Category Archive: Services

A Step-by-Step Guide to Our Deep Drawn Stamping Process

Since 1959, Manor Tool & Manufacturing Company has been fabricating metal components for a range of industries, including aerospace, automotive, medical, energy, and consumer goods. With a specialty in high-quality metal stamping, Manor Tool can create anything from a one-off prototype to a high-volume run requiring progressive tooling.

Manor Tool’s deep drawn metal stamping services include standard cylindrical and axisymmetric shapes as well as box-shaped items. We can make modifications to meet each customer’s unique needs, such as coining, curling, extruding, and embossing. Our shop is also ISO 9001:2015 certified for quality, and our process has been established to produce finished parts to tight tolerances that meet or exceed customer specifications.

The Process of Deep Draw Stamping

The deep draw process is necessary for parts with a depth that exceeds their diameter, like beverage cans, deep pans, assembly housings, and other containers. A blank piece of sheet metal is positioned over a die, and a punch is used to force the metal into the die and create a custom shape. Once the die is made and tooling set, the process is relatively inexpensive, especially for high-volume production, because it can be completed with minimal downtime or maintenance.

From start to finish, the deep draw stamping process is as follows:

  1. Engineers provide a design.
  2. Our Engineers review the design and determine whether the part can be created with Manor’s fleet of more than 30 400-ton presses.
  3. We consider the ideal thickness, shape, and radii of the finished part and what will work best based on customer specifications and our expertise. Typical parts we create are between 0.005 and 0.5 inches, with extremely tight tolerances. We can also make dies up to four feet wide and eight feet long.
  4. We implement Finite Element Analysis, or FEA. This allows us to virtually create the part using the final design and accurately simulate the entire manufacturing process. Any problems with design or tooling can be easily discovered and changed before it costs time and money.
  5. Based on material requirements, we select the right flat metal sheet. Options include aluminum, brass, copper, and steel.
  6. As part of set up, Engineers note the depth of the part and the degree of radius. They position the die and punch properly on the press. The metal sheet, or blank, is placed on the die.
  7. The punch is applied against the die with force, which shapes the workpiece as desired. This process is repeated to produce the correct depth and size.

The finished part, having been created from a single sheet of metal, is strong and seamless. The precision of the process allows it to be completed quickly, for less technical labor costs and quicker turnaround times.

What Can Be Made From Deep Draw Stamping Metal?

Metal stamping is widely used to manufacture a wide range of parts, and deep draw stamping produces parts with depth greater than the diameter. Commonly produced items from the deep draw stamping process include panels, tanks, containers, sinks, automotive parts and pots or pans for kitchen use.

Some types of parts or items are more likely to be produced via deep draw metal stamping:

· Parts that must be produced at high volume. Deep draw stamping works quickly and efficiently once it has been set up, making it ideal for longer runs.

· Parts that must be water- or gas-tight. The one-sheet process is seamless.

· Parts that must be produced to tight tolerances. Metal stamping has high accuracy and can be set to tolerances as low as ±.0005 in.

· Parts that have complex, axisymmetric shapes. The die and punch create these geometries more quickly and accurately than many machining processes.

· Parts for which cutting or welding would be undesirable from a durability or aesthetic standpoint.

Quality Metal Stamping at Manor Tool

Deep draw metal stamping is an ideal process for cylindrical or axisymmetric parts that can be manufactured quickly to tight tolerances. While anything from a prototype to a small run to high-volume manufacturing can be completed using deep draw metal stamping, it is most cost efficient for large production runs. Once the tooling is set, the process runs quickly and with little required oversight.

Manor Tool’s ISO 9001:2015 certified quality control processes at every stage of production ensure that a high quality finished part fits all specifications. Not only can our pre-production process identify inefficiencies before work begins, but we can assist in determining the ideal shape, thickness and materials to use for best results.

To learn more about our deep draw stamping services or to get started on a project, contact us today or request a quote.

Applications and Tips for Transferring Tooling

Developing effective transfer tooling procedures lets small and medium-sized manufacturers minimize their tool development costs and hedge against unpredictable component suppliers. Tooling is an expensive process, but it typically involves only a one-time cost, so anything that can make the tooling process more affordable will greatly impact your overall expense portfolio. As the trade war between the U.S. and China continues to heat up, it’s now more important than ever to consider transferring tooling back to American manufacturers to mitigate increased costs and other supply chain disruptions as a result of tariffs.

External suppliers perform a number of time-intensive processes during tooling development so that you don’t have to. Third-party tooling services include:

  • Machining
  • Heat treating
  • Routing
  • Barcoding
  • Turning assembly
  • Pressing
  • Debugging
  • CMM final inspection

When you let other manufacturers perform these tasks, you can dedicate more time and resources to applications more central to your company’s mission.

In this post, we describe eight transfer tooling strategies that will enable you to get the most from outsourcing your tooling production.

Eight Steps to Successfully Transfer Your Tooling

Following these tips will help you execute a successful tooling transfer.

1.) Make Sure Everything’s Covered in Your Contract

All parties subject to the transfer tooling agreement must sign nondisclosure agreements to ensure that any new innovations remain between those concerned. NDAs must cover part prints, quality assurance policies, and production requirements. Additionally, governmental and third-party regulators often require legally sound contractual agreements to be signed before work can begin.

2.) Create a Strong Partnership that Emphasizes Communication

A partnership based on trust and open communication between the businesses will ensure that parts arrive on time and that nothing is lost in translation. Both companies must be willing to take the appropriate steps to ensure that communication channels remain open throughout the process.

3) Perform On-Site Assessments Early and Often

It’s important to have a solid understanding of your transfer partner’s capabilities before entering an agreement. Additionally, once production has begun, frequent and respectful on-site assessments will ensure that you have as much information as possible on the status of your tooling.

4) Agree on a Clear Production Schedule

Create a detailed transfer schedule using data from on-site assessments. The schedule must include transfer dates for all parts and tools while allowing enough time to produce the tools to your standards.

5) Build Enough Safety Stock to Allow Efficient Tooling Transfer

The supplier must provide enough safety stock that you can use during the validation of production equipment and processes at the new facility. Typically, business partners set up a six-week timeframe within the transfer schedule, although it’s important to allow for the possibility of additional shifts and/or weekend work to make sure everything’s running on time.

6) Ensure You Buy the Correct Consigned Equipment

The third party may need to buy nonconsigned equipment to successfully build your transfer parts. Consignment equipment typically includes tooling and spares, fixtures, inspection gauges, and all other product-specific equipment.

7) Validate All Transfer Tools Before Ending Your Contract

When the third-party’s transfer tools leave production, you should ensure that they’re all compatible with your existing facility. Many companies validate transfer tooling by analyzing their new parts’ similarity to existing parts and performing golden sample processes.

8) Design Production Molding For Use in the Next Transfer

Once the tools have been validated and incorporated into your production processes, make sure you or your contractor save the production mold to simplify the transfer tooling process next time you go through it.

Applications for Transfer Tooling

Just about any industrial manufacturer needs to develop effective transfer tooling procedures. A wide range of manufacturers regularly contract third parties to ensure that their next generation of tools is of as high quality as possible. Industries that implement comprehensive transfer tooling procedures include:

  • Sheet metal stampers
  • OEMs
  • Appliance manufacturers
  • Automotive and aerospace OEMs
  • Furniture assemblers
  • Machine tool shops
  • Medical device manufacturers

Transfer tooling can work with a wide range of metal products, such as:

  • Aluminum
  • Cold-rolled steel
  • Spring steel
  • Stainless steel
  • HSLA

Manor Tool: A Trusted Source for Transfer Tooling

Manor Tool & Manufacturing is an ISO 9001:2015–certified company that can help you with all your transfer tooling requirements. If you’re looking for more best practices on how to implement the most effective transfer tooling procedures, download our free eBook, “Everything You Need to Know About Transferring Tooling.”

If you’re looking to embark on a transfer tooling procedure of your own, feel free to contact us at your earliest convenience to request a free quote.

Download Our Transferring Tooling eBook >>

5 Reasons to Consider a Tooling Transfer for Metal Stamping

As the U.S. economy and global manufacturing supply chain continue to evolve, many companies are realizing the need to maintain a consistent inventory of parts and tooling for their core operations. With OEMs examining supply chain risk management more closely than ever, it’s no surprise that tooling transfers have become increasingly popular in today’s industrial landscape.

Tooling transfers can prevent a number of common challenges that slow production or threaten to derail it altogether, including the following common tooling issues:

  1. Old tooling: Tool maintenance is essential, both to maintain safety and ensure high quality output, but requires appropriate resources like highly trained team members. If a trained staff is a prohibitive cost, however, you can easily outsource this work. Manor Tool and Manufacturing Co. has a team of qualified tool makers and apprentices on staff who can service and maintain your existing tooling for you.
  2. Supplier quality: Transferring your tooling to another company is a safeguard against inconsistency and poor quality from overseas suppliers. In fact, slipping standards are among the top reasons for tooling transfers.
  3. Timeliness: Suppliers don’t always deliver parts when promised. An in-house tool room reduces downtime spent on repairs and debugging.
  4. Minimize risk: When unexpected disruptions such as economic downturns, political unrest, or natural disasters affect the global supply chain, delays and inconsistent end-user experiences are likely to follow. An experienced tooling transfer provider can smoothly navigate these obstacles and minimize their effect on your company.
  5. Industry-specific expertise: Manor Tool has years of experience in custom tooling for metal stamping and formed components in a variety of applications. As an ISO 9001:2015 certified company, Manor Tool is deeply committed to quality in every project. Regardless of your company or industry’s demands, we can work with you to develop the right solution for your tooling transfer needs.

For more information about the benefits of transferring tooling and how to ensure a successful tool transfer, download our eBook, “Everything You Need to Know About Transferring Tooling.”

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To find out how transferring tooling with Manor Tool can help you address common manufacturing issues, including lack of in-house tooling staff, supplier uncertainty, and inefficient production operations, contact our team today.

Finite Element Analysis (FEA) Offers Problem-Free Production In Component Manufacturing

In component manufacturing and metal stamping, sometimes there are complex geometries in projects, and these complexities offer an infinite number of variables that could negatively impact quality control. For most component manufacturing or metal stamping projects, it makes sense to take advantage of the benefits of performing a Finite Element Analysis (FEA) to ensure problem-free production and positive end results. FEA offers you peace-of-mind by ensuring that your designed component can be manufactured at a production basis, at a point where you can make adjustments, if necessary.

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At Manor Tool & Manufacturing, we’re experienced at conducting FEA, and, with our clients, we’ve witnessed the benefits of FEA first-hand.

Here’s how FEA works: Using FEA software, we turn your product design geometry (the final part design) into tooling surfaces and use it in simulation to engineer a successful forming process in the “virtual world” – at a place and a point where design imperfections can be caught and fixed without negatively impacting tooling, production or your business’ bottom line.

Through our extensive engineering experience and FEA capabilities, Manor offers our clients the know-how and assistance required to help them decrease production costs, save time on their projects, and deliver problem-free production, no matter how complex the design specs might be.

On your next component assembly project, we can help you achieve these benefits – and give you confidence in the final results.

Work with Manor to get innovative component manufacturing solutions that deliver efficient, cost-effective, progressive die-stamped products. Contact us to learn more about our capabilities and to discuss Finite Element Analysis in more detail. Or visit our portfolio gallery and read one of our customer’s success stories using FEA to maximize the effectiveness of the die-stamping process. We look forward to working with you!

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