Reference Articles 1 - 100 of 132
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Press-Fit Current Carrying Capacity - Part 3
Description: Press-fit interfaces have been proven to support current capacities of 30 amps or more through a single press-fit eye and tested to maintain reliable, predicable current carrying performance curves ...
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Tumbling to the Finish
From: Plastonics, Inc.Description: Plastonicsâ unique powder coating process keeps costs down The Flow-Clad system of coating smaller parts at higher production rates uses a tumbling method not usually found in many custom coaters. â I ...
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Interdependencies Between Fluid Design and Coating Methods
From: Carestream TollcoatingDescription: Interdependencies Between Fluid Design and Coating Methods By Rick Daniels, General Manager, Carestream Advanced Materials and Tollcoating Choosing a specific precision coating method depends on a ...
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Lean Manufacturing in Precision Coating Contract Mfg.
From: Carestream TollcoatingDescription: Lean manufacturing refers to developing the right processes to achieve high quality results. For contract manufacturing involving coating and converting, the techniques are essential to high quality ...
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Modeling Multilayer Coating and Drying
From: Carestream TollcoatingDescription: The Modeling of Multilayer Coating and Drying By Todd Arndorfer | Account Manager, Manufacturing Business Development and Bill Devine | Project Engineer, New Product Development Precision multilayer ...
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Movement Toward Thinner Films
From: Carestream TollcoatingDescription: The Movement Toward Thinner Films By Todd Arndorfer todd.arndorfer@carestream.com As consumer and industrial products continue to feature smaller, thinner and higher performing attributes, there has ...
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Precision Casting: Membranes and Other Advanced Materials
From: Carestream TollcoatingDescription: Precision Casting: Membranes and Other Advanced Materials By Jason Payne, PhD | Director?Medical Film & Printing Solutions / Manufacturing jason.a.payne@carestream.com The use of precision coating ...
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Solution Delivery for High Precision Coating
From: Carestream TollcoatingDescription: Solution Delivery for High Precision Coating By Jason Payne, PhD, Director Precision coating is an advanced operation that encompasses sophisticated and highly controlled functions, including the ...
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Solvent Screening Studies.
From: Carestream TollcoatingDescription: Solvent Screening Studies By Derek Hammill, Defect Analyst Contract coating manufacturers possess a wide range of expertise and tools to conduct the complex processes required for roll-to-roll ...
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Understanding Complexities of Patterned Coatings
From: Carestream TollcoatingDescription: The majority of roll-to-roll coating projects use "blanket" or uniform continuous high precision coatings. Products ranging from imaging films to battery membranes to optical display device components ...
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Aluminum lock rod used for tractor trailers
Description: The customer needed these lock rods to be bright and shiny, in order to match chrome on tractor trailers. The customer was mechanically polishing the aluminum rods to remove weld discoloration and ...
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Complex stainless weldment used in marine, pharmaceutical and semiconductor application. Part needs high corrosion resistance.
Description: The customer needed parts to withstand a variety of environments, such as salt air, harsh chemicals, etc. without rusting or discoloring. The parts are used on fire fighting equipment, and in ...
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Large stainless weldment used in semiconductor chip fabrication. Part needed clean, chromium rich surfaces.
Description: This component pictured to the right is 32" x 35" x 9-3/4". The part is used for depositing substrates on semiconductor chips and required a clean smooth finish inside and out. The customer required a ...
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Nickel Silver medical part needing removal of surface contaminates caused by a brazing operation.
Description: The customer needed a process to remove the residual flux and discoloration created during the brazing operation. The part is a medical electronic component that makes contact with human skin. A clean ...
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Stainless animal containment fabricated from formed wire. Part needed economical brightening and improved corrosion resistance.
Description: This part is used in a laboratory or consumer animal containment system. The part is an assembled wire form, and in use, subject to harsh cleaning solutions and therefore very prone to corrosion. The ...
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Stainless assembly used in complex printing machinery. Surfaces needed smoothing without damage to base part.
Description: This assembly is used as a component for a complex printing machine. The customer was looking to improve the corrosion resistance of a clamp assembly and make the clean up cycle easier for the end ...
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Stainless food frying assembly needing high corrosion resistance and improved cleanability.
Description: This assembly in final use was constantly immersed in cooking oil and in contact with food products. Fabricated from multiple alloys of stainless that had been perforated and spot welded, the final ...
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Stainless medical rack needing high corrosion resistance. Part is immersed in hot water for long periods.
Description: This wire rack is used to hold heat packs for use in sports medicine. The customer was looking to improve corrosion resistance of the wire form beyond the normal corrosion specifications of the alloy. ...
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Stainless tubing assembly used in food application. Special masking of heating element was required to prevent damage.
Description: This assembly in final use was constantly immersed in cooking oil and in contact with food products. Fabricated from multiple alloys of stainless that had been perforated and spot welded, the final ...
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Weldment used in commercial ice making system. Part needed economical cleaning of weld discoloration.
Description: This part occupies a high visibility location on a commercial ice machine. The customer wanted a clean bright part that would be appealing as it came in contact with the ice. The welding operation had ...
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Bacterial Biofilms Less Likely on Electropolished Steel
Description: When the news came out that stainless steel can harbor bacterial biofilms, a Dallas, Georgia, company decided to test its metal against other materials. The results were good news for anyone wanting ...
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Electropolishing Can Improve Medical Part Performance
Description: Thanks to process improvements and exhaustive surface analysis, more people are beginning to see the full range of benefits from controlled metal removal via electropolishing. Restoration of a metal ...
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Electropolishing Moves into the NEW Millennium
Description: Electropolishing offers an excellent example. The physics of the process are relatively unchanged from the 1950's, though the applications have grown immensely the past 5 years. when properly applied ...
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Electropolishing Returns to the Surface
Description: Metal finishing has long been regarded as a last-step process with the main purpose of making a metal part look attractive. Vendors of various metal finishing processes certainly emphasize looks over ...
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Electropolishing Returns To The Surface
Description: Metal finishing has long been regarded as a laststep process with the main purpose of making a metal part look attractive. Vendors of various metal finishing processes certainly emphasize looks over ...
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New Ideas to Polish up Your Profits
Description: Electropolishing is a metal finishing process similar in theory to electroplating. Parts are immersed in a chemical bath and electrical current is applied to the parts. While electroplating deposits ...
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RECENT DEVELOPMENTS IN ELECTROPOLISHING AND TUMBLING R&D AT FERMILAB
Description: Fermi National Accelerator Lab (Fermilab) is continuing to improve its infrastructure for research and development on the processing of superconducting radio frequency cavities. A single cell 3.9 GHz ...
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A fluid control needle with tooling and machining surfaces that were being hand-finished
Description: Parts were originally blasted after casting, but this caused seating problems when assembled with other components, causing leaking to occur. The customer then machined the problem areas but the ...
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A medical assembly that needed to improve sharpness on a machined surface
Description: The 316L stainless steel shaft has two 316L stainless steel tabs that are welded on the outside of the shaft. This causes weld discoloration, a contaminating oxice. ...
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A thin, copper stamping with fine burrs related to normal die break
Description: Our customer receives the nine-inch long lead frames with a burr from the stamping die-break as well as sharp corners. The copper is 0.20" thick and very fragile, plus the design is complex. ...
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Aluminum Bronze fastener used in electronic application. The part needed to meet semiconductor cleanliness specifications.
Description: This part was fabricated out of an unusual material, leaving the customer with few references for finishing specifications. The customer needed to clean the parts efficiently so they would be ...
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Aluminum reflector needing improved reflective properties. The part needed surface smoothing without damage to part geometry.
Description: The customer needed to improve the reflectivity properties of the part. Increased reflectivity was necessary because this part was used in conjunction with low wattage halogen bulbs. The reflector was ...
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An aluminum component with imbedded contamination
Description: The component is part of an antenna splitter for a fixed signal cellular antenna. It is used to communicate with several radios on one signal. The part is black anodized as a final finish. The end ...
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Automotive casting used in critical painting application. Part needed high corrosion resistance.
Description: These stainless parts are used in an automotive painting application. End users reported to the manufacturer that they were experiencing corrosion problems when using the parts with water based ...
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Automotive stainless fastener needing high corrosion resistance.
Description: The customer needed to brighten the parts, but also needed to enhance the corrosion resistance because of the application and environment. The unique problem associated with this part is that the ...
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Brite Deburring-A
Description: The customer needed to deburr the part after stamping so no small burrs would cause the switch to fail prematurely or cause malfunction. In addition, this part was designed to be used in a dust free ...
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Brite Deburring/Brite Ultracleaning
Description: The customer needed to deburr the part after stamping so no small burrs would cause the switch to fail prematurely or cause malfunction. In addition, this part was designed to be used in a dust free ...
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Brite Deburring/Corrosion Resistance
Description: This component is part of a consumer assembly. The 410 alloy and fabrication processes were specified to match the application - a cutting utensil. Grinding operation left feather burrs along the ...
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Brite Microfinish/Brite Ultraclean
Description: The aluminum mandrel is used to mold hoses for the automotive industry. The customer needed a way to smooth the inside of the hoses, and improve the "cleanability" of the mandrel. By improving their ...
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Brite Microfinishing-A
Description: These parts were quite small (note comparison to the paper clip), yet had an important application in a medical assembly. The smaller diameter on the shaft moves up and down in conjunction with other ...
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Brite Microfinishing-B
Description: Actual size of the part is 3/32" diameter, and 1/4" long. After machining, this part is used as a mold for a cochlear implant. Nickel and Gold are plated over the part and the underlying part is ...
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Brite Microfinishing-C
Description: The customer was experiencing product flow and cleaning problems when used with powdered food products. The hopper had been blasted which impinges the metal, making the surface susceptible to product ...
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Brite Microfinishing/Brite Passivation/Brite Deburring
Description: This bracket is used in a knife assembly. The customer needed a smooth part free of burrs after stamping. The customer used a vibratory finishing process, but found the media could not penetrate into ...
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Brite Microfinishing/Brite Ultracleaning/Decorative
Description: This small and delicate part is used in an aircraft lighting application. The customer needed a clean part overall, but also shiny enough to improve reflectivity on the critical surfaces. ...
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Brite Microfinishing/Brite Ultracleaning/Pre-Plate Finishing
Description: This part is used as a visible component in a high quality bicycle. The customer was spending extensive time and money hand polishing and cleaning the rough forging before color anodizing. Their ...
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Brite Microfinishing/Recast Layer/Sizing
Description: Customers main objective was to remove the recast layer on parts that might interfere with other moving parts. Also, parts were not falling into specified range tolerances as called out by the blue ...
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Brite Microfinishing/Reduced Galling
Description: The part depicted is a critical component of a needleless injection system. The part literally rubs against another metal part surface, and the metal-to-metal contact was creating some product ...
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Brite Passivating
Description: The customer needed a reliable method to insure corrosion resistance on spraying system components. Passivation alone would not stand up to constant use. These parts are used in a variety of ...
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Brite Passivating and Sizing
Description: This wire form is an antenna wire used in a cellular application. The customer needed a clean part that could withstand the weather and road salts. Being a visible part, the surface needed to be ...
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Brite Passivating/Decorative
Description: Customer needed a bright decorative finish that would stand up to harsh environment. In addition, there was a need to remove the copper coating which is used for lubrication during machining. ...
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Brite Passivating/Decorative-A
Description: The alloy's skin has iron and steel particles imbedded on the surface after coming in contact with carbon steel tooling during fabrication. This normal surface contamination caused rust to appear on ...
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Brite Passivation-A
Description: Customer needed to enhance corrosion resistance of complex compression springs that hold down tarps for swimming pools. Parts were rusting due to contact with outdoor elements and a chlorine ...
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Brite Passivation-B
Description: The customer was experiencing corrosion problems after brazing the two metals on the inside of the seal (see photo of critical area). The customer needed to remove the rust while still maintaining the ...
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Brite Passivation/Brite Deburring
Description: The customer needed a way to deburr the nozzle orifice and improve corrosion resistance. Being a point of focus for the gun assembly, the customer also wanted a highly decorative finish. ...
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Brite Passivation/Brite Ultracleaning-A
Description: Customer needed parts to stand up to harsh outdoor environment and to match chrome parts on semi-tractors. The parts were dull and contaminated with surface impurities from normal fabrication. ...
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Brite Sizing
Description: The threads on the part were machined oversize. Parts wouldn't accept go gage and their customer rejected parts. ...
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Brite Ultraclean/Brite Passivation
Description: Our customer is looking to package poultry product with their equipment. The atmosphere in the packaging area is humid and cold. They want to offer their customer the cleanest possible components on ...
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Brite Ultracleaning/Brite Microfinishing
Description: The customer needed to have the surface of the machined flange clean from any contaminants. Being a critical pharmaceutical application, the engineers wanted to have all product contact surfaces clean ...
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Brite Ultracleaning/Brite Microfinishing-A
Description: The customer needed extremely clean parts that are used in biological labs, and pharmaceutical labs. After mechanically polishing, they needed to insure that all surfaces were clean and smooth, free ...
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Brite Ultracleaning/Brite Passivation/Brite Microfinishing
Description: This complex and expensive assembly is used in a critical semiconductor application. The customer needed to meet very stringent surface cleanliness standards as well as meet high corrosion resistance ...
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Brite Ultracleaning/Decorative
Description: Customer needs part to be clean and free from contaminants but still have a somewhat bright finish. ...
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Brite Ultracleaning/Decorative-A
Description: The part needs to be free of contaminants for use in a surgical environment. In addition, excess brazing had to be removed to improve the overall aesthetics. Finally, there was a need to enhance the ...
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Brite Ultracleaning/Decorative/Deburring
Description: The customer had to find an economical way to remove contaminants from the surface of the finished parts. The part is used in a critical medical oxygen environment. The customer was also looking to ...
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Clean room component needing contaminate-free metal surface
Description: Our customer chemically etches intricate, thin components. The material can be as thin as .008". The part must be chemically clean and burr free, as they are part of a clean room component/assembly. ...
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Complex assembly made of multiple alloys needed improved sealing surface
Description: The 'Hermetic Assembly' which is made of 304L stainless steel 'body' and a molybdenum 'pin'. They are glass fused in an oven. The glass baking operation created a green oxide layer, which needed to be ...
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Complex assembly that was too expensive to hand polish
Description: The 'Proximal Arm Tube' is part of a wheelchair accessory. It is part of a component that simulates a shoulder and elbow joint to allow paralyzed people to feed themselves. Our customer had been ...
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Complex machined casting needing surface cleaning without part damage
Description: Our customer requires a clean contaminant free surface. The part is part of an assembly that moves products such as milk, beer and pharmaceutical products. The part is machined then mechanically ...
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Complex machined components with burrs and galling problems
Description: The customer was looking to improve upon the performance of their parts. The Ball Screw and Ball Screw Nut are part of an assembly. ...
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Complex stainess part needing safe burr removal
Description: The subject is an integral part in the handling of hard drive components. Each arm on the 'Comb' has a tolerance of +/- .0002". There must be a smooth finish on the angle of each arm. Smoothness is ...
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Complex stainless machined part needing corrosion protection
Description: Our customer manufactures pressure regulators for the 'high purity' semiconductor industry. They found the gases used in that industry are moderate to mildly corrosive. Other applications use purified ...
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Component used in a piston assembly that needed surface improvement
Description: This part is used as a flex coupling and has seal rings inserted inside. The part is copper plated to act as a mask prior to Malcomizing/heat treating. After Malcomizing, the 'Sleeve' is stripped of ...
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Copper drawn part used in Aerospace oxygen application. Part needed clean surfaces free of contamination.
Description: This component held chemicals that produce oxygen on demand for emergency air breathing masks on commercial airliners. It had to be totally clean and free of contaminates. Engineers feared that ...
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Copper stamping used in electronic assembly needing safe removal of fine burrs
Description: The customer's part is stamped and slotted in one operation. The small size of the part makes it very difficult to mass finish in order to deburr the four slots. A feather burr is still present after ...
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Decorative/Brite Passivation-A
Description: The weldment is used in a food heating system for a major fast food chain. The part is formed and welded. They require a uniform and stain-free appearance. However, the welding creates discoloration ...
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Decorative/Microfinish
Description: Our customer has designed a fail-safe method to alert the end customer that their fire detection system is working. The 316 stainless steel reflection ring Able® electropolishes reflects ...
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Decorative/Salvage
Description: Our customer had heat treated 30,000 303 stainless steel 'Stop Nuts' by accident. As a result, the entire batch of parts were highly discolored and heavily oxidized. They were looking to remove the ...
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Extruded and machined brass part needing burr removal from complex surfaces.
Description: These parts are machined out of extruded material. The customer needed smooth surfaces and to deburr the edges of the parts after machining. Several of the bores were of exacting tolerance, and ...
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Food application assembly needing high corrosion resistance
Description: This assembly is used in an important leak testing application under a high vacuum environment. Used in a continuous manufacturing process, it needed to be highly corrosion resistant. The part is ...
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Formed and welded 430 stainless panel used in computer application, needing contamination free surface.
Description: The part is similar to panels used in computer hardware applications. Consequently, the part needs to have clean surfaces, free of any contaminants. In addition, the components needed to maintain a ...
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Heat treated part used in packaging machinery. Galling and other problems in teeth caused binding in the assembly.
Description: This part is machined from stainless steel and heat treated for hardness. The outside edge around the part is the most critical surface. In final assembly, the remaining micro burrs and "as machined" ...
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Heat treated stamping needing both brightening and improved corrosion resistance
Description: Our customer makes a compact breathing oxygen tank, which attaches to a belt around the waist of mining personnel. The Hook/Latch is part of the carrying case. In case of a lack of oxygen the mine ...
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Heat treated tool steel part used in plastic molding application. Customer was looking to remove burrs and improve mold release characteristics.
Description: The customer needed to improve the mold release characteristics of the tip of the core that comes in contact with product. Those mold release failures were traced to a combination of surface finish, ...
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Immersion heater made from tubular stainless needing improved corrosion resistance.
Description: In a review of product quality, the customer was looking to extend the life of their immersion heater by removing contaminants from the surface of the tubes. Some of the contamination came from normal ...
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Machined brass assembly used in industrial spraying application. The customer was looking to replace a destructive bright dip operation.
Description: The customer needed to replace a bright dip operation. In production, the bright dipping caused problems by creating varying end finishes including severely etched conditions. The customer needed a ...
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Machined part needing fully clean surfaces in complex recesses
Description: The end customer designed the 'Extruding Head' as a casting. The casting became extremely difficult to polish in the slotted areas. They tried mechanical polishing, buffing, aluminum oxide blasting ...
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Machined parts that needed brightening without part damage
Description: The 'Rinse Arm' is a critical component in a kidney dialysis machine. Our customer requires a clean contaminant free surface after machining and vibratory finishing. There is a blind hole in the ...
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Machined roller surface needing smoothing after shot blasting.
Description: Our customer needs to obtain a hydrophilic (absorbent and smoothly wetted surface) on the large diameter of the Ductor Roller. ...
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Machined steel gear needing surface improvement for noise reduction
Description: Our customer had a problem with extraneous noise in the electric motors they manufacture. After extensive investigation, the noise was traced to the drive system, and specifically the gear surfaces. ...
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Medical casting needing to withstand cleaning agents that contain bleach
Description: End customer needs part to withstand corrosive environment in a hospital setting. Part must withstand regular cleaning with a solution made up of 25% bleach and 75% water. ...
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Micro-Inch Finish Improvement and Micro Deburring
Description: Our customer required a 32-microinch surface finish and smooth threads. As the volume of production increased, our customer could not handle the volume and pace that costly hand deburring and ...
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Multi-alloy medical part needing removal of surface contamination.
Description: This assembly was specified with two different alloys. After machining, the 303 cap is assembled onto the 13-8Mo tube, and is captive after the tube is formed to the desired shape. After assembly, the ...
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Optics Component Needing Decontamination
Description: This formed bracket is used in a military optical application. The part after forming was dull and under closer inspection showed evidence of imbedded contaminates normal for this type of fabrication. ...
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Stainless assembly used in a highly corrosive environment
Description: Our customer welds 304 stainless steel tubes to the 304 stanless steel body. The surfaces must be extremely clean because this equipment operates in a high vacuum. ...
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Stainless drawn part used in water fountain application. Parts needed to be bright and corrosion resistant.
Description: The customer had been fabricating components for outdoor fountains in playgrounds and parks, but found that the parts were rusting, and had to be replaced. The finish on the parts was dull, typical ...
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Stainless stamping used in a corrosive battery application. Part also needed deburring on complex surfaces.
Description: This part is used as a cover for a battery power source. Stainless steel was originally specified to withstand a highly corrosive environment. The customer needed to deburr the edges on the part, but ...
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Steel music wire spring used in a lock assembly. The part was failing prematurely due to surface cracks.
Description: This part is used as a cover for a battery power source. Stainless steel was originally specified to withstand a highly corrosive environment. The customer needed to deburr the edges on the part, but ...
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Steel spring with surfaces too rough and contaminated to accept plating. Plating was peeling causing a high reject rate.
Description: The customer was experiencing problems with the part after plating and installing. The surface of the parts may not have been clean prior to plating, with resultant adhesion problems and flaking of ...
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Surgical assembly used in tracheal procedures. The parts needed high corrosion resistance to corrosive sterilization chemicals.
Description: The component is used in Europe in an important tracheal application. The customer needed to insure that the part was free of contaminants and offered maximum corrosion resistance to stand up in ...
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Various formed tubes needing removal of surface contaminates
Description: Our customer requires the cleanest surface possible. The 'formed tubes' are part of an instrument, which detects volatile and hazardous gasses. ...
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Wireform used in food service application. End customer needed a corrosion resistant surface that was easy to clean.
Description: This shelf is used in a food service application. The customer needed a clean assembly with a surface that is resistant to corrosion. The customer also desired to remove weld discoloration. Finally, ...
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