making it a suitable solution in most environments. It’s best usages are in chemically-exposed environments, outdoor applications, and in hygienic environments. 

Galvanized steel is a cost-effective solution in comparison to stainless steel. While it doesn’t offer the same high levels of corrosion resistance, when coated with a protective zinc treatment, it becomes incredibly rust resistant and is commonly found in electrical enclosures as well as outdoor equipment. 

For a lightweight option, many customers will utilize different aluminum alloys. Aluminum also features corrosion resistance, but usually features protective finishes to enhance durability and extended a product’s lifecycle. 

Custom Sheet Metal Manufacturing Secondary Operations for Harsh Environments 

While some materials don’t require any secondary operations in the form of coatings or other finishing treatments, largely due to their natural properties – stainless steel’s natural corrosion resistance as an example – there are instances where secondary operations can be used to further enhance materials and offer another level of protection while boosting the aesthetic properties as well. 

• Powder coating operations create a thick and durable layer that’s protects the surface of a component from potential scratches, corrosion, and promotes UV resistance. Many colors can be used in powder coating as well to provide a stunning visual aspect while providing key protection for parts. 

• In aluminum-based programs, the product can be anodized in order to increase surface hardness, wear resistance, and corrosion protection. A byproduct of anodizing is the sleek metallic finish. 

• Whether it’s zinc, nickel, or chrome, plating is another surface treatment operation that can be performed to enhance both chemical and corrosion resistance in products. Electrically conductive products commonly feature plated operations. 

• Steel and specific grades of stainless steel can be galvanized to provide additional corrosion resistance. 

Design Considerations 

The design of an enclosure, bracket, or structural component is just as important as the material selection of a product. Designs must consider the environment as well as being manufacturable, so weighing these two items together can make for a long process to ensure proper product usage and lifecycle expectancy. These are some of the biggest recommended design considerations for custom sheet metal manufacturing of enclosures, brackets, and structural components intended to serve in harsh environments. 

• Incorporate sealing and gasketing to prevent water, dust, debris, and other harmful agents from entering a specific component. 

• The use of ventilation that allows heat dissipation without sacrificing protection, which can be achieved in a few ways such as sealed cooling systems or filtered vents.
• For bracket specifically, incorporating mounting solutions that promote reinforcement and ensure stability in numerous types of applications, namely vibration-centric environments.

Contact Industrial Support Inc. for Premier Custom Sheet Metal Manufacturing in the Harshest Environments 

Industrial Support Inc. has served as the contract manufacturer that numerous OEMs and large supplier programs trust. Located in Buffalo, New York, we’ve created numerous metal components, assemblies, and systems through our wide range of capabilities. Not only do we offer our manufacturing services, but we also have value-added operations in our facility as well to deliver the final version of your product and eliminating another stop along the way. 

ISI is both ISO 9001 and AS9100D certified, along with our ITAR-compliance and DDTC registration. Simply put, our quality management systems have undergone some of the most thorough internal and external audits in the industry and we’re capable of creating some of the most demanding parts serving in the harshest environments. 

Contact our team for your custom sheet metal manufacturing needs and we’ll work with you to offset your program and create the parts needed.

The post Custom Sheet Metal Manufacturing of Enclosures, Brackets, and Structural Components for Harsh Environments appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

The International Traffic in Arms Regulations, commonly known as ITAR, features compliance metrics rooted in legal and operational requirements that any defense contract manufacturing company must adhere to in order to create the metal assemblies and systems needed for U.S. defense programs. ITAR’s control of information associated with the U.S. Munitions List (USML) is vital in properly labeling all aspects of a defense contract manufacturing program. 

Industrial Support Inc. details how we navigate through ITAR compliance as a contract manufacturer when creating the parts necessary for defense programs with key points on how to avoid the severe civil and criminal penalties that can be imposed by not following all compliance requirements. 

What ITAR Covers in Metal Assemblies and Systems 

ITAR compliance measures are associated with three main points in defense contract manufacturing and it all ties back to the USML. 

Defense contract manufacturing programs are required to follow ITAR compliance metrics when performing operations on defense articles listed in the USML. These articles contain thorough lists and examples of specific products or systems where ITAR compliance must be followed. Some examples include weapon system housings, armored vehicle components, guided-missile structural parts, specific sensors, and avionics enclosures. 

If technical information such as drawings, designs, CAD files, specific process specifications, inspection plans, BOMs, and test results are exposed to a defense contract manufacturer that ties directly into articles in the USML, ITAR compliance must be followed. 

And the final coverage of ITAR compliance in defense contract manufacturing falls under any defense services including but not limited to: repair, maintenance, training, or technical assistance regarding items on the USML. 

How ITAR Impacts Defense Contract Manufacturing and Manufacturers 

Industrial Support Inc. and other defense contract manufacturing companies are impacted by ITAR compliance measures for as long as defense contract manufacturing services are offered. This entails a few different registrations and internal organizational tactics to provide streamlined support, quality, compliance, and record-keeping. 

DDTC Registration 

As a defense contractor, registration with the State Department’s Directorate of Defense Trade Controls (DDTC) is mandatory. This organization is the group responsible for enforcing ITAR compliance measures along with the Arms Export Control Act. Every manufacturer that’s registered with the DDTC has an internal officer to serve as the main compliance contact. 

Internal Compliance Program Set-Up 

Once registration with the DDTC has occurred, they require an internal compliance program (ICP) containing written policies and procedures specified to a manufacturer’s operations. Within the ICP also includes employee training that covers USML information including list awareness, technical data controls, and more. 

As the DDTC can perform audits of any defense contract manufacturing company, recordkeeping procedures for at least five years are required of registered manufacturers. 

Technical Data Controls 

When defense contract manufacturing entails metal fabrication and metal shops, this means access to drawings and process documentation is more prevalent and common compared to other forms of manufacturing. 

Manufacturers are required to limit access control to this information to authorized individuals only. Labeling of data is required so there are no mistakes made on sensitive or even classified information. And both digital and physical security measures must be in place.

Supply Chain Management 

Any organization that comes into contact with an ITAR-compliant project is subject to ITAR compliance measures, and that includes the supply chain. Defense contract manufacturers are required to verify subcontractors and vendors are ITAR registered and can prove compliance with all measures. 

Common Manufacturer Failures in ITAR Compliance 

With so many measures in place for defense contract manufacturing in ITAR compliance, mistakes still happen and those mistakes can prove to be costly in the form of civil and criminal penalties – the extremes include a $1 million fine, debarment, and even 20 years of imprisonment. 

To avoid these costly and harmful penalties, be mindful of these common oversights. 

• Assumption of part exemptions because of how they look. 

• Never assume, always validate 

• Sharing information with offshore suppliers. 

• Validate organizations are properly registered with the DDTC and are ITAR compliant. 

• Poor data classification 

• It is always better to over label information that adheres to ITAR programs. 

• Reliance on prime contractor assurances. 

• Constantly verify your own compliance status. 

Practical Checklist 

When selecting a defense contract manufacturing company keep this practical checklist in mind to ensure ITAR compliance is being followed properly. 

• Classify products and data so it’s known what pieces fall under the USML. 

• Ensure your manufacturer is registered with the DDTC. 

• Ensure your manufacturer as a built out or recently refreshed ICP. 

• Ask for implementation of technical controls. 

• Ask for an audited supply chain record. 

Contact Industrial Support Inc. for Defense Contract Manufacturing Operations and Experts in ITAR Compliance 

Industrial Support Inc. serves as the contract manufacturing company that OEMs and other large manufacturers and suppliers rely on to create the products they need. We’ve proudly operated out of our Buffalo, New York, facility since 1995 and have served numerous industries with our wide range of metal manufacturing capabilities. 

One area we are certainly proud to serve in is as a defense contract manufacturing company. Creating the complex metal assemblies and systems that are used by our nation’s finest is an honor and a privilege, and a massive responsibility to get it right every single time. That’s why we strictly follow and adhere to ITAR compliance measures and are constantly reviewing the USML to ensure our customers – and ourselves – aren’t exposed to extremely severe penalties associated with improper manufacturing. 

If your team is searching for a defense contract manufacturing company with an exemplary record in following ITAR compliance, look no further. Contact ISI today and let’s begin the initial review of your program’s needs.

The post Securing the Mission: Navigating ITAR Compliance in Defense Contract Manufacturing for Complex Metal Assemblies and Systems appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

When these two operations are integrated, it’s typically for projects such as an industrial control where a control board is built out in the PCB portion and then the fabrication shop creates the enclosure and hardware necessary to support the PCB.

ISI walks through the importance of integrating these two services within contract electronic manufacturing and how one company can handle board assembly, custom enclosure builds, bracket, chassis, wiring, and final system integration all under one roof.

Outlining Integrated Operations

One of the most critical aspects of integrating these two services within the umbrella of contract electronic manufacturing is working with your manufacturing company or supplier to properly identify a streamlined path so that PCBA and metal fabrication can happen simultaneously.

This typically means outlining appropriate corresponding design times for both the PCB as well as its enclosure and other items to enclose the circuit board. Manufacturing of the pieces traditionally has the PCB assembly services performed first and then it flows into the metal fabrication where parts can be created, finished, and ultimately assembled into subframes or enclosures.

Once the metal fabrication services have concluded, these two physical aspects are integrated with one another including PCB harnesses, power supplies, and the user interface parts. Not only does installation and assembly take place, but product testing and validation also occurs to ensure functionality as well as quality.

Understanding the Why in Contract Electronic Manufacturing

The integration of PCBA services along with metal fabrication in contract electronic manufacturing ultimately boils down to why. From a customer standpoint, both the OEMs utilizing services and subsequently, their customers, when the supplier can consolidate operations into one singular task, it eliminates more vendor handoffs which impacts multiple avenues including fit-up problems, costs, scheduling, logistics, and supply chain woes.

From the supplier’s perspective, when they can consolidate operations into a more streamlined approach through integration, it improves overall manufacturability as all facets of production occur underneath one roof. This allows for better communication on project timelines and easier access for part validation and testing protocols. Not only those points, but quality remains consistent when one manufacturing company is in charge of operations.

Considerations to Make on Specifying Items to the Supplier

If OEMs and other customers are weighing whether or not to choose contract electronic manufacturing, there are some recommended considerations to make from a supplier.

• When requesting a quote for services, include BOM, Gerbers, assembly drawings, enclosure CAD, stack-up and thermal requirements, test specs, and necessary volume profile.

• Seek clarity on the need for turnkey sourcing, partial consignment, or customer-supplied parts.

When these considerations have been made, it allows for better dialogue on expectation between supplier and customer, which then trickles down to the primary customer who is expecting the final component

Check List of Capabilities

A final consideration for customers and this should be performed whether you’re searching for a contract electronic manufacturer, a fluid transfer systems manufacturer, or any other type of manufacturer. Perform a thorough search and investigation on a few company’s capabilities and what all they entail.

• In-house sheet metal fabrication is essential when integrating metal fabrication and PCB assembly services is central to your needs for a contract manufacturer. In-house services can including welding, finishing, machining, and mechanical assembly.

• Ensure supplier program has an IPC-based PCB assembly operation and can perform AOI/ICT tests to validate build responsiveness.

• View industries served if able. This can showcase a supplier’s wide-range of expertise and capabilities.

• Search for any quality certifications, such as an ISO 9001 or an AS9001D.

Contact Industrial Support Inc. for More Information on Contract Electronic Manufacturing Services

Industrial Support Inc. is the manufacturing company that OEMs and other manufacturing companies trust. When a project falls outside of the original manufacturer’s scope of work, that’s where ISI comes into play. And since 1995, we’ve served numerous customers in multiple industries with the services they need to deliver their products on time to satisfy customers.

Our contract electronic manufacturing services are wide ranging and entail multiple facets of electronics manufacturing including PCBA, assembly and component manufacturing, and elective CNC machining operations. We hold both an ISO 9001 certification and an AS9001D certification, both of which demonstrate our commitment to superior quality management services. Specifically, to our AS9001D certification, this allows us to perform high-level work in the aerospace industry, including contract electronic manufacturing operations.

If your team has a challenge with electronic manufacturing and needs support, ISI is here for you. Contact us today and we will set up an initial consultation to review project specs and get to work immediately.

The post Contract Electronic Manufacturing: Integrating Metal Fabrication With PCB Assembly Services appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

The decision makers for OEMs have the ability to utilize suppliers and a network of other manufacturers, however, to actual manufacture and assemble the box builds and ultimately ship them back to the OEMs for final assembly into a more integrated system.

Industrial Support Inc. has a high-level guide on key aspects of the electromechanical box build and enclosure manufacturing processes along with considerations to make on finding a suitable supplier for your program.

What Electromechanical Box Build Services Cover

No two supplier programs are ever going to be the same, but they all should have common groundwork and foundations to provide OEMs with the solutions for electromechanical box builds and enclosure manufacturing.

Box Builds

Box builds feature the integration of mechanical and electrical services and systems into a self-contained unit fit inside an enclosure. The box build itself traditionally features a PCB as its base and contains power suppliers, relays, displays, switches, connectors, and many, many electronic components that all speak together. The services for these include SMT, Through-Hole, Selective Soldering, and extensive testing and part validation such as AOI or X-ray.

Enclosures

When PCBs are fully assembled, that entails them placed within an enclosure. Often performed by metal fabrication where welding, stamping, forming, and finishing are performed, enclosures are typically made from custom-sheet metal.

Chassis, brackets, wire harnesses, and wire routing guides are included with the enclosure as well as a cover to contain the PCB.

Why Power Generation OEMs Use It

Power generation OEMs not only use electromechanical box build and enclosure manufacturing, but by extension supplier programs, for a few key reasons. Box builds are used to lessen supplier count as well as shorten assembly time. These two operations go hand in hand with box builds because when a manufacturer performs box build and enclosure manufacturing services in-house, the need for handoffs from vendor to vendor is drastically reduced. This saves OEMs on costs and reduces the need for multiple suppliers to create a singular production run.

Testing services on the box build (PCBs) are vastly improved as well through AOI, X-ray, and performance testing to validate the builds. Quality testing on the enclosures through stringent QMS programs that are ISO certified can enhance manufacturing as well.

Power generation OEMs will rely on supplier programs for the main point of they have more enhanced capabilities from a infrastructure standpoint. While OEMs are ultimately responsible for the part as the front-facing manufacturer, supplier programs have the in-house capabilities, equipment, engineering, and experience in creating the builds and enclosures themselves. With this, OEMs can save costs on capital investments, overhead, and labor, all while obtaining high-quality builds for their projects.

Common Applications

While this isn’t an exhaustive list, power generation OEMs can rely on electromechanical box builds and enclosure manufacturing for the following items.

• Generator control cabinets

• Battery enclosures

• Inverter enclosures

• Switchgear-adjacent control modules

• Remote monitoring boxes

• Interface panels for varied industry applications

• Backup power systems

Contact Industrial Support Inc. for Electromechanical Box Build Services Today

Since 1995, Industrial Support Inc. has served as the manufacturer that manufacturers trust. In our Buffalo, New York, facility, we perform numerous services and our customers are some of the most recognizable OEMs in the world, all trusting us to provide support to their projects through manufacturing excellence, quality, timeliness, and accuracy.

Our electromechanical box build services entail just-in-time shipping, Kanban scheduling with pull methods to appropriately respond to supply chain needs and manage in-house inventory control. We also have custom capabilities with production volume runs starting at just a few prototypes to hundreds of thousands of builds in a high-volume capacity.

If your team is searching for an electromechanical box build supplier, contact the ISI team today.

The post A Guide to Electromechanical Box Build and Enclosure Manufacturing for Power Generation OEMs appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

For CNC machining medical parts, finishing touches mean more than just aesthetics. Every aspect of a CNC machined part with a medical application is focused on functionality, compliance, and performance.

Learn more from Industrial Support Inc. about why CNC machining medical parts requires a burr-free finishing strategy, and how to best achieve it.

Why Burrs Are a Deal-Breaker in the Medical Industry

Burrs — a raised edge, rough ridge, or excess material — on medical parts interfere with assembly, sealing, and precise mating features on medical parts. These blemishes on surface area finishes create defects and difficulties for applications such as implants, surgical tools, and fluid-handling components.

Depending on the medical component itself, burrs can also create biological risk for both medical professionals and patients by trapping contaminants or making a surface more difficult to clean and sterilize.

Why Finishing Operations Need to be Controlled

A burr-free strategy for CNC machining medical parts has to be the solution, but it’s more than just the blemishes on the surface and potential impacts in its applicable field. Medical parts traditionally feature tight tolerances, and where uncontrolled deburring happens, critical edges, threads, sealing lands, or microfeatures can be extensively damaged.

Ultimately, the end goal is to remove burrs without creating surface contamination or creating new geometric problems.

How to Create an Effective Burr-Free Strategy

A strong, effective burr-free strategy for CNC machining medical parts combines both process choices where burr formation at the source is reduced, and controlled secondary finishing. There are multiple avenues for engineering teams to divest into these combinations, including: sharp tooling, optimized cutting parameters, cleaner coolant or cutting methods, and selective deburring methods.

Strategy is also dependent upon material selection, and more advanced methods of deburring might have to take the place of standard operations. Key tactics include cryogenic deburring, ultrasonic micro-deburring, or even forms of electrochemical methods that ultimately reduce manual work.

Achieve Burr-Free CNC Machining Medical Parts Services With Industrial Support Inc.

Since 1995, Industrial Support Inc. has been the manufacturer that manufacturers trust with their projects. Serving OEMs across countless industries, our highly skilled and experienced team creates the parts manufacturers need but can’t create themselves.

Our CNC machining services extend to numerous industries and feature critical operations such as live tooling, which in turn allow us to mill, drill, tap, face, cross drill, and turn various metals, catering to the diverse needs of automotive, electronic, medical, dental, military, and aerospace customers. When your medical parts need to be burr-free, we can handle it.

Backed by multiple quality management certifications, including an ISO 9001 certification, when your projects leave our Buffalo, New York, facility, you can be assured that quality was central throughout the entire manufacturing process.

Contact our team today for more information on CNC machining medical parts and see how ISI can make a difference in your next operation.

The post Why CNC Machining Medical Parts Requires a Burr-Free Finishing Strategy appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.

In medical metal fabrication applications, performing a tolerance stack up analysis can ensure that multiple pieces can properly assemble together. Industrial Support Inc. shows how to solve the tolerance stack up challenge without compromising precision.

Defining Tolerance Stack Up

Tolerance stack up in metal fabrication is how small allowed dimensional variations from multiple parts of features add together and impact the final fit, form, or function of an assembly. Parts have to be in an exact tolerance holding pattern in order to assemble together perfectly. Even if they are close to perfect, it can cause potential issues such as improper fit by being too tight or too loose.

Pre-Manufacturing Problem Solving

While tolerance stack up is a natural aspect of a metal fabrication service that features multiple components, having an imbalance stack up needs to be resolved in order for the final assembly to pass testing and quality control measures. There are a few ways this can be done.

• Engineers can perform a tolerance stack up analysis where calculations are run on the accumulated variation of part dimensions in an assembly in order to ensure proper fit, performance, and manufacturability.
• As it relates to medical metal fabrication projects, teams can perform a tolerance stack up analysis but also run simulations on tolerance variations early in the engineering process. When the variations have settled from simulations, teams can decidedly place nominal tolerances and begin manufacturing.

Technical Problem Solving

When proper engineering has been performed, it makes manufacturing much more streamlined, but even then, proper engineering has to translate into accurate production processes. That is evident through a few different options when creating medical metal fabrication products.

• Along with engineering services, design options can be implemented to ensure proper stack up. It is recommended to loosen non-critical dimensions so more tolerance can be shifted toward functional features.
• Perform geometric dimensioning and tolerancing (GD&T) to control form, position, and datums rather than only relying on plus/minus dimensions.
• When performing design for manufacturability processes, have the focus be on the intended capability and application of the part, rather than whether it can be manufactured.
• Ensure proper fit and tolerance levels by utilizing prototyping services if applicable and further tolerance studies.

No matter the form of fabrication — CNC machining, laser cutting, welding, or any other form — these services are intended to help hold vital dimensions in place in medical parts. It’s critical to perform other operations during production to ensure dimensions are in check. Key services can include in-process measurement, probing, and automated inspection to catch drift prior to defective parts throughout the manufacturing process.

Solve the Tolerance Stack Up Challenges in Your Medical Metal Fabrication Projects With Industrial Support Inc.

Industrial Support Inc. opened its doors in 1995 as the manufacturer that manufacturers trust. Our wide-ranging set of capabilities and specializations allow us to tackle some of the most pressing problems and complex operations in multiple industries. No matter what the challenge is, our team will work to find the solution.

In our medical metal fabrication services, tolerance stack ups come across our plates every time there’s a complex build featuring multiple assemblies. With skilled and knowledgeable technicians, our processes allow us to identify the strengths and weak points of a project and ensure streamlined production.

Contact us today for an easier experience creating the parts your team and your customers need, starting with a perfect fit.

The post Precision Without Compromise: Solving the Tolerance Stack-Up Challenge in Medical Metal Fabrication appeared first on Integrated Manufacturing for Metal Assemblies and Electromechanical Builds | ISI.