Author: hqt

How you can save your aluminum extrusion?

If you want to secure your aluminum extrusions by using best finishing process then you are at the right place. Because we are here to guide you in the right direction. Furthermore, just like several other industries, there are also plenty of options to finish your aluminum extrusions. For example, powder coating.

Basically, you also have other helpful options for high quality aluminum finishing. The other options are also very popular and useful such as, anodizing and painting. All of these choices have several unique benefits and they are also suitable according to some specific conditions.

What is the role of better finish in powder coating?

These finishes can provide you best protection against corrosion and many more. As well as they also have ability to provide you ideal aesthetic appeal. But here we will discuss about powder aluminum coating. What does it mean and how it is advantageous for your aluminum extrusions?

Moreover, you can also get some important steps to prepare aluminum for powder coating. How you can do it at home and some problems while coating aluminum by powder?

What does powder coating mean?

The powder aluminum coating means that you coat your metal workpiece with a special powder. Nowadays it has become a very popular process to secure your aluminum parts and components. In this process, you can add finishing to your aluminum extrusion according to the needs of its medium.

Basically, by using this process you add a special paint on the surface of your aluminum extrusions. Moreover, this special paint comes in the form of powder. The object on which you have to apply this powder must be electrostatically charged.

Moreover, you have not to use any type of solvent for completing the powder aluminum coating. But before powder coating, for the best adhesion of the paint, you have to properly treat the whole surface. So that there should not be any kind of issue after the coating process.

Actually, this process of coating is only appropriate for all of your metal parts.

How to prepare aluminum for powder coating?

In fact, you do some pretreatments in other processes of finishing your metal pieces for better painting or anodizing results. Similarly, in this process of powder aluminum coating, you also have to do some vital treatments for better finishing solutions.

Furthermore, there are generally 6 initial processes to ideally prepare the aluminum for powder coating.

Such as,

• The surface cleaning;
• The solvent cleaning;
• Hand and power tool cleaning;
• Sweep blasting;
• Phosphate treatment;
• Aqueous Alkaline cleaning.

The surface cleaning:

At first you have to make sure that your aluminum parts are totally clean. For example, you have to make sure that all type of

• grease;
• dust;
• and several other particles;

have perfectly removed in order to do proper adhesion. Basically, the cleaner your aluminum part is, the better and more durable the powder aluminum coating layer will be.

The solvent cleaning:

In this process of cleaning the aluminum part, you have to clean by using conventional cleaning solvents. Generally, you can use,

• high-flash naphtha
• mineral spirits, etc.

Because they are best to remove grease and oil from the aluminum components for ideal results of powder coating. For perfect cleaning, you should always use appropriate brushes or rags to wipe parts perfectly.

Further, you should strictly clean these brushes or rags. Because remaining dirt or oil in these brushes have chances to transfer back to the aluminum part. You can clean all these parts with the help of ultrasonic baths of solvents.

And after this bath rinse them thoroughly in hot water. After rinsing, dry all these parts before the next process.

Hand and power tool cleaning:

You can also clean light deposits of aluminum by using power tool and hands.

Sweep blasting:

The brush blasting or abrasive sweep actually uses the movement of rapid nozzle. Moreover, this rapid movement has ability to roughen the aluminum surface. Hence, it can make the aluminum part ready for powder coating.

Phosphate treatment:

In this process, you actually convert the aluminum surface to a crystalline phosphate coating of proper texture. This process has done to inhibit corrosion for durability and adherence of the powder aluminum coating.

You can apply this process with the help of spray, soft bristle brush application or with the help of immersion. Moreover, after 3 to 6 minutes, you should wash the whole surface with simple clean water. Leave it for a while to dry it completely before applying the powder aluminum coating.

Aqueous Alkaline cleaning:

Actually, the solution of alkaline contains 2 to 5 % sodium compounds. Further, it also has a very small addition of,

• chelating;
• emulsifying;
• sequestering agent or may be combination.

You can easily apply this solution by using spray machines or with the help of brushes. If you want its best results, you should keep it in the temperature of 60°C to 85°C. Basically, this temperature is ideal for this process of preparing aluminum for powder coating.

So, after cleaning with the solvent of Alkaline, you have to wash the aluminum part deeply by hot water. Let dry it properly. But for better results, you should use heated drying in order to best removal of water.

Hence, all the above methods are necessary to prepare aluminum components for aluminum powder coating.

What is the powder coating process?

The whole process of coating the powder to your aluminum extrusions is as follow;

1^st step:

As we have already described that before starting the process of powder aluminum coating, you have to pretreat aluminum surface. It is essential part of this coating process. Because it helps to ensure the ideal adhesion. Further, the powder coat will not flake and it will be extra durable.

2^nd step:

In this step, your selected technician will spray the powder with the help of electrostatic spray gun. But for accurate powder coating, first the technician has to make sure that aluminum part must have the positive charge. Actually, this positive charge helps to make the powder bond with the extrusion of electrically-grounded.

3^rd step:

In the 3^rd step, your technician will put the aluminum extrusion inside the big curing oven. This oven actually will bake the aluminum component till you get a uniformly-melted coating.

4^th and final step:

In this final step, the technician removes the baking extrusion in order to cool it completely. So, after cooling the aluminum part, you can easily get a very smooth and hardened powder coating.

What are powder coating aluminum problems?

As this latest powder aluminum powder method has lots of benefits, like,

• It has ability to give you lots of charming and bright colors options;
• More reliable and environment-friendly than anodizing or liquid paint;
• It has strong bond and can’t peel or chip easily and many more.

But this method of coating also can create some problems for your aluminum extrusions.

Generally, there are 5 most common problems which can create problems for you. Moreover, you will have to face all these general issues, if you use polyester powder coat. These 5 common problems are:

1. Skinny Corrosion
2. Inclusions or orange peel
3. Chalking
4. Failure of the aluminum coating in order to adhere
5. Unstable color match.

Does powder coating weaken aluminum?

When you are making your aluminum extrusions safe by using powder aluminum coating, you may think,

• is it safe for your aluminum parts?
• can powder coating weaken your aluminum components?

So, we are here to explain you. In fact, there is no harmful effects of this method to your aluminum or any other metal alloy. In this method, technicians actually use the curing temperature around 177 - 190 C (350 - 375 F). Hence, this temperature has no side effect on the metals.

Conclusion:

The powder coating process is highly advantageous in comparison to anodizing. Because it gives you a vast range of colors selection. Moreover, when we compare it to oil paint, we find it safer. Because, the waste powder is not hazardous like the wet paint.

Further, you can also collect this waste powder and can reuse it. So, this coating will be an ideal choice for you, if you want extra unique textures with some bright colors.

What are the pros and cons of plastic extrusion molding?

Nowadays we can see a great innovation and versatility in plastic products. All these plastic products are making our lives better and safer like never before. Moreover, these products are adding extreme comforts in our daily lifestyle. But all these useful plastic objects are just because of plastic extrusion.

In fact, extrusion is a very effective way to produce several shapes using many different materials. Further these shapes and products are helpful in both industrial and domestic industries. But here we are discussing the plastic products that have created by extrusion.

If we consider at the uses of modern plastic products, we will acknowledge that,

• our modern life;
• and all its comforts;

are only possible because of these products. You can see them in your smartphones, computers, television and several other electronic devices. Moreover, there are countless uses and benefits of plastic products which have created by plastic extrusion.

In this guide, we will explain you about, extrusion, plastic extrusion and its different types of processes. Additionally, you will see the pros and cons of extrusion by using material of plastic.

So, let’s dive in!

What do you mean by the word extrusion?

Basically, extrusion is a manufacturing process which creates shapes by forcing the melting material into a specific die. This die helps to create objects with several particular profile and shape. As the melting materials pass via this die, it changes its shape according to the shape of die.

The process of extrusion is highly systematic. Further, it is almost similar for materials of rubber and plastic. The only difference is between their operating temperatures and some other necessary deference. But all the basic rules and principles are same in all extrusion process.

Today, manufacturers are widely using several metals, plastic and ceramic materials in extrusion to get the desired shapes.

Now let’s start to know deeply about plastic extrusion.

What is plastic extrusion?

In this type of extrusion, manufacturers use plastic as the base material. In fact, plastic extrusion helps to get the several different types of shapes. It is very easy to get simple to complex designs by using a die. Actually, in extrusion, manufacturers put melted plastic and then resolidified it.

So, they use thermoplastics in getting their final designs. Because only thermoplastics have ability to undergo extrusion. This type of plastic has many good properties. Because it is good for recycling,

• numerous post-consumer goods;
• scrap pieces, etc.

with the help of plastic extrusion, manufacturers create consumer as well as industrial goods. It is very easy to get simple to complex designs by using a die.

Different types of products which you can get from plastic extrusion

In fact, plastic extrusion helps to get the several different types of shapes. Moreover, it can produce different items, such as,

• tubing or pipe;
• fencing;
• window frames;
• plastic sheeting and films;
• weatherstripping;
• deck railing;
• wire insulation;
• solid shapes;
• thermoplastic coating and many, many more.

Which kind of plastic is ideal for plastic extrusion?

Actually, manufacturers use commodity plastics in plastic extrusion because they are suitable for the majority of applications. Additionally, they are account for almost 90% of all thermoplastic use.

Basically, these plastics are very easy to process. Moreover, they are very easily available as well as extremely cost effective to use for your extruded products.

Its most common examples are:

• polyethylene (PE)
• polypropylene (PP)
• polyvinyl chloride (PVC).

How does plastic extrusion work?

You can get several different forms of plastic products by the help of extrusion. But the process which takes place to get these different objects is same whether these products are,

• small;
• simple or complex.

Furthermore, they all start with the same material, like, resin and in the same place. It is actually very easy process. We can easily describe the whole process in just few words. For example, in plastic extrusion, the selected plastic beads are melted then filtrate to get uniform consistency.

In the next step this melted resin have pushed into die for specific shape. Hence, the required shape has to cool down for a while and your final product is ready now. Further, these plastic items are helpful to use in,

• building materials;
• industrial goods;
• countless consumer objects and so on.

Although this process of extrusion by using plastic is simple but it is highly technical also. So, we have decided to describe you, the whole process in a step-by-step guide. Let’s take a deep look!

Step # 1:

In the first step of plastic extrusion, manufacturers load raw plastic materials, such as

• pellets;
• powder;
• granules;

inside a hopper. Next, this resin has fed into a long heated cylindrical chamber. This long heated cylindrical chamber has known as an extruder.

With the help of a revolving screw, it moves through this chamber. In fact, several extruders may have one or two revolving screws. But it totally depends on their particular designs.

For a best shape of plastic profile, it is very important to design the die in a smooth way. Because melted resin should flow smoothly to get the final shape of the object. Actually, for getting best products, the consistency in the flow is extremely critical.

What are the types of plastic extrusion process?

Basically, there are different types of extrusions in plastic. And it totally depends to the types of products which you want to get through plastic extrusion. These different types of plastic extrusion are:

1. Film or sheet extrusion
2. Blown film extrusion
3. Over jacketing extrusion
4. Tubing extrusion
5. Extrusion coating

Famous uses of plastic extrusion

The manufacturing companies are rapidly using extrusion molding to produce consistent cross-section products. Furthermore, if we consider its uses in our surrounding, we can easily find these products, like,

• rain gutters;
• PVC pipes;
• automotive trim;
• vinyl siding;
• windshield wiper and much more.

What are the pros and cons of plastic extrusion?

In fact, extrusion molding process offers several advantages to the manufacturers. As well as it has some disadvantages also. So, here we are giving you some pros and cons of plastic extrusion.

Pros	Cons
This process is actually low in cost than other molding processes	It provides you limited variations in designs
It is highly efficient	Your plastic products can little expand even after final design configuration due to unpredictable expansion
It allows you to some post-extrusion manipulations	Actually, there is a problem of die swell
You can produce complex shape with great flexibility

 

Conclusion:

Basically, plastic extrusion has ability to provide high volume output with continuity. Hence, this benefit makes this process extra economical method to produce plastic products. Moreover, its cost of tooling is extremely low. Plastic films, tubing, piping are only some examples of its products.

However, in this modern age, its uses are countless due to its flexibility and effectiveness.

Why grinding is important for perfect components?

The grind and welding process can actually give a perfect look to all the metal objects after welding. The expert welders always know the importance of grind process. Because this post-processing method is essential for the demands of the customers.

At first, the process of welding has done to fabricate the metal parts by heat or pressure. Then grinding process has used to give them a perfect and stream look.

Both of the processes have their own importance whether it is welding or grinding. Moreover, they are essential while you are creating a master piece. They are actually part and parcel for the metal products for a perfect look.

So, let’s fully know about the grind and welding process. And also, about the different types of welding. Moreover, you will get complete information about 3 most important types of discs which are highly beneficial for grinding.

What is welding?

Basically, welding is a process of fabrication which helps to join two or more metal parts. In the welding process, you can join the metal parts by using

• Heat

Sometime, you can also use both of the above means with the use of some gases or metals. Furthermore, you can use welding process to join several different metals. But it is also helpful for thermoplastics and wood.

The process of welding has ability to join two or several pieces of metal to make them one. However, this important technique first had discovered in order to manipulate iron in many helpful shapes and designs.

Which are different types of welding?

Generally, there are several methods of welding which has used for different methods. Such as,

• Spot welding
• Tungsten inert gas
• Metal inert gas (MIG)

Moreover, these methods are special forms of,

• Arc welding
• Gas metal arc welding
• Gas welding.

What is grinding? grind and welding process

Grinding is the second most important part of grind and welding process. In fact, it is the essential part for producing highly accurate and the most finished products. Actually, grinding is a harsh machining process. In this process, a grinder or a specific grinding wheel has used for the purpose of cutting tool.

Furthermore, designers use the process of grinding to produce finish workpieces. These final workpieces will show high accuracy of dimension and shape as well as an extreme surface quality of objects. Moreover, you can also call it a subset of cutting. Because it is truly a process of metal cutting.

Basically, grinding in the grind and welding process can remove high level volumes of extra metal most rapidly. It has ability to provide you the metal objects which have,

• Most attractive
• Extremely smooth
• Well consistent appearance.

So, grinding has great importance for perfect looking metal objects.

Which are the best types of discs in grind and welding process?

It is crucial to select the right type of process for perfect and streamline objects. It totally depends on the special requirements of the customers. There are several types of abrasive products for perfect looking metal objects.

In fact, these are a complete family of abrasive products in which include

• Wheel hardness grit size
• Backing material
• Wheel or disc shape and many more.

It totally depends on you that which type of abrasive product will suit in the situation which you are handling. There are 3 main types of discs which you can choose according to situation for perfect grind and welding process.

Moreover, these are:

1. Coated abrasive fiber discs
2. Bonded abrasive thin wheels
3. Coated abrasive flap discs

Coated abrasive fiber discs: grind and welding process

These discs are ideal to use for grinding. There are great records of safety while you get only few reports of disk breakage. But you have to make proper efforts to prevent the breakage. Furthermore, they are highly advantageous for perfect grinding.

Hence, you should keep them in a perfect storage with best environmental factors. Because,

• Humidity and temperature can make these discs unsafe
• Immoderate or excessive moisture cause the damage to the disc's abrasive grains
• Exorbitant humidity can also damage the disc because it can totally change its shape

The new shape of disc will be in a cupping shape. So, you cannot use these discs as they will create problems and also can break. As coated abrasive fiber discs are best to use in grind and welding process. So, you should follow some safety rules to reduce the breakage or corrosion of these grinding discs.

5 most important safety rules:

In fact, there are lots of safety rules to store coated abrasive fiber discs. But 5 most important rules are:

• Must store the discs in 15 to 29 degrees C (60 to 80 degrees F)
• The better humidity for these discs is 40 to 50 percent
• Always store the discs into their own actual packaging
• Keep the discs away from water and any other liquid solvent
• Store the discs away from the sunlight or any other heat source.

Bonded abrasive thin wheels

The bonded abrasive thin wheels are highly useful in grind and welding process. You can use these thin wheels in,

• Construction
• Welding
• Almost all foundry to primary markets of metals.

Furthermore, you can also use them in order to cutting and snagging ferrous and nonferrous materials. They are greatly beneficial because they can,

• Minimize cost
• Improve the operator efficiency
• Their welding products have long life span

These have designed with best-in-class abrasive grains so you can get precise and rapid cuts without extra effort.

In addition, bonded abrasive thin wheels can give you high performance products with best productivity.

Important safety rules: grind and welding process

Basically, all types of abrasive wheels are better choice for a perfect grind and welding process. They are extremely delicate and fragile. So, you should follow some important rules to store them. Some essential rules are:

• It is really important to save these wheels from bumping and dropping
• Always use a safe container to transport these fragile wheels
• Always avoid to put heavy items on the top of wheels
• keep them away from the sunlight or any other heat producing source and excessive cold places
• Must store them in bins and dividers which have proper dividers for easy access

Coated abrasive flap discs for better grind and welding process

The flap discs have actually become one of the most increasing categories from several past years. These types of discs are ideal for fast removal. Additionally, they provide better,

• Blending
• Grinding
• Finishing

by using just one product. These discs are highly effective to use in grind and welding process as well as in,

• Cleaning flash from molds and casting
• Edge grinding
• Weld-seam blending
• Removing rust

Coated abrasive flap discs have basically constructed by using cloth coated-abrasive material. The manufacturers glue the cutting pieces of cloth on the backing plates. Hence, these flap discs have created very easily.

Important and necessary safety rules:

 

1. Always use abrasive products with great care and handle them properly
2. Must try to use coated abrasive products within 3 months for better results

• Avoid shocks or bumps during transportation

1. Store in ideal humidity at 45% to 65% and 10°C/30°C temperature

Conclusion:

All the above important types of discs are helpful for ideal grind and welding process. Moreover, you have to follow the instructions which we have given to store them for long life span. It is also essential for you to use proper fumes suction systems or any respiratory protecting tool during the welding.

Because there is a chance to some serious injury during grinding or welding. In fact, during their applications they release dangerous and harmful contaminants in the air. So, always use complete precautions for the safety of your life.

 An Ultimate Guide to PEM Fabricators and Assemblers

When you need a perfect light solution for you manufacturing needs PEM assembly will be your first choice. Today PEM solutions have become world leaders in the modern fastening technology.

These products have specially designed for some specific purposes. Moreover, they are highly beneficial, like they have long life span and are durable. Basically, they are alternative of the wire threaded insert. In fact, the wire threaded insert had first introduced in 1930 by an aircraft industry. Its main purpose was to use for weaker and lighter materials of aircraft.

Nowadays manufacturers are making use of PEM solutions for lighter materials. They have ability to give you the lighter materials without sacrificing the strength or durability.

These PEM assemblies are extremely helpful in modern automobile industries. So, come with us to know about PEM assembly and its advantages. How it works and about its beneficial applications as well as about 3 main types of PEM assembly?

What is a PEM assembly?

PEM actually stands for Polymer Electrolyte Membrane. This is entirely new and revolutionary product which was first established in 1942. This product actually has solved all problems to find light solutions in some specific conditions. Such as, light solutions have greatly needed in the aircraft industry and in modern automobile industry and many more.

Basically, PEM have designed for the following purposes,

1. In order to easy installation
2. For faster self-clinching.

Furthermore, the extreme quality of self-clinching is highly advantageous for

• Time reduction
• Less labor
• Less weight.

All the above benefits have introduced an entire new world for designers and engineers. Moreover, by using PEM assembly they can actually make a wide variety of thinner metal designs. And it has become possible for the first time only because of PEM.

Its fastener self-clinching quality provides the designers easy load-carrying threads in sheets of metal which are very thin to tap. Furthermore, PEM is also very beneficial for electronic designers. Because they can use it for several products in the Printed Circuit Board assembly. Because there is a great need to joint in the very small holes with the help of PEM.

What are the main parts of a PEM assembly?

The PEM cells has actually made by using many layers of several different materials. Moreover, the main parts of a PEM assembly have the following essential parts. Such as,

• (MEA)
• The catalyst layers
• GDLs

The Membrane Electrode Assembly (MEA):

As we have described that MEA or Membrane Electrode Assembly is the core and heart of the PEM. Moreover,

• The membrane
• Catalyst layers (like, cathode and anode)
• Diffusion media

All these media gather and forms the membrane electrode assembly of the PEM.

The catalyst layers:

Basically, the catalyst layer has further two layers which have added on the both of the sides of a membrane.

The layer of anode on one side of the membrane. While the layer of cathode on the other side of membrane. Additionally, these traditional catalyst layers of PEM assembly also consist of platinum particles with nanometer size.

Gas Diffusion Layers (GDLs):

The Gas Diffusion Layers (GDLs) stays at the exterior side of the catalyst layers. The GDLs also help to transport of reactants inside the catalyst layer. Moreover, it also helps to remove the water of the product.

What are 3 main types of PEM assembly?

In fact, there are several kinds of PEM fasteners. Furthermore, most of the applications generally need only one, from these three common types. For example, these three main and highly beneficial types of PEM assembly are:

1. The PEM Self-Clinching Studs
2. PEM Self-Clinching Nuts
3. PEM Self-Clinching Standoffs.

Furthermore, today designers have also introduced numerous innovative products like,

• Rangle right angle threaded fasteners
• Flush rivets
• Snaptop standoffs (ideal for mounting PCBs in order to chassis)

Actually, there is an inclusive range of PEM assembly for electronics designers. And a huge range of mount products which is extremely helpful for PCB assembly.

1.      PEM Self-Clinching Studs:

The Self-Clinching Studs have designed to use in very pliant and ductile metals such as,

• Stainless steel
• Steel
• Aluminum, etc.

These are ideal to use in all heavy-duty application programs.

2.      PEM Self-Clinching Nuts:

Basically, the PEM Self-Clinching nuts are very cost efficient. Moreover, they provide a low-price process in order to install imperial and metric threads in almost all kinds of,

1. Cast Metal
2. Sheet.

In fact, these nuts give more advantages in comparison to rivet nuts. These river nuts have also known as Hank bushes or may be river bushes. By comparing rivet nuts with PEM assembly self-clinch, you will get that PEM self-clinch provide very lower back side knob.

Moreover, it also has ability to improve torque in order to rotate characteristics. Furthermore, when you try to make a comparison between rivet bushes and PEM self-clinch nuts. Then you find that PEM self-clinch nuts have ability to make better performance for,

1. Push out
2. Torque to turn.

3.      PEM Self-Clinching Standoffs:

The PEM Self-Clinching Standoffs have ability to offer very simple and rapid solution in order to mount the components like,

• Circuit boards
• Touch pads
• Control panels
• And many other items inside the metal chassis, etc.

These are the best type of PEM assembly and can provide reliable solution to sheet metals. Actually, these standoffs are very beneficial and you can install them into several different varieties of ductile metals, for example,

• Steel
• Stainless steel

Moreover, they have also designed in the version of open and close end. They mostly come in the size range of M1.0 to M5.

What are popular applications of PEM assembly?

Today in this highly innovative and progressive era several kinds of PEM are rapidly using in all areas. Several different types of PEM like,

• Studs
• Spacers
• Nuts
• Standoffs
• And many other components have used by all the industries around the world.

These popular types of PEM assembly are extremely advantageous. So, all the major manufacturers and producers such as,

• Automobiles
• Spacecraft
• Industrial and electronic equipment and appliances
• Communications systems
• Farm machinery and transportation equipment
• Furniture
• Vending machines
• And aircrafts.

What are benefits of PEM assembly?

There are several kinds of PEM assemblies which are highly beneficial in all modern applications.

In automotive industry:

Basically, if we deeply peep into the automotive industry they are almost in all parts. For example,

• Bumpers
• Airbags
• Steering components
• Brake systems
• Fluid carrying components
• Transmission components
• Anti-vibration requirements and so on.

In the modern electronics:

Moreover, PEM assembly is also beneficial in the field of modern electronics. As you know that modern electronics are totally depending on the PCB boards. The PCB boards use these modern PEM assemblies to mount all the essential components on the boards.

Only these special kinds of PEM can truly mount the components on the circuit boards. Because they are best to use on thin metal sheets. Hence, by using these latest PEM assemblies, PCBs of complex electronic designs have become possible to mount.

Furthermore, these nuts, studs and standouts have extreme importance to design,

• Scooters and Bicycles
• Utility Vehicles,
• Stationary Power Applications and many more

Conclusion:

Hence, all kinds of modern PEM assembly are highly important and advantageous in all latest devices. However, they are cost effective and very easy to install. Consequently, the installation of complex hardware is only become possible because of these PEM assemblies. They are useful even when loose nuts and hardware are not possibly to use.

How much Auto Stamping Parts Cost? (Equipment selection for tooling Manufacturing)

Auto Stamping Parts are common in engineering, shipbuilding, aircraft construction. Only earlier we used to carry it manually. In addition, the method gained wide popularity. Because it was possible to make everything - from a small, insignificant part, to an airplane wing.

Today's technologies and equipment allow automatic metal stamping. This process has a number of advantages, which we will discuss below.

What is Auto Stamping Parts?

There are two methods of metal processing:

1. cold and
2. hot

Generally, cold forging is common in producing:

• machine bodies
• aircraft parts
• and other single or multi-batch parts.

The advantages of cold stamping include the cost-effectiveness of consumables. Moreover, it increases the ability to manufacture parts that will absolutely match each other, and high production efficiency.

Auto Stamping Parts is a technological process that we use to produce metal sheets up to 4 mm in volume. Moreover, during operation, the material is subjected to high heating.  And then special machines carry the process.

How does Auto Stamping work?

Automatic metal stamping according to customer's drawings allows you to create products of original configuration and shape in a single version and multi-batch. Thanks to automatic stamping, the parts are exactly the same. Similarly, the error can be a maximum of 0.05 mm.

Technological processes of metal stamping:

1. The two pieces of sheet metal work in a straight or curved line.
2. Notching. Subsequently, notches and cuts work on the metal without disturbing the overall integrity of the sheet.
3. Simultaneously, the process is designed to work with the edges of the sheet. In addition, we peel off and waste the unnecessary parts.
4. Punching. Auto Stamping Partsprocess with one or more holes. Hence, a pattern or pattern appears.
5. Cutting down. A closed loop is made inside the metal blank and a whole fragment is removed along it. In this case, the entire part remains closed.
6. It is a decorative element that allows you to correct irregularities in the metal sheet and smooth the ends.
7. Cones appear on the metal surface, in other words, breaks, but without cutting off the metal layer.

How much Auto Stamping Parts Cost?

The most frequently asked and popular question: "How much does a stamped part cost?"

To calculate the cost of manufacturing, you need to add the following components:

• material cost + shipping cost / useful output (pcs),
• cost of design documentation + cost of a stamp + cost of commissioning / estimated life of a stamp,
• Cost of medium and minor repair of a stamp + cost of spare parts. Moreover, it also includes / number of parts produced from service to service,
• Moreover, Shift cost / production rate.
• Information for customers

1. Generally, mass production of metal products requires technology, raw materials, equipment and tooling.
2. a) Technology - we will develop,
3. b) raw materials - we will purchase,
4. c) equipment - in stock,
5. d) equipment - we will design and order.
6. We work using your tooling and can make our own.

Technology development of auto stamping

This is the very first stage of Auto Stamping Parts. Furthermore, here the cost of the part depends. At this stage, you need to clearly understand your monthly need. Based on many years of experience, we will develop the most optimal manufacturing technology for the parts you need according to the criteria "need - terms - price - quality".

At the moment, for cold stamping of parts, you can select the required steel grade: cold-rolled, hot-rolled, cold-worked, stainless, etc. Moreover, there is cretion of waste during the production of steel products. Unlike foundries, this waste cannot be recycled locally and must be disposed of. Therefore, we include the costs of disposal in the price of the products.

• Metal waste from production can range from 3 to 80%.
• Material selection - steel grade Material selection - steel grade

Equipment selection for Auto Stamping Parts

For the production of products based on the technology, equipment is selected taking into account:

• the steel grade
• the size of the workpiece
• the permissible force of the forging and
• Pressing equipment and the size of the finished product.

Production of documentation

For the manufacture of dies, design documentation is required - drawings. Similarly, the term for the development of design documentation is 3-4 weeks. The cost of a set of drawings for a stamp depends on the project.

Moreover, the development of design documentation is an important process. Therefore, we recommend checking cost of the forming equipment.

Tooling (stamp) manufacturing

For the manufacture of tooling (stamp), it is enough for us to receive a drawing or a sample of the part from you. Furthermore, you can allocate the cost of Auto Stamping Parts. For the manufacture of large batches of products on an ongoing basis, it is necessary to have at least two sets of dies. Subsequently, it is in order to ensure the required volumes of products. Moreover, it is to exclude downtime in the event of their breakdown.

How to even approximately understand the cost of Auto Stamping Parts? 

Generally, the more complex the part, the larger the holes in it, the larger its size - the higher the cost of the stamp.

In addition, the term for making a stamp is from 1 month, the term for debugging a stamp is up to 2 weeks

Service stamps

Stamps are equipment that undergoes a high operational load and require regular maintenance:

• Inspection
• replacement of parts

Generally, small and medium repair of dies is done according to operating time and if necessary. The Auto Stamping Parts production facility carries on-site operations. Similarly, it includes:

• disassembly
• fault finding
• replacement of wear parts
• sharpening of cutting surfaces
• demagnetization and assembly

Advantages of Descartes punching scanner-positioner

Improving punching efficiency:

• reduction in the cost of procurement
• Moreover, it increases in productivity (maximum positioning speed 50,000 mm / min).

Saving material:

• 5 times more parts from one metal volume,
• Hence, reduction of waste by 2.5 times,
• The possibility of stamping from illiquid blanks.

Savings on wages up to 9 times:

• One person can serve 3 presses.

Reducing the price of stamps by 30%:

• Moreover, you can use 2-column and non-column dies,
• Stamps without guides, stepping knives and catchers.

Occupational Safety and Health:

• The presence of a person directly near the press is not required.

Brief Description of Auto Stamping Parts Scanner-Positioner Assemblies

1. High strength frame

Auto Stamping Parts includes the high-strength, full-size frame. Similarly, it comes with high-tech welding. Moreover, it can withstand loads of up to 63 tons, ensuring stable and reliable operation.

Stamp frame Descartes   Stamp frame Descartes

2. Technology of compensation of unevenness of the workpiece

Generally, the roller can freely follow the curvature of the sheet surface. To compensate for unevenness of the sheet during travel, the drive rollers have a vertical stroke.

Friction welding: principle, advantages and applications

Friction Stir Welding (FSW) is a type of pressure welding. Here, the melt of the surfaces comes by converting the mechanical energy of the friction force of the parts into thermal energy.

Friction Stir Welding (FSW) - what is it?

Friction stir welding is a type of connection using pressure. It means that the parts to be welded will heat up as a result of friction against each other. One part remains stationary, while the other rotates, which allows the parts to connect with each other.

This method is quite new. And, perhaps, not all specialists or amateur welders had time to get acquainted with such welding technology. Therefore, we will read the principles of its operation, advantages, disadvantages, parameters, features and varieties of this method in more detail.

In this article we will look at:

1. How Friction Stir Welding (FSW)works?
2. What types of technology exist?
3. What are the advantages and disadvantages of friction welding?

 

Application and types of Friction Stir Welding (FSW)

Generally, friction welding is commonly applicable in the following operations:

• compounds of metals and alloys with a melting point of up to 1800 degrees
• welding flat parts of the same thickness at a turned angle
• longitudinal pipe welding
• making bolts
• Replacing soldering of small parts with machined surfaces.

Friction welding is suitable for joining contaminated parts, since it does not require their preliminary cleaning. Moreover, we remove the oxide film and grease at the beginning of mutual friction of the surfaces.
There are the following main types of friction welding:

1. oscillatory (linear)
2. with stirring, with continuous drive
3. radial
4. orbital, inertial

Advantages and disadvantages of the method

The advantages of Friction Stir Welding (FSW) are:

• lower energy consumption compared to other types of welding
• Moreover, a small number of defects
• uniform structure of the weld
• the ability to accurately control the process
• Small amount of harmful emissions
• Hence, high metal utilization rate
• The ability to automate the process.

1. Low requirements for surface cleanliness. There is no need to clean the surface of the parts to be welded. The side surfaces may also be uncleaned. Similarly, this significantly saves time spent on auxiliary operations.
2. Possibility of welding various metals. The welding process allows welding both alloys and metals of the same name and dissimilar alloys. Furthermore, other welding methods are useless here. For example, it is possible to weld steel to aluminum, copper; aluminum with copper, titanium and so on.
3. Hygienic process. The welding process compares favorably with the absence of ultraviolet radiation.

Disadvantages of the Friction Stir Welding (FSW):

• Friction Stir Welding (FSW) giveslimited applicability
• bulky equipment
• Limited connection surface.

Friction welding, principle and features:

Friction welding is a type of pressure welding in which heating goes out by friction caused by the rotation of the welded product.

Due to the emerging frictional forces at the points of contact, a very rapid heating and transition of the material into a plastic state occurs.

Thus, friction welding goes by a process in which mechanical energy supplied to one of the parts to be welded is converted into heat.

Friction welding is a process that converts the mechanical energy of the movement of one of the parts into heat energy. Rotation is the most common method for this. Similarly, either one of the parts or an insert between them can rotate. At the same time, the parts presses against each other by constant or increasing pressure. In this case, heating occurs directly at the junction of the parts.

How does Friction Stir Welding (FSW) work?
Friction Stir Welding (FSW) process is not so simple. After the completion of the welding process, upsetting occurs and the rotation stops quickly.

In the welding zone at the joints of the parts, the following processes take place: with an increase in the rotation frequency of the workpieces and the effect of compressive pressure, the contact surfaces rub against each other.

Similarly, fatty and contact films present on parts in their original state are destroyed. After which the boundary friction comes by dry friction. Hence, individual micro protrusions begin to contact each other and deform.

Juvenile areas form, where the bonds of surface atoms do not saturate. Moreover, metal bonds immediately appear between them. In addition, they immediately destroy due to the relative movement of the surfaces.

Principles of using friction stir welding for joints

This process means that one does during its rotation. Moreover, it will create thermal energy, as a result of which the materials combines with each other.

But not only one of the parts can rotate, but also a special tool for friction stir welding in the form of an insert. In addition, it also contributes to a high-quality connection of parts.

Friction welding: technology features

 

Friction welding is a subtype of pressure welding. The technology involves heating the parts to be welded using friction. For this, one of them moves (rotates), while welding with the other.

Application area of Friction Stir Welding (FSW)

Friction Stir Welding (FSW) is most widely applicable in mechanical engineering, primarily in tool production. It is also common in the assembly of internals of nuclear reactors. Friction bonding of aluminum and magnesium alloy workpieces is popular in:

• electrical engineering
• electronics and
• aerospace

The technology is also common in transport engineering. The radial method is famous in the production of equipment for the mining and processing industries.

Conclusion

More recently, Friction Stir Welding (FSW) has begun its journey in shipbuilding and food processing engineering.

We have covered such a process as friction welding. As you can see, this welding process is different from others, and has many advantages. However, it is quite specific and not suitable for all tasks. Nevertheless, in many cases its use is justified.

 

The technology demonstrates efficiency and a tendency to replace traditional welding methods in such areas as:

• to replace soldered and riveted joints;
• Replace contact electric welding;
• to restore products and complex tools;
• for welding workpieces to prepared surfaces

How aluminum is helpful to create automotive parts?

Today Aluminum is considered one of the best alloys to use in metal stamping. And Aluminum Stamping is getting utmost popularity for its outstanding reasons. Basically, aluminum is an ideal metal to use because of its durability. Moreover, it is extremely light weight.

Hence, because of these fantastic benefits, aluminum has ability to transport the energy to the very long distances. Aluminum is really cost efficient. Moreover, it is best for getting maximum items with great accuracy.

So, it will be an ideal and flawless choice for your bulk productions. Let’s check out 5 amazing reasons to choose aluminum in metal stamping. And also check some additional benefits of Aluminum Stamping in automotive industry.

What is Metal Stamping?

Basically, stamping is a special technique which manufacturers use to form their required shapes. There are various materials which manufacturers use to form their specific shapes. However, metals have most beneficial advantages in comparison to any other material.

Hence, the process of stamping by using metals is called metal stamping.

Types of metals to use in Metal Stamping

There are various kinds of metals to use in metal stamping. All of them have their own benefits. Each type of metal has different strength and unique properties. So, it is very important for you to choose the best metal for your special needs.

Furthermore, all types of metals are good and beneficial. But it totally depends on you to select the right one for your requirements. Here are some most common and advantageous types of metals.

For example:

• Aluminum
• Stainless-steel
• Copper
• Brass
• Nickel and many more.

What is Aluminum Stamping?

Aluminum Stamping is actually metal stamping in which manufacturers use aluminum alloy. Moreover, aluminum is extremely suitable in stamping because it is very strong kind of alloy. Additionally, it has great workability as well as has extreme strength.

Aluminum not only allows to produce quality products but there is low chance to occur any weakness in your production. Nowadays you can easily notice the components which have stamped by aluminum in your daily routine. Most popular uses of aluminum include,

• automotive
• medical
• aerospace
• marine
• electronics and many more industries which depend on Aluminum Stamping.

Aluminum components are ideal to use because they are low in weight. So, they are best option to use in automotive industry where low weight parts are necessary elements.

6 types of elements which manufacturers add in pure aluminum

In fact, manufacturers use 6 other important elements in the pure aluminum to get best aluminum parts. These 6 elements have ability to increase the essential properties of aluminum. Moreover, these elements are also helpful to improve the actual strength of aluminum.

Basically, manufacturers add them only 15% of the total weight of aluminum. They have to use in a very small quantity but are essential for greater performance.

However, these 6 important elements are:

1. Iron
2. Copper
3. Silicon
4. Zinc
5. Magnesium

5 wonderful reasons to use aluminum in Aluminum Stamping

Today aluminum alloy has become one of the most popular metals in all over the world in Aluminum Stamping. Aluminum becomes ideally flexible when it has processed in metal stamping. With the help of stamping you can create complex geometrical shapes of aluminum.

If we compare aluminum with steel, we find that it is more costly. But in spite of the cost aluminum is much light in weight. Moreover, it is natural corrosion resistance and its products have long life span.

Actually, aluminum becomes more flexible during the special process of stamping. Hence, in metal stamping you can form greatly complex geometrical shapes of aluminum products.

In addition, here are 5 amazing reasons to use aluminum in Aluminum Stamping.

1. Greatest Strength Even in Low Temperature:

Aluminum alloy has not to face the problems like brittle cracking. It is greatly strong in very low temperatures. For example, when the environment's temperature reduces, it cannot leave bad effect on the aluminum products.

In fact, in low temperature, aluminum has ability to maximize its strength. The change in temperature can’t leave bad effects on the aluminum parts. Hence, aluminum components are highly suitable for low temperature.

2. Highly Resistant to Corrosion:

One of the best qualities of aluminum alloy is that it is highly corrosion resistant. Basically, it can generate a natural protective layer. Hence, when the aluminum objects come in the oxidizing environment this protective layer truly save it.

Actually, this protective layer has capability to save the Aluminum Stamping products' surface from corrosion. When you paint your aluminum objects, their corrosion resistance ability further improves.

3. Great Conductivity for Thermal and Electricity:

Aluminum products actually have great conductivity for thermal and electricity. In fact, it is less conductive in comparison to copper. For example, it is only 60% conductive like copper. Aluminum alloy is best metal for the power transmission lines.

Moreover, it also has extreme conductivity for heat. And aluminum has got great popularity to use for heatsinks in several applications. Such as,

electronic devices

LED lights

computer motherboards and much more.

4. Extremely Flexible and Greatly Workable:

The ideal metal of Aluminum is highly flexible. Aluminum Stamping makes it more elastic in comparison to steel alloy. So, because of this great flexibility you can create even more complex shapes much easily. Moreover, aluminum has great workable quality than any other metal.

5. Incredibly Lightweight:

Aluminum is actually much lower in weight in comparison to several other metals. Basically, its fixed weight is almost 2.71 g/cm3. This great feature makes it cheaper than any other popular metal, like steel.

So, all these great characteristics of aluminum like,

• corrosion resistant
• very easy in order to create products
• naturally low in weight, etc.

makes it ideal to use in automotive industry.

Why Aluminum Stamping consider ideal in automotive industry?

Aluminum Stamping components has become the world's first choice for their natural properties. All of its good features have essentially needed in automotive industry. Since, aluminum is lightweight and corrosion resistant, so it is ideal to make parts for automobile sector.

Aluminum metal has ability to increase performance. This special alloy can generally improve fuel economy of auto industry. In spite of all these, it is really strong and durable metal. Among all other metals steel and aluminum are popular to use in motor vehicles.

Nowadays, by using aluminum, manufacturers are rapidly introducing most efficient vehicles. Furthermore, its great features have made it the world's second most famous metal in car industry.

So, all in all Aluminum Stamping can provide you,

• Safer and strong
• Greatly energy effective
• Corrosion resistant

auto parts. Moreover, aluminum metal can easily provide you smooth and shiny excellent finish for latest models of auto vehicles. Aluminum has perfect weldability and remarkable strength. Hence all these amazing advantages make this metal ideal for automotive industry.

  Important applications of Aluminum Stamping

When we talk about radiant energy, aluminum is incredibly reflective. In fact, its perfect quality of nonmagnetic make it highly suitable to use in all industries.

Hence some important applications of aluminum metals are:

For Construction:

• doors
• windows
• building wires
• siding, etc.

Electronics devices:

• CPUs
• fin stock
• transistors and many more.

Aluminum Stamping for Transportation:

1. Automotive
2. Trucks

• Railroad cars

1. Aircrafts
2. Marine vessels
3. Bicycles

Cooking utensils:

• Mixers
• Mixing pots
• Pots
• Blender parts
• All residential parts
• In whole equipment which manufacturers use in food and beverage processing.

Conclusion:

All in all, aluminum has great properties than many other metals which manufacturers use in metal stamping. Moreover, it is best for,

• Treating of heat ability
• Great level of weldability
• Strength
• Corrosion resistant
• Cost effective and so on.

So, choosing aluminum for your bulk productions will be your great and beneficial decision.

Because aluminum stamping is a wise choice for several mass projects.

How stainless-steel is best metal to use in metal stamping?

Nowadays we can see the different objects that have created with the help of Stainless-Steel Stamping. From our household items to industrial goods there are hundreds of kinds of objects which manufacturers are creating using stamping.

Although all materials have their specific features but stainless steel is best among all the other metals and materials. Moreover, Stainless-Steel Stamping has become the world’s best technique from small gauge components to large and heavy products.

Additionally, stainless steel has extremely great features and provides precision parts whether they are complex or simple. Let’s have a deep look about the stamping and its benefits while using the metal of stainless steel.

What is stamping?

Stamping is actually the process of creating the products of different materials. This is also known as pressing. Basically, it is the process of putting the flat or plane sheets of specific materials inside a stamping press. In this stamping press these special materials have shaped into particular designs.

So, stamping is the process of forming some particular shapes of different materials according to your needs and demands. Although manufacturers most commonly use metals but there are also different kinds of materials which have used in stamping. For example, polystyrene.

However, metal stamping has got popularity among all the other materials because of their fascinating benefits.

What is metal stamping? Stainless-Steel Stamping

Metal stamping is the same process of manufacturing different shapes by using the metal with the help of stamping. Basically, it is a complicated process which has included several types of metal techniques. Furthermore, these complex forming techniques are,

 

• Bending
• Blanking
• Piercing

Stainless-Steel Stamping is actually the famous type of metal stamping. However, there are several types of materials which have used in metal stamping.

5 most common metals which have used in metal stampings?

Although there are numerous metals which manufacturers are using in stamping machines to create different items. And these 5 most common metals stampings are:

• Steel Stamping
• Aluminum Stamping
• Brass Stamping
• Polystyrene Stamping
• Automotive Stamping.

What is Stainless-Steel Stamping?

Basically, stainless steel is a unique alloy of steel. Moreover, by mass it has minimum of 10.5% chromium content. Today it has become one of the most beneficial alloys because it is corrosion resistant.

However, Stainless-Steel Stamping also has the additional advantage of staining resistance. Stainless steel has become manufacturers favorite metal due to its extremely good gloss. In addition, by using stainless steel manufacturers can get their required shape more easily.

In fact, it has a perfect hardness which is ideal to shape it in desired shaped. Additionally, the stainless-steel products have great durability and get less damage even in tough using. I think most of us did not know that actually there are different variations in the stainless-steel alloy.

However, the most common type which industrialists use to create adorable items is 300 Series Stainless Steel. It is one of the best and most popular kind of stainless-steel series. Furthermore, stainless steel of series 400 is also available which also has exceptional advantages.

But manufacturers are rapidly using 300 Series of steel alloy for its awesome advantages.

Why manufacturers prefer Stainless-Steel Stamping?

Most of the industrialists are preferring Stainless-Steel Stamping as it is corrosion resistant and highly low in weight. But despite of all these, stainless-steel has ideal strength. Moreover, it is,

• easily available
• extremely cost efficient.

In order to make it more versatile and fascinating manufacturers make use of,

• steel blanks
• coil-fed steel.

Industrial manufacturers are highly preferring to use those components which have created by using stainless steel metal stamping. Because these components provide,

• better corrosion resistance
• greater life span (almost 10 to 12 years).

Furthermore, the most beneficial alloy of stainless-steel also has ability to bear the following important treatments. Such as,

1. wire drawing
2. sandblasting

• coating

1. polishing
2. electrolytic polishing and so on.

In fact, stainless-steel have great strength to bear the high temperatures. It also has the rich layer of chromium oxide on its surface. So, it is extremely corrosion resistant.

3 popular types of steel used for Stainless-Steel Stamping

Basically, in Stainless-Steel Stamping, manufacturers use different types of stainless-steels. All of them are important and favorable for several different industries. Automotive manufacturers are rapidly using high grade stainless steel for high temperature components.

 

Generally, the amount of carbon in stainless-steel makes it enable for different industries. For example, the manufacturers which make surgical tools and pocket knives mostly use stainless-steel that has great amount of carbon.

The good features of carbon make it specific for several uses. Moreover, carbon makes it highly hardened even in high heating processes. However, there are three basic kinds of stainless-steels which manufacturers are successfully using in Stainless-Steel Stamping. For instance:

1. Ferritic
2. Austenitic

Ferritic:

It will not wrong to say that ferric grade is ideal for automotive components. In fact, in automotive industry, we need both

• heat resistant
• corrosion resistant.

Actually, ferritic grades do not have any amount of nickel. Additionally, these are magnetic and consists very decent formability.

Famous applications of ferritic:

• dryers
• dishwashers
• automobile exhaust systems and many more.

Special types are:

• 409
• 439

Austenitic

Austenitic grades have become one of the most popular type for their deep drawing quality. This type of stainless-steel actually consists of lower carbon. So, because of this good quality it is ideal for Stainless-Steel Stamping to create household items.

In fact, Austenitic steel has greatest moldability. Hence, it is the best in comparison to any other grades of stainless-steel. Furthermore, it has ideal amount of nickel, chromium and many other important alloys.

It is highly stretchable, so Austenitic is ideal to use for kitchen or home items.

Famous applications of Austenitic:

• household items
• deep fat fryers
• kitchen sinks
• several other deep formed components, etc.

Special types are:

• 304
• 304L
• And 316

Martensitic:

If we compare martensitic stainless-steel with the above two steel grades, we find that,

1. This is not highly suitable for stretching
2. It is not perfect to use for drawing purposes.

Moreover, it is extremely strong and much harder. It is fragile, hard and brittle. In spite of all these facts, it is harder to weld and transform in specific shape during Stainless-Steel Stamping.

Generally, martensitic is similar in many features to the above grades but it has great amounts of carbon. In fact, it is highly heat resistance.

Famous applications of Martensitic:

• tweezers
• pockets knives
• razor blades
• surgical tools
• plastic injection methods
• ball bearings and much more.

Special types are:

Its greatly popular kind is 420.

Conclusion:

We have tried to explain you the most beneficial uses of stainless-steel alloy in metal stamping. Furthermore, it has really advantageous features to use in residential accessories as well as in industrial equipment. Actually, stainless-steel is extremely useful in Stainless-Steel Stamping. 

Additionally, stainless-steel metal is

• corrosion resistant
• cost effective
• has great durability
• and has long life spans.

So, for ideal metal stamping, stainless-steel is highly reliable.

Revolutionary SLA 3D Printing and SLS 3D Printing Systems for The Win

Additive manufacturing is a phenomenal attestation to the swift evolution from analog to digital processes. Among the few renowned 3D printing technologies, SLA 3D Printing and SLS 3D Printing are eminent. SLA and SLS are two different techniques performing similar functions however concluding with different results.

3D printing has allowed medicine, manufacturing, education, agriculture and many more industries to revolutionize themselves.

At long last, all functional departments are applying 3D Printing. The journey of 3D printing has come a long way. 3D printing was once considered a mere fragment of the imagination is now visually representable. The whole process of printing is explained the same way it gets performed; a thin layer at a time.

SLA 3D Printing and SLS 3D Printing

Essentially additive manufacturing and 3D printing are umbrella terms, they include a variety of additive technologies. It is safe to assume that 3D printing is the way we will deal with hypothetical situation in the near future. Crafting structures out of thin air is an art we all have to become accustomed to.

Although 3D printing is not a novel innovation, its surge has occurred over the past few years. Boomers in question do not trust the innovative evolutions as much as the next generation do. This generation revels in technological shortcuts. In recent years’ 3D printing has invariably become more cost effective and accessible, diversity in technologies similar to SLA 3D Printing an SLS 3D printing has made this possible.

Advocates of 3D printing predict supremacy in regards to efficiency, time reduction, technique and much more. It is time to acknowledge 3D printing with all its glory intact. The digitally equipped future we once dreamt of is now within our grasp.

Embodiment of 3D Printing technology

There are numerous natures of 3D printing technology erupting all around. The layer by layer construction process of 3D printing is not confined to one technique. Since 3D printing has been around for a while, the phenomenon of it has been applied in different printing systems. Common 3D printing technologies comprise of:

1. Stereolithography (SLA)
2. Selective Laser Sintering (SLS)
3. Fused Deposition Modeling (FDM)
4. Polyjet
5. Multi Jet Fusion (MJT)
6. Electron Beam Melting (EBM)
7. Direct Metal Laser Sintering (DMLS)

Understandably every industry has to figure out which 3D printing technology is applicable for their requirement. Assessing the pros and cons of each technology narrows the choice down. Of the many printing technologies SLA 3D Printing and SLS 3D Printing are prominent in Polymer 3D printing processes. SLA and SLS are common printing techniques however DMLS and EBM are the forerunners in metal 3D printing processes. Polymer 3D printing in addition to its constituents is familiar and widely practical.

The Metamorphosing of SLA 3D Printing and SLS 3D Printing

Stereolithography (SLA) is a 3D Printing process applied abundantly. Similar to other additive manufacturing technologies, it uses light-reactive thermoset material (resin) as a raw material. SLA was the first industrially used 3D printing mechanism. The process breakdown of an SLA printer is fairly simple.

The first step in SLA 3D Printing is conforming a design. The design is the basis on which the whole model rests. Any CAD software is adequate to create a hypothetical design and the digital model is further divided in to layers. The instruction to print digital design layers is forwarded to the printing machine.

The real magic happens in the SLA Printing machine. The machine is able to complete the printing process without aid. Most of the SLA printing process relies on the printing machine itself.

As soon as the printing process is finished the final product needs isopropyl alcohol rinsing in order to eliminate any uncured resin. The printing does not end after exiting the printing machine. Exiting parts of SLA have to be polished and scanned for any errors. These parts can later be painted, primed or fashioned to perform any function.

Designers favor SLA Printed 3D parts largely because they have a smooth surface and that is the only factor most designers are concerned with. Engineers and manufacturers are only concerned with the theory of the parts.

SLA parts are watertight; this aids the engineers who are experimenting on fluids. SLA 3D printing is raging in the jewelry industry. Expert jewelers are using 3D prototypes to represent hard surface diamonds and jewels. Resin has the quality to imitate both soft and hard surfaces ranging from rubber to ceramics.

Selective Laser Sintering

Selective laser sintering (SLS) is yet again another type of additive manufacturing. It varies from SLA printing with regard to technique and procedure. SLS is a more representative form of printing suitable for industrial use.

Nylon based powders are solidified to formulate an object. Tiny particles are the starting point of the SLS printing process. The first step in this particular printing method is spreading a layer of the powder in the building chamber of an SLS machine. The following steps take place due to the ability of the SLS machine to fuse the particles together.

The SLS machine melts the powder in order to integrate it into a solidified structure. The machine heats the chamber below the melting point of the powder, this aids in tracing the model. The bed of infused particles supports the fused particles. Once a basic structure is established unmerged powder particles are coated on the top layer by layer.

So, now the final product is left to cool down in the printing machine and then removed from the printing station for inspection. The process thoroughly examines the SLS parts for any unseen excess powder or slips.

Both SLA and SLS parts have their own strengths. SLA parts are actively used in medical industries and microfluidics. On the other hand, SLS parts are used to prototype designs for mechanical purposes. The final parts are all set for use in businesses in need.

Deconstructing 3D Printing Machines

Since printing machines do most of the work in SLA 3D Printing and SLS 3D Printing, a formal deconstruction is in order. 3D Printing machines are not as expensive as they were once. Since it is possible to mass-produce the 3D printing machines, thus there has been a significant decrease in their cost.

An archetypal desktop SLA Printing machine is likely to have a UV laser, elevator, liquid photopolymer, XY Scanning mirror, and a sweeper. Therefore, an SLS Printing machine has the attributes corresponding to a basic oven. It consists of a laser power source, scanning mirror, part build chamber, powder bed, leveling roller, and a powder cartridge.

These machines are pawns in the whole process. A proper design is created before the printing takes place and human resource is required to bead blast the final products. Granting we rely on printing machinery, human participation is inclusive.

Taking a Leap in SLA 3D Printing technology

Low force stereolithography is the latest leap towards advancement in 3D Printing. SLA 3D printing has been around for a while, in the meantime, technological was moving towards greater development. These technological progressions have taken a toll on the existing SLA 3D Printing machines.

Low force printing reduces the tension on the surface of parts and sources of high print quality and a flawless exterior. A flexible tank and linear lighting help accomplish LFS 3D printing. The prerequisites for LFS are crucial, without them LFS printing would not bear the same results.

Low Force Stereolithography is still in the works moreover it satisfies the market pull more than the vintage SLA Printing machine. Providing a better finish in any 3D part is the goal every and any manufacturer is aiming towards.

SLA VS SLS- The simple explanation

SLA and SLS 3D printing systems are both efficient methods to assemble 3D products. They are reliant on laser technology. Laser technology is the mutual denominator in both processes. The end-product, machinery, material, size, and cost are the dividers.

Final Product:

SLA and SLS parts have their own distinct features. The difference in SLS and SLA parts is the direct outcome of the way manufacturers produce them. So, SLA parts have extensive details and smoothness.

Its parts have a level surface finish and tight tolerances. since SLA parts offer greater visual accuracy, thus the medial field favors them. SLS parts are not as visually appealing as SLA parts nonetheless they have a sturdier exterior.

Since SLA parts are brittle, thus you do not pair them with mechanics. SLS parts are able to handle hardcore operations. Both parts are valuable in their respective fields.

Material:

The high price factor for SLS Printing derives from its expensive raw material. Although the powders are expensive they are easy to use. The raw material for stereolithography printing is liquid resin. Liquid resin is not only highly dangerous to handle but also has worse post printing results. SLA parts are inspected more than SLS products after printing and that is more often than not a lengthy process.

Raw Materials contribute to the final expenses of the parts and machines. The powders used in SLS machines are expensive and that is why SLS machines are pricier than SLA machines. Resin is fairly common in industries that require it. It is not a rare item.

 Size:

SLA printers have a compact size; they are suitable for small scale purposes. Compared to an SLS printer, the size of a SLA printer is miniature. SLS printers are bulky and cover a larger surface area. SLS printers typically create larger models than SLA printers. It is understandable to have a larger build if the result is loftier.

A standard coffee machine has the same size as a standard SLA machine. Manufacturers use nano technology in order to make the technology inside the machines instead of thick wires.

Cost:

Although SLS and SLA 3D printing has become common, the cost of production is fairly high. Therefore, SLA 3D printing is functional on a larger scale and one of the foremost inventions in 3D Printing therefore its price falls below 500USD. SLS Printing machines exercise expensive materials with high transport costs. 5000USD per unit is the retailing price for SLS machines.

Large industries have the capability to bid for any price however small-scale businesses cannot benefit from this technology as of yet. The near future entails mass production for 3D printing machines, hopefully sinking the cost.

Technology:

The technology for SLS and SLA machines are alike. Lasers are mutually present in both machines however the presence of a rotating mirror is obstructive for SLA machines. The rotating mirror in a SLA printing machine reduces precision of the final part. SLS machines face the same problem yet the advanced system shelters for it.

Stronger laser power is the USP for SLS 3D printing machines. The strong laser power inarguably yields better results but then again it is dangerous to handle. Asserting caution with the machine is necessary for any inexperienced personnel.

Final Verdict

The decision power to choose the best 3D Printing machine solely resides with the buyers. To put it simply financial partiality, workspace, and nature of business have an impact on choosing a 3D printer. Therefore, smaller businesses with smaller spending capacity resolve to buy an SLA machine. SLA machines are affordable and give decent results.

Industries looking for unchallenged technology are not reluctant to purchase expensive equipment, they find themselves interested in SLS machines. So, they use high-quality material to manufacturer the parts of SLS, this fact separates them from other parts. SLS machines can forge intricate geometrical shapes that only exist in theory.

Additive manufacturing provides durable prototypes and long-lasting 3D parts at a norm. Thus, this technology has surpassed others in the matter of versatility and throughput. The supremacy of 3D Printing in fashioning exceptional structures remains unmatched.

Being the leaders in the Printing Industry, we can assure you that we provide top-notch quality manufacturing services. We ensure the highest industry standards as we firmly believe in having a long-term, healthy relationship with our consumers.

For further assistance regarding SLA 3D Printing and SLS 3D Printing, have a look at our website now.  You can contact our customer service and they will guide you in the best possible way.

Learn About The Concept of PEM Assembly

PEM Assembly technology offers a breakthrough. Well as we all know there is a worldwide concern for the protection and well-being of planet Earth. Climate change is no longer a threat but actually has become an evident reality. Consequently, research has lead to finding an adequate replacement of fossil fuel energy through alternative energy sources.

Proton Exchange Membrane technology happens to be one of the most promising discoveries of the 21st century.  It has helped scientists to opt for Fuel cells instead of the traditional energy source. Fuel cells are highly efficient, climate-friendly, and have low maintenance costs as well.

Although Fuel cells have gained much-required attention it is not the only use of PEM. In fact, the PEM Assembly is vital in a range of application areas such as water purification and gas separation.

PEM technology-A break through

PEM Assembly Functionality

Before we appreciate the PEM applications it is essential that we understand how the PEM functions. The Proton Exchange Membrane happens to be a semi-permeable membrane. It is usually polymer in nature but we can also come across composite membranes as well.

The PEM Assembly is maneuvered in such a magnificent way that it allows only protons to be conducted. However, at the very same time, it also acts as an electronic insulator.

This happens to be the beauty and essence of the membrane and that is why you can use it in Fuel cells and other applications. It simply separates the reactants and the transport of protons. Also, at the very same time, the PEM blocks a direct pathway through the membrane.

You categorize the PEM membranes essentially through their proton conductivity, methanol permeability, and thermal stability.

So, now that you understand how a PEM works let us move on to its applications.

PEM Fuel Cell

Fuel is one of the most popular and widely used applications of PEM. The membranes used in the Fuel cell have high chemical stability and act as an electrolyte as well as a separator. The separation of gases is very important as it the basic ground upon which the fuel cell works.  The PEM very beautifully transports protons from the anode to the cathode and at the very same time ensures insulation.

PEMFC has out beaten solid oxide fuel cells. PEMFC’s operate at a much lower temperature and are lighter and compact in nature. This makes them an excellent source of fuel car cells.

Main Reaction in the PEMFC

Let us take a look at the main reaction taking place in a PEM Assembly fuel cell. The PEMFC uses hydrogen as its fuel. However, hydrogen oxidation by air is not the only available source. Thus, you have other options such as methanol and formic. The choice of fuel actually depends on the medium material.

Below helps us understand the PEMFC further. The PEMFC has a polymer membrane that is quite flexible in nature. The electrolyte thickness varies from 15 mm to 180mm.

Chemical Reaction in the Fuel Cell

You introduce hydrogen through the anode compartment and air goes through the opposite cathode compartment.

Both of the specific gases go through a gas diffusion layer with the help of diffusion and convection. Therefore, The gas diffusion layer is highly important in the fuel cell as it enables the reactant to be delivered and remove the actual product from the electrodes. It also makes sure that the heat transfer made through the gases is sufficient and low resistance is incurred.

Moving on from the GDL the gases then make their way to the PEM. The PEM has been coated with a catalyst most often Pt is used. At the anode, the hydrogen molecule is caused to split forcing the electron to flow out. The PEM is a semi-permeable polymer membrane which only allows the positive ions to be conducted to the cathode.

The electrons which have been previously split at the anode rejoin at the cathode producing heat and water. The water makes its way out of the cathode along with excess nitrogen and oxygen.

The water usually produced may cause flooding and may impact the reactant transportation.  This is why it is ensured that the temperature of the Fuel cell does not go beyond 80 degrees Celsius.

Anode reaction:

2H₂ → 4H⁺ + 4e⁻

Cathode reaction:

O₂ + 4H⁺ + 4e⁻ → 2H₂O

Overall cell reaction:

2H₂ + O₂ → 2H₂O + heat + electrical energy

The energy obtained from the reaction is 1.23 V

Analyzing the Fuel Cell

Let us briefly analyze the PEMFC. Some of the advantages of the PEMFC are as follows.

• High efficiency
• Highly reliable
• There is a great decrease in Noise Pollution
• Environment friendly-A great alternative to fossil fuels
• Compact size

Disadvantages of the Fuel Cell

• High Production Cost
• Infrastructure not available to manage hydrogen
• Technology still in the prototype stage
• Hydrogen is yet hard to produce
• High sensitivity

PEM Assembly in Electrolysis

We also use Polymer electrolyte membranes in the process of electrolysis. PEM water electrolysis is an intricate process we will explain further. Although there are other ways for hydrogen extraction PEM electrolysis happens to be the most promising. It has a higher productivity and efficiency rate along with a compact design.

The design of The PEM Electrolyzer manages to overcome the problems that take place during a typical alkaline electrolyzer. It helps magnificently in the areas of partial load and hydrogen density. It provides fast dynamic response times and facilitates high gas purities.

You can use the hydrogen that you obtain from PEM electrolysis in hydrogen fueling stations as well as household units. PEM electrolysis actually helps to increase the operating pressure at which you store the hydrogen in vessels. Thus, this prospect is mind-blowing for stationary systems that have a relatively small power capacity.

Most interestingly PEM electrolysis provides hydrogen that can also use form biogas or flue gases which are excellent sources of renewable energy.

The biggest advantage of PEM electrolysis is its ability to perform at high densities.

The Fundamentals of PEM Electrolysis

The whole process is endothermic and so electricity is applied as the energy source. The PEM electrolysis is very much similar to the PEM fuel cell. The PEM works with a very thin membrane measuring about 2mm in thickness. Due to its solid structure, there is a low gas crossover that enables high products of gas purity.

Reactions

The reaction that takes place at the anode is popular by the name Oxygen Evolution Reaction.

Anode Reaction

At the anode, oxidize the water to produce oxygen, electrons, and protons. Then transfer the protons over the PEM so that you can reduce them to hydrogen. The catalyst typically used for this reaction is iridium. It is popular due to its anti-corrosive properties.

Cathode Reaction

Hydrogen Evolution Reaction is the name of the reaction that takes place here. The cathode reaction is very similar to the PEM Fuel cell. Manufacturers use a Piece of carbon paper to make the gas diffusion layer.

So, to conduct the protons, you use the membrane to produce hydrogen. The figure below will give you a better insight as to the reactions occurring at the cathode and anode.

 

Efficiency

To measure the efficiency of PEM electrolysis, use the higher heat value. Thus, the temperature for operation in PEM Electrolysis is 80 degrees Celsius. Therefore it is possible to redirect the waste heat to make the steam. This increases efficiency immensely.

The calculated value of efficiency for PEM electrolysis is 80 percent.  This has been calculated in terms of the hydrogen produced as per the unit of electricity required for the reaction.  We anticipate that efficiency will increase with the passage of time.

PEM Assembly Producers

PEM assembly is a much-sought process and currently there are many producers. It is essential that a good PEM has good proton conductivity, mechanical durability, and high efficiency. Nafion is the first PEM that fell in line with all the requirements.

There are many other companies which are producing PEM but most of them are based on the Nafion polymer structure. To ensure that the chemical and thermal stability is optimum, use the Carbon-fluorine resin.  So, Nafion makes use of the sulfonic group which in case of water absorption can make good mobility.

Recently research has to lead to reduce the poisoning of methanol on the platinum catalyst. This can only be done if an original PEM  is used or by doping the polymer to reduce the swelling of the Nafion.

Conclusion of PEM Assembly

Proton Exchange Membrane technology is an outstanding breakthrough in the modern world scenario. It has become essential for future climate-friendly and efficient devices. Below we will be giving you a comprehensive introduction to the fascinating PEM Assembly methodology used in applications.

This was a brief introduction to the PEM Assembly and its incredible uses. Hopefully, you have a better insight. We offer a wide range of PEM services. To learn more about our services, we recommend you reach out to us.

Our learned staff would provide you with all the information. They would ensure that you are able to find the best product.