The sophisticated manufacturing process used in the creation of the new Apple watch combines technology with engineering to produce a product that is as beautiful to look at as it is complicated to construct.
The deep draw process is very well known for manufacturing products such as caps, ferrules, and other small items, but can often be overlooked as an option when the project calls for tubes. No doubt, this is due to some common misconceptions regarding the capabilities of the latest deep drawn stamping technology.
The deep draw forming process is rapidly gaining popularity as one of the most cost effective and sought after methods of manufacturing, and with good reason. The process is capable of creating parts from a vast number of different materials quickly, efficiently, and at low cost, generating plenty of interest from markets all over the world.
In any project, communication is the key. Without a strong communication plan, some of the most pertinent information can get lost in the shuffle. When starting a new project, it isn’t always easy to establish a good base of communication as everyone involved typically has their own ideas and experiences. This can lead to some very interesting, but damaging, gaps in information.
Change is inevitable. Even the best, most long term contracts are bound to come to an end at some point. It could be relocation, a change in design, or a new focus for the company. Whatever the reason might be, changing deep draw suppliers can be a stressful event. Moving a project from a known source to an unknown brings about new issues and concerns regarding quality, reliability, and cost.
By design, deep drawn cans have many benefits over other manufacturing methods. They are seamless, concentric, and the speed of the process makes the cost per part lower than almost every other method. Like any other manufacturing project, there are a few important facts to remember when deciding to produce cans with the deep drawn process.
The deep draw process relies on detailed calculations regarding the way the material will behave during the process. For each new product, precision dies and punches are developed that are carefully designed to create the highest quality part with the least amount of scrap.
The dimensions and desired wall thickness of the finished deep drawn cans determine not only the design of the die, but also the set-up of the press and the maximum production speed of the process. It is important to compare the desired dimensions to the capabilities of the process in order to best balance quality, speed, and cost.
As mentioned in #3, it is important to understand how the attributes of the deep draw process affect the design of the desired product. It is possible that a few simple design changes can improve quality and reduce cost. As the customer it is impossible to be an expert on the deep drawn process, which makes it imperative that the lines of communication between you and the supplier are well developed. The discussions between customer and supplier should always be a smooth transfer of information, beginning with the part concept and developing in to the best possible compromise between function and feasibility.
The decision regarding the type of material to be used can often be far more complicated than you may think. As mentioned above, there is a fine balance between final function and process capabilities. Carefully deciding material type during the development phase is critical to the success of the project.
Information on material properties is readily available via the internet (www.matweb.com) as well as a host of books on the subject. By talking with your deep draw supplier and understanding how the properties of material work in relation to the deep drawn cans process, you can develop a design that not only meets the specifications of the product but works fluidly with the manufacturing process.
Every manufacturer knows that to stay competitive in the market, cost is king. The ability to reduce cost while maintaining quality is the number one concern for any profitable company. There are many methods that a manufacturer can use to reduce cost, each with their own pros and cons.
For many industries, one of the most attractive cost saving methods is the acquisition of raw materials or components from suppliers overseas. The low cost of labor in less developed regions creates a market of goods that at first glance seem to be comparable quality at a significant discount.
In reality, products and materials from these regions carry with them a host of other complications. Difficulties in communication, lack of understanding regarding culture and processes, and limited control of quality all combine to make working with foreign suppliers a significant challenge.
The recent events surrounding the Lumber Liquidators company is a prime example of this kind of difficulty. In this case, the company had decided to accept raw materials from foreign suppliers at reduced costs as is common practice among many industries. When questions arose regarding material quality and environmental issues of certain chemical content of the wood, the company was faced with providing explanations for a process they did not fully control. This creates an extremely volatile condition for both the company, and their customers. Maintaining local suppliers reduces risks such as these by offering more detailed communications, adhering to U.S. industry standards, and even providing facilities tours. Knowing exactly how your supplier is operating can eliminate difficult questions in the future.
Manufacturers of deep drawn parts are world-wide. The Chinese industrial market has been a powerful workhorse for many decades, and provides many of the products used in the U.S. market every day. Although the industry is strong, there are many issues that make choosing a local provider the better choice.
One of the major strengths of U.S. deep drawn suppliers is flexibility. Issues regarding design, quality, and volume can be addressed quickly and efficiently. By comparison, communication with suppliers overseas can be cumbersome, quality is difficult to control, and purchase volumes need to be high in order to make the cost of shipping viable.
Producing the right deep drawn parts for any product requires detailed information regarding quality, material source, and operating standards. Having your supplier nearby ensures that answers are just a phone call away.
Choices…choices. As people, much of our lives revolve around the choices we make. Some are simple and we make them without even really noticing, while others are far more complex and take considerable time and thought. The process our minds work through when making decisions is actually a highly complex balance of needs versus risks. Whether it’s deciding to try the new restaurant in town or buying a new car, we weigh the known risks against our needs or wants, and we choose a balance.
