Manufacturers often struggle with the fast sourcing of precise and high-quality parts for their outdated machine components, leaving them with two options – either to replace the machines or somehow acquire the parts. Acquiring the parts may be subjected to high costs and long lead times.

Therefore, the best solution for manufacturers in such a predicament in terms of cost and time is to use reverse engineering.

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Backwards engineering or reverse engineering is the process of deconstructing an artificial object using both hardware and software tools to reveal its designs, code, and architecture or to extract knowledge from it.

For example, laser trackers or laser scanners (hardware) take down the measurements of a component, and CAD or CAM systems (software) are then used to reconstruct its 3D model.

Reverse engineering in engineering and manufacturing is used for a variety of reasons. However, if you are unsure about how it can prove beneficial for you, then have a look below.

Filling Voids in Design Information:

Reverse engineering can be used to discover the design data that may have been lost, got undocumented, or got full design information about obsolete components. This critical process helps generate accurate design data documentation that can ensure production efficiency in computer-aided manufacturing.

Optimizing the Manufacturing Process:

Reverse engineering can also help improve the lean manufacturing process by identifying the most efficient way to manufacture components. It can help find the quickest and easiest way to manufacture a product without compromising its quality or performance, helping cut down on manufacturing costs.

Improving Product Designs:

Reverse engineering can be used in product failure investigation so improvements can be made to extend the product’s life cycle period and improve functionality.

For example, if a component shows signs of early failure, reverse engineering can be applied to investigate and identify critical stress regions or cracks for improvement.

Encouraging Innovation:

A significant influence of reverse engineering on manufacture, design, and product development is innovation. Engineers are provided with the necessary information and semantics they need to reinvent, iterate, and improve their existing designs to create products with higher functionality, maneuverability, and performance.

Therefore, this inverse approach can help in the implementation of more innovative and avant-garde ideas.

Promoting Healthy Competition:

Apart from manufacturers using reverse engineering to analyze their own products or generate design documentation for obsolete components, they can also analyze their competitors’ products.

By studying the products manufactured by their competitors, organizations will be encouraged to evolve, innovate, and optimize continually. They will continue to search for ways to elevate the manufacturing process and product design to retain or improve their position in the market and stand firm against their competition.

Also, this will improve the overall products that are available in the market as smaller firms will get their hands on superlative techniques, technologies, and mechanisms developed by industry giants without spending billions on R&D. It can even be used to protect patents by analyzing competitor products to see if they have used your patented idea.

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The manufacturing industry has dramatically evolved over the past 100 years. There have been innumerable advancements in the field – production methods, tools, techniques, raw materials, and everything in between has changed, all thanks to technology. Manufacturing is just one more industry that now is in some way or another dependent on technology.

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There are uncountable ways technology has affected manufacturing, whether it is through automating the production process or storing important business documents on the cloud, business operations have changed due to technology, and this is how:

Industry 4.0

It is a widespread belief amongst the experts’ community that we are currently in the middle of the fourth industrial revolution. New technologies like photonics and nanotechnology are replacing old technologies. New sectors are popping up, and the future looks ever so bright for manufacturing than it did a few years ago.

Mass production has revolutionized due to complex machinery and automated systems, which has increased output and cut down manufacturing costs. As a result, electronic gadgets are now cheaper than ever, contributing to bringing down manufacturing costs.

On top of that, small-time manufacturers can now compete in the big league thanks to the rise of digital technology, resulting in a change in the global marketplace. Small companies can connect with customers from around the world and work remotely and order from micro-factories.

Robotics

Adding industrial robots to production lines has contributed significantly to the resurgence of manufacturing and the country’s GDP.

Previously, factories used to rely on humans to assemble complex parts, which made output slow, laborious, and prone to human errors, which affected quality consistency.

However, when robots were initially introduced to production, the idea of automation was met with a lot of opposition, mainly because it was considered a threat to workers’ jobs. And while the concerns proved right to a certain extent, their impact did not turn out to be anywhere as destructive as people predicted.

Robots perform complex engineering and production task with much greater precision, ease, and swiftness than humans. Robots do not need breaks or time off; they do not have to be paid regular salaries and cannot become unionized. All of these are major advantages for manufacturing companies.

Furthermore, technology reduces risk and liability in projects where safety is a problem by monitoring, conducting, and containing all high-risk procedures.

3D Printing

3D design and printing have made it easier for manufacturers to create customized and detailed components with greater precision and lesser time and cost. In fact, it is safe to say that 3D technology has revolutionized the manufacturing industry by providing individualized solutions to manufacturers.

3D printing is perfect for low volume and high-quality manufacturing that has allowed small innovators and inventors to tap into the global market.

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Stamping of sheet metal parts is a prevalent technology today, by which products are produced for almost all industries. Thanks to this technology, it is possible to obtain small and dimensional parts of even complex geometric shapes from a flat metal sheet.

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Speaking of stamping parts made of sheet metal, they mean a technological operation, which is when precisely designed dies and significant pressure is exerted on the workpiece. Under the influence of such pressure, the workpiece is deformed, helping it acquire the required configuration and dimensions.

You might find metal stamping an easy process to design your products, but it can be time-consuming and costly if you don’t make the right decisions at the right moment.

If you are looking for tips to reduce your metal stamping process’s time and cost, here’s what you need to do.

Using the Right Raw Material

The selection of raw material plays a vital role in efficiently completing the metal process. Even small changes or variations in raw material can make a big difference when calculating your time and cost.

For instance, if the material is hard, it will take some time for it to melt, demanding more effort and time, and money to process it. Here, switching to a softer but quality material won’t compromise your product’s quality but may reduce time and production cost.

Using the Right Equipment

When using die in manufacturing, you need to be particular about which manufacturing tool you’re going to produce your products. If you are looking for a fast machine with fewer chances of delays, you can go for four-sliding machining processes to help you get faster results.

It can produce 25 to 30 parts per minute, depending on the complexity of the product required. However, it has fewer designs and fewer post-production steps that prevent you from delays and save on manufacturing cost.

Considering The Downstream Costs

Keeping a check of downstream costs while production is essential in evaluating part quality. Because if you think saving a few dollars on every product is going to save you money, then you might be wrong. In reality, it can actually cost you a considerable amount since the quality produced may not be up to mark, causing you to perform the production again.

If not this, then there can be an increase in the warranty replacement rate or higher cost parts in the rest of your assembly.

All in all, a good in-die assembly manufacturer can also help you reduce cost and time despite the complexity.

If you contract out your metal stamping process to CAV Tools, you can decrease your overall production cost without compromising the product’s quality or durability! We ensure clients satisfactory products and hassle-free deliveries in Atlanta, GA. Click here to get a quote today!

Metal is an ideal material for various projects, but you must use the appropriate metal for the job to ensure optimum functionality. The decision is not easy. Simply put, evaluating the strengths and drawbacks of all the metal and alloy options available today is time-consuming.

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You can navigate through the metal selection process by carefully considering your project’s needs and comparing them against the properties of each metal.

Five key properties that you need to consider are:

Tensile Strength – Tensile strength is the amount of force a metal can withstand without snapping. Having a high tensile strength is important for projects where the metal will have to bear significant pressure.

Weldability – Some metals can be much easily welded as compared to others. Metals that are hard to weld negatively impact the manufacturing process as they require additional time and expertise, affecting the budget and timeline.

Machinability – Machinability is the ease with which a metal can be cut using a blade. A less machinable metal will require specialty tools, which affect the project cost and lead time.

Ductility and Formability – Ductility and formability determine the ease with which a metal can take on a shape. A less formable metal cannot be bent without it snapping, and metal with lower ductility cannot easily be shaped into a wire.

Another factor that you need to consider when choosing a metal for your project is cost. The cost of raw material is always essential when planning a metalworking project and often the final deciding factor; there are other factors that you also need to look into.

Metal Options

Below is a list of some metal options that you will find in the market.

  • Cold Rolled Steel
  • Stainless steel
  • Aluminum
  • Copper
  • Brass
  • Hastelloy
  • Monel
  • Titanium
  • Kovar
  • Hy-Mu 80
  • Cupronickel 715
  • Nickel Silver Alloy 2
  • Haynes 242
  • 17-7 PH
  • Inconel

Steel is the most popularly used metal for retainers, punches, buttons, dies, fixtures, and other similar products. The reason for this is the low cost and versatility of the metal, which makes it an ideal choice. However, this doesn’t mean that steel is free of all cons. It is susceptible to corrosion and rust.

Therefore, it all comes down to only one thing – the properties of which metal best suits your projects’ requirements. Once you find the right metal, do not hesitate. As for cost, take quotes from various suppliers to identify who is offering a more reasonable price.

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If it weren’t for tool and die makers, we literally wouldn’t have any manufactured goods. There would be no one to create molds that shape plastics, craft tools that make other tools, or produce die to stamp out other parts.

Once the engineer creates a blueprint, it’s up to the tool and die maker to decide on the best way to shape a workpiece (usually a sheet of metal) according to the specifications. They operate several machines to perform a variety of actions, such as cutting, boring, milling, and grinding a finished piece with amazing precision.

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free quote.

In today’s article, we go behind the scenes and see what tool and die makers actually do.

Job Description

Serving a crucial function in manufacturing, tool and die makers produce precision parts, instruments, and tools with mechanically-controlled or computer-controlled machine tools.

Tooling involves precision tool manufacturing to form metal and other materials. Toolmakers also produce jigs, fixtures, and measuring devices.

Die making is the process of constructing metal forms (dies) for stamping and forging and metal molds for plastics, ceramics, and composite materials.

Before setting up the tool and die equipment, they have to study blueprints, computer-aided design (CAD), or computer-aided manufacturing (CAM) files. Based on the specification and tooling requirements, they compute and verify sizes, shapes, dimensions, and tolerances of metal workpieces and choose the best machine tools for the job.

Toolmakers have to file, grind, and adjust parts to see if they fit together correctly, and they also test tools and dies after production to verify specifications. Likewise, they also look out for any defects in the finished product.

Finally, they smoothen and polish the surfaces of tools and die parts.

Skills And Education

Tool and die makers need a skill set more extensive than the average machinist.

At the very basic, a tool and die marker needs mechanical skills to use both hand tools and large scale machines with safety and precision. Tool and die companies also need to use CAD software and other computer programs to design and craft tools, parts, molds, etc., which adds to their skill set.

This line of work also requires mathematical knowledge, analytical skills, and attention to detail. And while problem-solving and analytic skills are a given, tool and die making also requires physical strength, dexterity, and stamina.

One can start training for the job after passing high school by enrolling in a vocational school or community college. Or one can begin with an apprenticeship through a union or manufacturer. Of course, tool and die making requires ongoing on-the-job training as well.

Work Environment

Most tool and die makers work in machine shops, tool rooms, and factory floors. Tool and die companies have regular business hours, but overtime is expected in this line of work. Following safety precautions is necessary to prevent hazards, such as wearing protective glasses and gloves.

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free quote.

Mold manufacturing is a tough business. On the one hand, manufacturers need to help customers design products right the first time. On the other hand, they have to deliver molds faster (and cheaper) than others.

Product estimates are another challenge. Most tool and die companies quote estimates at the initial stage of the design. However, production costs continue to escalate during the product’s life-cycle. That’s why it is crucial to come up with accurate tooling estimates.

But this is easier said than done. That’s why in today’s blog, we discuss all the factors that influence die and tooling costs.

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free and accurate quote.

Challenges Of Tool & Die Cost Estimates

Tool and die companies have several factors to consider when giving price estimates on custom orders.

  • Competition

Manufacturers have to price their services competitively to survive in the global market.

  • Quality

Maintaining part quality is of the essence; otherwise, the manufacturer will lose business.

  • Time

Part of the mold builder’s job is to spend a significant amount of time (and money) each month to provide estimates on projects they will never receive.

For all these reasons, mold builders need a system to quote prices that are not so high that they lose the order to a competitor and not too low to incur a financial loss.

How Manufacturers Estimate Costs

There is no uniformity among tool and die companies on how to calculate the cost of production. It’s also not uncommon to see different ways of quoting the same project in the same company.

So, how do manufacturers estimate tool and die making costs? Most companies calculate costs based on similar past orders, while others use spreadsheets.

Manufacturers can also consider using an integrated application or third-party applications for tooling and die costs in CAD software. This will include surface area, volume, wall thickness, feature ribs, and other geometric parameters that influence costs.

Things To Consider When Requesting Die Estimates

It is difficult to price custom products uniformly, which is why you need to consider these factors to increase estimate accuracy:

  • Type

The cost of the die depends on its type. For instance, progressive dies are designed to make, feed, and sequence carrier strips through each station. Strip lifters are also used in the process, and each station also needs to be timed. As a result, progressive dies will be more expensive than single-station dies.

  • Geometry, Tolerance, And Material

Tooling cost also varies with how complex the geometry is. Likewise, the die’s cost will vary with the tolerancing requirements (tool and die parts with small tolerancing generally cost more since they require additional stations).

Material strength also affects the overall price of the die. Using a higher grade of tool steel will raise the tooling cost because you will need a higher grade of tool steel to cut and form the material.

Other factors that influence die and tooling costs include:

  • Volume
  • Delivery time
  • Location of the die shop

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free and accurate quote.

With advancements in manufacturing technology, businesses need to know which processes and equipment work best for them.

In today’s blog post, we will talk about subtractive and additive manufacturing processes and compare CNC machining with 3D printing.

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free custom quote.

Continue reading to learn more about CNC machining and 3D printing and determine which one is best for your manufacturing project. 

Defining Terms

CNC machining and 3D printing are both computer-controlled technologies that can be used for prototyping, parts production, custom punch processes, etc. Since the processes are programmed and automated, there’s less chance of error and greater consistency in parts produced.

The main difference between the two is that CNC machining is a form of subtractive manufacturing, while 3D printing is additive. Machining cuts away a workpiece to create a finished part. This is achieved through milling (rotating tools) or turning (rotating the workpiece against a tool). CNC machining offers great dimensional accuracy on various materials, including metals, wood, and plastics.

3D printing creates finished parts adding layer upon layer using a laser, heated extruder, or any other energy source. There are different 3D printing technologies, each using different materials to create parts:

  • Plastic filaments (FDM)
  • Resins (SLA, DLP)
  • Plastic or metal powders (SLS, DMLS, SLM)

CNC machining is the older of the two technologies, so it still has a strong foothold in the manufacturing sector. 3D printing came to the fore in the 1980s, and modern 3D printers are significantly more accessible and versatile than their predecessors.

In the past, 3D printing was more focused on plastics, as metal processes were costly and time-consuming. However, manufacturers now have access to more efficient additive manufacturing technologies that offer accuracy, speed, and cost savings.

Let us now compare the benefits of machining with 3D printing.

Ease Of Use

3D printers are easier to use than CNC machines. Once you prepare a 3D printing file, you need to select the part orientation, fill, and supports. The printer can be left unsupervised until the process completes.

On the other hand, a CNC machine requires a skilled operator to select tools, rotation speeds, the cutting path, and positioning of the workpiece.

That said, in case a 3D printer malfunctions, someone has to troubleshoot it to avoid the production of faulty parts.

Wastage

CNC machining creates wastage as it involves cutting material away from a workpiece. However, there is little or no mess with 3D printing, which makes it an environmentally-friendly option. 3D printing also reduces the ‘buy-to-fly’ ratio, which is the weight difference between the raw material and the finished product.

Scale

While 3D printing permeates the manufacturing sector, it still hasn’t been utilized successfully for mass production. For larger orders, CNC machining still proves more effective.

Accuracy And Size Of Parts

While 3D printing offers greater freedom of shape and high geometric complexity, CNC machining provides greater tolerance and build volumes.

Cost

Finally, comparing the costs of 3D printing and CNC machining involves several variables. Generally, 3D printing is cheaper for low-production volumes or when you need prototypes or parts quickly. For larger quantities, CNC machining may prove more cost-effective.

At Cav Tool Inc., we help businesses in Detroit with all their custom die, punch, and tooling needs. Click here to get a free custom quote.

Injection molding is an intricate manufacturing process that helps create the same part thousands or even millions of times in succession. There are several benefits of this technique. The main advantage is that the price of producing each successive part decreases significantly during the process.

At Cav Tool Inc., we provide companies in Detroit with custom and high-quality close tolerance products. Click here to get a free estimate.

Today’s post will talk about injection molding, its benefits, and things to consider. This information is pertinent to both engineers and business owners interested in custom tooling.

Why Go For Injection Molding

Injection molding is primarily used for its ability to scale production to any given quantities. The initial set-up is both costly and time-consuming, but injection molding results in an extremely low per-unit price, which decreases as more parts are produced. It also helps to finalize prototypes for consumer or production.

Benefits Of Injection Molding

There are two main benefits of injection molding.

  • Lowers Scrap Rates

Firstly, with injection molding, you can reduce wastage that is common in other manufacturing processes. For instance, CNC machining cuts away large parts of a plastic workpiece. Injection molding, on the other hand, lowers scrap rates.

  • Ensures Consistent Parts

The second major benefit of injection molding is that it is repeatable. Every successive part will be identical to the first one. This helps to achieve consistency and part reliability when scaling production en masse.

That said, the consistency and accuracy of parts depend a lot on the initial design and prototyping. This brings us to the next point.

Design Considerations In Injection Molding

While injection molding lowers the production price of each unit, the upfront costs are substantially high. Setting up an injection molding process involves meeting all design, testing, and tooling requirements.

Specifically, you have to ensure the right design initially to reap the benefits of injection molding. This involves three major factors.

The first one involves designing and prototyping the part to specification. This is achieved on a 3D printer. The material used to develop the prototype is usually different from the material used to construct the final part.

The second factor is designing the injection mold tool for a test run. Thirdly and finally, all details in the injection mold tool have to be refined before proceeding with mass production in the manufacturing plant.

The aim is to simplify geometry and reduce the number of parts early on. This can be achieved by designing the part with injection molding in mind. Engineers and manufacturers need to understand the difference between various fabrication techniques when designing parts.

Moreover, the design of the mold tool should be as such as to prevent manufacturing defects. Running simulations proves beneficial in this regard.

Finally, one also needs to be aware of possible design constraints in injection molding. For instance, injection molding becomes intricate if you are designing parts with a thermoset material.

If you want to learn more about injection molding, click here to talk to our experts. At Cav Tool Inc., we help companies in Detroit by providing custom and high-quality close tolerance products.

CNC Milling 101

Oct 22, 2020

When we talk about modern manufacturing technology, Computer Numerical Controlled (CNC) machining involves programming specific and detailed instructions to drill or machine-identical parts. CNC milling machines are powered by controls and code from CAM and CAD software to perform automated machining functions on a workpiece.

When it comes to CNC machining, milling is a common technique to create specific shapes or holes by removing small pieces of material from workpieces. These can be metal, plastics, or wood, etc. The milling process uses rotary cutting tools to shape or create holes in various types of materials.

At Cav Tool Inc., we specialize in CNC machining to create parts from custom designs for various industries in Chicago, IL. Click here to get a free quote.

In today’s blog post, we will provide a brief overview of the CNC milling process and its application and benefits.

CNC Milling Over The Years

Modern CNC milling equipment has undergone significant advancement over the years. The latest milling equipment offers more accurate milling capabilities at greater speeds.

For instance, the latest CNC lathes can machine materials with diameters of 457.2mm. Moreover, computerized hardware can model, manufacture, and analyze results faster than before.

These, and other technological advancements, are a key reason why CNC machining is growing exponentially in industries across the globe. In a similar vein, it has become cheaper to install, maintain, and operate CNC milling equipment, offering greater capabilities to manufacturers at lower costs.

Let us now go over some benefits of CNC milling.

Advantages Of CNC Milling 

Here are some of the reasons why CNC machining and milling, in particular, is so popular in manufacturing:

  • Achieve Complex Parts

CNC machines enable the fabrication of ever complex milled parts with precise directions from intricate CAD or CAM models. CNC machines can mill a workpiece from different angles and with different tools with up to five-axis systems of control.

  • Drive Innovation

CNC milling facilitates engineers to create intricate designs with less wastage. This helps companies drive innovation with fewer manufacturing limitations. Indeed, CNC milling is an ally to any R&D department.

  • Achieve Versatility

Finally, CNC milling offers versatility because it works on a variety of materials of varying thicknesses. Likewise, CNC milling, being a reductive process, can also work on parts with varying dimensions.

Applications of CNC Milling

Due to its wide-ranging capabilities and benefits, CNC milling has become an integral part of several industries. Examples include:

  • Automotive
  • Aerospace
  • Medical 
  • Transportation
  • Electronics

CNC milling also has commercial applications to create home décor, tools, and other commercial equipment.

Finally, all technology requires accuracy and precision, and CNC mills enable you to achieve just that. In manufacturing as well as other industries, CNC machining ensures the fast and accurate assembly of multiple parts and layers with reduced error margin.

That said, you need to find a reliable service provider to achieve the full benefits of CNC milling. Companies in Chicago, IL, can always reach out to CAV Tool Inc. for all their machining needs. Click here to get a free quote.

Dies are a tool used for cutting and shaping different materials in manufacturing industries by using a press. Just like mold, a die transforms different materials into customized shapes in industrial settings.

They are used for shaping substances from paper clips to much more complicated designs. When these dies are used for cutting and shaping sheets, it is called sheet metal operations or press working operations.

This article comprises a list of five common types of dies used in sheet metal operations that can add value to your understanding of efficient mold building solutions.

Before we move to the list, here is a quick note for clients who are looking for mold building services at reasonable pricing in Chicago, IL. Engineers and manufacturers at Cav Tool Co. offer a comprehensive list of services in this field without costing too much. Don’t believe it? Click here and get a free cost estimate for molding products and services.

List of 5 common types of dies used in sheet metal operations

Here is a list of five different types of dies that are commonly used in sheet metal operations.

Simple Die

Simple die is a type of sheet metal operation die that performs only in one stroke at one stage. As the name suggests, this type of die is for most simple shaping and cutting tasks.

Compound Die

Unlike a simple die, a compound die is designed to perform more than one cutting operation in one stroke, and that is what makes it a compound die. However, all the cuts made in compound die operations are made on one stage.

These features of this type of die in metal sheet operations make it an advantageous die as it can increase the production rate. However, compound die also has some limitations.

First, this type of die is not suitable for a task that involves more than three operations since manufacturing and designing of punch and die to build a combination of the two is a difficult process.

Moreover, this type of die requires high force, and none of the methods for force reduction can be used in this type of operation.

Progressive Die

Progressive die is the procedure where more than one cutting operation is performed in one stroke. However, the progressive die functions at more than one stage at a time.

This means that the sheet progresses through different stages to complete the punching operation that lasts with the blanking operation. The advantage of this type of die is that the manufacturer can get productivity rates similar to the compound die but with reduced force.

Transfer Die

A transfer die is similar to a progressive die operation. The only difference between the two types of dies is that, in transfer die, blanking is the first operation.

This means that the blank produced in the first stage progresses until the punching operations are completed. This type of die is considered more economical and versatile compared to a progressive die.

Combination Die

Combination dies are the ones where cutting and forming operations are performed in one stroke at one stage. Some of the examples of combination die include the combination of deep drawing with blanking or punching.

A combination of blanking and bending is also a fine example of a combination die. This type of die is one of the most beneficial versions of sheet metal operation dies as it takes the production rate to new heights.

Our list of five common types of dies used in sheet metal operation completes here. Are you thinking of installing any of these die types in your manufacturing company in Chicago, IL? Cav Tool Co. is here to help you with the high-quality products and facilities required to complete the task. Click here to get a free quote right now.