While each method is useful in their own ways, our team suggests injection molding services when the customer requires the following:
Large Part Quantities
While compression and transfer molding have their benefits, injection molding comes out on top when it comes to high-volume production.
In our efforts to increase efficiency at all times, MTI decided to add injection molding equipment which allows for more automation and significantly faster cycle times. We also have the ability to increase part density in our tooling and exponentially increase our quantity throughput per cycle. By molding multiple parts per cycle, injection molding maximizes efficiency, making it ideal for projects that require tens of thousands of parts annually.
Second-to-None Precision and Consistency
Injection molding paired with highly engineered and accurately produced tooling delivers precision and consistency. Automated processes ensure that each part meets exact specifications, resulting in uniform dimensions and properties. This level of precision is crucial for industries where consistency is non-negotiable.
Minimal Secondary Processing
Another benefit of injection molding is the potential for minimizing secondary operations. By designing molds effectively, unnecessary trimming and finishing processes can be eliminated, streamlining production and reducing overall costs. This efficiency is particularly valuable for projects with strict budgetary constraints.
Reduced Lead Times
Injection molding offers significantly faster cycle times, making it the preferred choice for mass production. This rapid turnaround ensures that parts are delivered promptly, meeting tight project deadlines and minimizing downtime.
How Micro-Tronics Handles the Design and Production of Mold Tooling
For customers tackling new projects, MTI offers comprehensive mold design and manufacturing services. Our engineering team has decades of elastomer tooling design and production experience. We make sure to take everything into consideration including:
Material properties: shrinkage, curing behavior, and flow properties are taken into account
Part Geometries: complex geometries may require special considerations like draft angles for easy part removal, uniform wall thickness and properly designed venting for air escape
Parting lines and ejector placement: the placement of parting lines and ejectors may have requirements from the customer. We ensure to design around these requirements to ensure the final part has the desired appearance and functionality.
Tolerances and surface finish: Tight tolerances must be maintained and the mold surface finish should align with the required final part finish callouts. We utilize our in-house tooling department to ensure our tooling is up to the task.
Whether it’s a simple or intricate design, we ensure that the resulting mold meets the highest standards of quality and precision.
Efficient, Quality Injection Molding Services from Micro-Tronics
Injection molding services at Micro-Tronics provide top-quality custom-molded elastomer components for customers across a range of industries. Here are some of the main value-adds of working with MTI for your elastomer molding processes:
Material Selection
In our elastomer injection molding services, we handle a range of materials, offering flexibility and resilience for a wide range of applications. These include:
natural rubber (NR)
silicone (Q)
nitrile butadiene rubber (NBR)
ethylene propylene diene monomer rubber (EPDM)
styrene butadiene rubber (SBR)
fluorinated hydrocarbon (FKM)
polychloroprene (CR)
butyl rubber (IIR)
Precision and Efficiency
Elastomer injection molding allows for precise control over material usage, minimizing waste and therefore reducing customer costs.
Consistency and Reliability
Due to a highly automated manufacturing process we can ensure uniformity and reliability across the entire production run. This consistency is essential for industries where product quality and performance are critical.
Streamlined Production
By minimizing secondary operations and optimizing production processes, injection molding offers exceptional efficiency and cost-effectiveness. Shorter lead times, reduced waste, and lower production costs translate to significant savings for our customers, making injection molding the preferred choice for high-volume manufacturing projects.
At Micro-Tronics, we’re committed to delivering exceptional results through our elastomer injection molding services. With state-of-the-art equipment, a team of experienced professionals, and a dedication to quality and innovation, we serve as your trusted supplier for all custom molded elastomer products.
Contact us to learn more about our comprehensive injection molding services, or request a quote to get started.
At Micro-Tronics, we feel the need to debunk a serious misconception about our industry. When people think of manufacturing, they often imagine dark, dirty, dingy facilities with outdated, paper-based processes and antiquated machinery.
This is a far cry from what we are at MTI, and we’re eager to rewrite that narrative. We’re committed to modernizing our business and processes at every turn, ensuring that when customers entrust us with their projects, they’re met with efficiency, precision, and reliability.
OEMs increasingly seek partners who invest in themselves, coordinate and streamline processes, embrace efficiency, and leverage cutting-edge tools and technology. At MTI, we’ve embodied this forward-thinking approach and, in turn, have provided the following benefits:
Shorter lead times
Better pricing
Exceptional quality
On-time delivery
Let’s explore some of the systems we’ve implemented to streamline production at MTI.
New Product Introduction (NPI)
The MTI team implemented this process to respond to a pain point: the difficulty of learning the idiosyncrasies of a new part. Getting new parts and acquainting ourselves with new specs, quality standards, special processes, and approved vendor lists can feel like learning a whole new language.
To better respond to new parts coming in, our engineering team developed an NPI system that automatically recognizes and flags new part numbers. This ensures new parts are included in our NPI process where we can identify potential issues, and develop a strategy for making the part in a quality, timely manner. MTI’s NPI process ensures seamless integration of new projects into our workflow. By identifying possible issues upfront and devising clear game plans, our team streamlines production and guarantees adherence to customer requirements.
Advanced Equipment
Since we utilize cutting-edge equipment, our customers feel confident that we’re handling parts efficiently and with exceptional lead times.
In addition, the MTI team leverages three robots in our facility that help us run lights-out. This leads to efficiency and lead time compression, as we can continue running the machines after our people clock out for the day.
Scheduling Solutions
With over 2,000 unique parts numbers shipped annually from the MTI team, scheduling is paramount to our operations. Our recent adoption of advanced scheduling software has transformed our approach, providing real-time visibility into job statuses, machine and people allocations, and deadlines. This proactive approach ensures that no project falls through the cracks and that customer deadlines are consistently met.
Custom Dashboards
In-house custom dashboards located in each functional area further enhance our operational efficiency at MTI. These dashboards pull data directly from our ERP system, offering machinists, operators, and supervisors instant insight into job progress and due dates, allowing for swift adjustments as needed.
These dashboards are updated every 60 seconds to ensure any changes from a customer are almost immediately shown to the shop floor so we can adjust on the fly.
Proactive Solutions for Custom Molded Elastomer Products
Whether it’s building our own custom dashboards, investing in the latest equipment and software, or implementing processes to respond agilely to pain points, Micro-Tronics is proactive in doing what it takes to streamline production and yield the best possible results for our customers.
Building a Career and a Community at Micro-Tronics
At MTI, we’re not only interested in pleasing our customers with our spectacular range of elastomer products, CNC & EDM machining, and assembly – we’re committed to producing a rewarding work environment for our employees.
Joining the Micro-Tronics team makes you more than just a number; it makes you an essential member of our talented team. We offer unique benefits and foster a positive work environment to ensure MTI is a rewarding and fulfilling workplace.
Let’s walk through life at Micro-Tronics so you can see for yourself what makes us a desirable place to work.
Employee-Centric Culture
We consider ourselves an “employee-centric culture,” prioritizing the needs of our team. We currently have a 92% retention rate and an average tenure of 8.35 years. These impressive statistics show that our employees feel valued and appreciated, creating a sense of loyalty and dedication unparalleled in the industry.
Wellness Benefits
At MTI, we believe in creating a workplace that promotes health and wellness. Our clean, safe, organized facility offers a welcoming environment where employees can thrive. With an onsite gym and monthly wellness events, including workout classes and scheduled morning walks, we prioritize our team members’ physical and mental well-being.
What’s more, MTI is currently the only manufacturer in the state of Arizona with a healthy workplace certification. We go above and beyond to ensure our teams’ health and happiness, as demonstrated by our Healthy Arizona Worksites Program gold certification.
MTI Rewards
To encourage our team to participate in our enriching wellness program, we’ve developed a rewards program that awards points for partaking in wellness activities. Our people use the MTI Rewards platform to log their participation in health and wellness events (both in and outside of work). Accumulated points earn them gift cards to some of their favorite retailers and restaurants, adding a new level of value to MTI’s wellness program.
Engagement and Recognition
We believe in open communication and transparency, not just for our customers but also for our internal personnel. Our monthly town hall meetings, accompanied by company-sponsored breakfasts, provide team members with insight into company performance, goals, and updates regarding upcoming events.
These meetings also offer us the perfect opportunity to present our quarterly Founder’s Award. This peer-nominated award celebrates people who have gone above and beyond in living out our core values. Team members have responded resoundingly positively to this recognition program, as it offers them a greater purpose in their day-to-day and an opportunity to support and uplift their peers.
Work-Life Balance
At Micro-Tronics, we understand the importance of work-life balance. That’s why we offer a four-day workweek (Monday through Thursday) that allows our employees to enjoy more time for themselves and their families. For individuals looking to earn extra income, we also offer the option to work Fridays when available.
It’s vital that our employees take time off to unwind so they can return to work refreshed and rejuvenated. MTI team members also have access to a generous Paid Time Off package. New employees begin with one week of PTO, with additional time earned as the employees accumulate time at the company.
Events
Micro-Tronics hosts various events to engage employees, such as:
Lunch and Learns
Team members can learn new skills in a collaborative, welcoming environment during our monthly Lunch and Learns. Our lessons range from healthy cooking classes to financial seminars on topics such as insurance that equip them with the knowledge they need to succeed in their everyday and economic lives.
Color for Cause
Every month, our people wear a color (or costume!) to bring awareness to a particular cause. It’s an excellent opportunity for our teams to unite to highlight a cause that matters to us. (Plus, those dressed up earn wellness points in their MTI Rewards account!)
Annual Founder’s Day Barbeque
Every November, MTI’s management team organizes a barbeque to celebrate our holiday, Founder’s Day. Founder’s Day is a day MTI honors and remembers its founders – John and Angie Marusiak who started the business in 1968. Everyone comes together over a delicious lunch of burgers, dogs, and all the fixings and spends quality time with their coworkers. Because some of our employees have collector cars, we even host a car show as part of the Founder’s Day festivities.
Professional Development
We’re committed to supporting our team members’ growth and development. That’s why we offer tuition reimbursement, training opportunities, and clear pathways for career advancement. It’s important to us to empower our people to reach their full potential and achieve their career goals.
Community Outreach
The Micro-Tronics team is actively involved in our community beyond the four walls of our shop. Our people participate in charity events, such as the Phoenix Heart Walk, to positively impact the world around us. We also host food/toy/water/back to school drives to support the economically disadvantaged in our local community.
At Micro-Tronics, we’re more than just a business; we’re a community where employees can thrive, grow, and make a difference. Join our team to experience our dynamic and welcoming workplace for yourself.
The Benefits of Collaborating with Micro-Tronics on Part Design
In precision machining, the road to success begins with part design.
Every engineering blueprint, including every specification and tolerance, must be carefully considered to ensure optimal and efficient production of parts. However, even the most well-optimized designs can benefit from input from manufacturers.
It’s not that we can’t meet challenging requirements. With advanced in-house capabilities like wire EDM, we can do just about anything. But if time and cost savings are your goal, we’ve found that 20% of the prints we receive could benefit from time and cost-saving design improvements. In one case, we provided design recommendations that had the potential to reduce a customer’s cost and lead time by an incredible 75%!
The Benefits of Early Engagement with Your Precision Machining Partner
Knowledge transfer is a crucial aspect of early engagement. Design engineers and manufacturers can exchange ideas and share expertise, leading to a more collaborative and informed approach to precision machining.
Engaging with Micro-Tronics in the design phase offers two main advantages:
Optimized designs that are faster and more cost-effective to manufacture
Insights about new materials, technologies, or manufacturing methods
When customers take advantage of early engagement, they can avoid issues like missed deadlines and budget overruns.
The Importance of Partnership in Precision Machining
At Micro-Tronics, we believe in forming true partnerships with our customers. Our approach goes beyond building a transactional relationship—instead, we actively engage in detailed discussions with our customers to address potential challenges related to tolerances, material specifications, preferred suppliers, and more.
This level of collaboration accelerates the manufacturing process and eliminates common errors, assuring the optimal and efficient production of parts.
Customers who actively participate in the design process with us typically achieve a more streamlined production experience and receive higher-quality parts delivered in a cost-effective manner.
How Micro-Tronics Saves Customers Money
When collaborating with Micro-Tronics on part design, there are two common areas where costs can be reduced.
Adjusting things like tolerances can have a significant impact on both time and cost savings. By identifying areas where tolerances can be optimized without compromising the integrity of the final product, Micro-Tronics can produce parts more efficiently and cost-effectively.
Micro-Tronics’ Collaborative Process
Our team excels at manufacturing parts, but we aren’t design engineering experts. The best results occur when customers design the part and then consult with us to ensure that the part is manufacturable. This approach leverages the strengths of both parties and results in a seamless transition from design to manufacturing.
Our commitment to true partnerships and active collaboration sets the stage for manufacturing success that goes beyond mere execution, ensuring every component’s design is optimized for the highest quality and efficiency.
4 Reasons to Use EDM Services for Space Components
Once considered a niche capability, EDM, or Electrical Discharge Machining, is now a mainstay in the aerospace and space industries manufacturing world.
EDM is a highly precise technique that uses an electrical discharge from an electrode to quickly and accurately remove material from any electrically conductive material (the workpiece).
In recent years, Micro-Tronics has expanded into the space industry to work with a variety of customers. We’ve used our EDM services to manufacture small parts that fit on the tip of your finger to large thrust chambers for rocket engines.
When producing critical components like those used in space applications, manufacturing must be repeatable, controlled, and precise. No one understands this better than Micro-Tronics—that’s why we put our EDM services to use for space components.
Why Use EDM Services for Space Components?
Many factors come into play when determining if EDM is the best choice for a part. Here are four reasons you might choose EDM manufacturing for space components:
1. Low-volume, high-precision
Compared to commercial flights, which take off about 45,000 times per day, space missions are much less frequent, so space customers typically request low-volume orders. Like all aerospace applications, components must be exceptionally precise. It can be expensive to produce low volumes of precise components using traditional machining—but that isn’t always the case with EDM services.
Unlike CNC machining, EDM manufacturing can be cost-effective for small orders because tooling can be minimal and set up times are typically less. We can achieve the necessary precision for space components at low volumes while maintaining reasonable customer costs.
2.Complex geometries
EDM services are well-suited for machining complex geometries because of the unique nature of the machining process. Virtually any contour and varying tapers can be machined precisely via either Wire EDM or Sinker EDM. Extremely thin sections can also be machined because the electrode never contacts the workpiece. Non-contact material removal eliminates cutting stress and mechanical distortion.
We can easily cut precision keyways, hexes, internal splines, shaft pockets and slots, and other special shapes without the need to make custom (expensive and long lead time) broaches.
The cuts are also burr-free because of the non-contact process.
3. Material versatility
Space components often require exotic, unusual alloys to withstand the extreme demands of space. Machining Inconel, a common material for space applications, using traditional CNC machining is especially difficult due to the material’s high work hardening rate, high cutting forces, and tendency to generate a lot of heat during machining.
Fortunately, those factors are irrelevant when using EDM because the process removes material using electrical sparks instead of cutting tools. There is no need to worry about tool wear, chatter, work hardening, or other issues that can compromise the accuracy and precision of a component during traditional machining operations.
4. Safety and precision
In the high-stakes world of space travel, safety is the first priority. Precise components are essential to ensuring everything from rocket engines to control surfaces function properly.
EDM manufacturing is an excellent choice for space components due to its extreme precision. We can reliably achieve tolerances of feature accuracies up to +/- .0001” using our EDM services.
Harness the Power of EDM Manufacturing with Micro-Tronics
As EDM manufacturing remains a critical manufacturing technology in the space industry, choose Micro-Tronics for your manufacturing needs. We’ve been perfecting our EDM services since 1968, so trust us when we say we’re ahead of the curve.
Micro-Tronics is proud to offer niche services like Kapton film molding from our ITAR Registered, ISO 9001:2015 and AS9100D-certified shop.
Kapton film molding refers to using heat and pressure to shape Kapton®, a thin polyamide film developed by Dupont, into customized 3D parts.
We use a proprietary process involving special tooling and molds (all manufactured in-house here at MTI!) to form the thin Kapton into precise shapes. We’ve fine-tuned this process over 30 years of experience with Kapton film molding to ensure the material isn’t damaged and its critical properties are preserved.
Kapton: Properties, Applications, and Types
Properties
Kapton polyimide film is suitable for a wide range of industries and applications due to its thermal, electrical, and mechanical properties. The material is an excellent electrical insulator. With remarkable temperature and chemical resistance, Kapton operates well in demanding environments.
Kapton has excellent temperature properties, as it has the highest UL94 flammability rating: V-0. Its temperature resistance allows for continuous service capabilities ranging from -452 degrees Fahrenheit to 464 degrees Fahrenheit (-269 degrees Celsius to 240 degrees Celsius) and intermittent service up to 752 degrees Fahrenheit (400 degrees Celsius). The materials’s exceptional chemical resistance prevents static buildup and discharge.
Applications
Kapton is commonly used in applications such as seals, pneumatic actuators, and bearings. The full list of applications is quite extensive, so feel free to reach out if you have questions about your application.
Types
At Micro-Tronics, we use Kapton HN, which is typically used for wire insulation, conductors, cables, motor windings, solenoids, transformers, and capacitors. While Kapton HN is our go-to, we can obtain the type of Kapton polyimide film you need for your part’s application.
Advantages of Working with Micro-Tronics for Kapton Film Molding
When you choose Micro-Tronics for Kapton film molding projects, you benefit from our specialized knowledge and experience working with Kapton, which distinguishes us in the manufacturing industry. We can develop tailored solutions to meet your specific requirements.
We’re also happy to offer high-volume production services, meaning we can easily handle larger orders right off the bat or help you scale your parts as needed.
Request a quote to work with us on your next Kapton film molding project.
Manufacturing supply chains continue to pose a challenge for companies across industries.
The good news is that supply chains are more stable now than at the height of the pandemic. The not-so-good news is that manufacturers still face difficulties sourcing materials and outside services as quickly as they once could.
Micro-Tronics has implemented a many-layered approach to mitigate the impact of supply chain issues and keep lead times to a minimum.
Minimizing the Impact of Manufacturing Supply Chain Issues
Micro-Tronics offers a competitive cycle time and is committed to delivering critical parts like bonded seals and elastomer products on time. We take our reputation for reliable delivery extremely seriously and do whatever it takes to uphold it.
Here’s a look at the supply chain safeguards Micro-Tronics has implemented in recent years.
1. Diversifying our sources
We maintain a network of multiple suppliers for raw materials and outside processes. If one supplier can’t fulfill an order, we have plenty of other suppliers we can contact.
2. Monitoring and grading our supply base
We continuously monitor the suppliers in our network and grade them monthly on delivery and quality metrics. By closely tracking these metrics, we gain real-time insights into the health of our supply chain and can swiftly address any potential issues before they escalate.
3. Maintaining consistent communication with suppliers
We keep open lines of communication with suppliers to avoid any surprises. For instance, if a supplier’s timeline changes, we’ll know in advance and react accordingly, possibly by placing an order earlier than usual.
4. Collaborating with customers
We work with customers collaboratively to understand their future needs so we can plan around anticipated challenges.
5. Building our material inventory
We are willing to build and maintain an inventory of materials that typically have long lead times so that we have those materials on hand for customers’ critical elastomer products and other projects.
6. Creating an in-house elastomer spec
We created our own in-house elastomer spec that meets the mechanical properties of aerospace material specifications (AMS). Controlling our elastomer spec enables us to strategically choose which materials we use and where we source them, which is extremely valuable if availability issues arise.
What Can Customers Do?
Customers often ask us if there are any steps they can take to minimize the impact of supply chain issues. Here are a couple of recommendations.
1. Consider material substitutions
Depending on your part’s application, you may have the opportunity to be flexible with your material selection. If your desired material is unavailable or difficult to source, are you open to using an alternative material with similar properties?
One of our customers clarifies on their blueprint which alternative materials are acceptable for their parts. This flexibility allows us to source their materials more strategically amid manufacturing supply chain challenges.
2. Transition from castings to hogouts
Lead times for castings are exceptionally long currently—upwards of a year in many cases. If you need a casting, consider transitioning to a hogout. We can precision machine hogouts in-house, saving you substantial time and money.
Micro-Tronics Is Committed to Customer Satisfaction
Micro-Tronics strives to be the precision manufacturer of choice for our customers. We attribute our decades of success to our commitment to continuously improving our workflows and systems, including our sourcing protocols.
When you partner with Micro-Tronics for elastomer products, EDM manufacturing, or one of our many other offerings, you partner with a company committed to quality products and customer satisfaction.
EDM Services for 3D Printed Parts Made from Specialty Alloys
3D printing technology is undoubtedly impressive. But it isn’t quite at the level of CNC machining when it comes to achieving tight tolerances and smooth surface finishes.
Therefore, 3D printed parts often require additional machining operations to meet all critical specifications. Many 3D printed parts also have support material that must be removed.
Typically, shops use CNC machining capabilities to perform these additional operations. But what happens when a material isn’t a good candidate for CNC machining?
Keep reading to learn why Micro-Tronics leverages our EDM services to finish 3D printed parts made from specialty alloys that are too tough to machine conventionally.
3D Printing Specialty Alloys
Many highly sensitive applications demand parts made from specialty alloys, like the hypersonic missiles one of our customers makes using a tungsten-rhenium alloy. Other examples of specialty alloys include:
Refractory (Molybdenum, Rhenium, C103)
Copper Alloys (GRCop-84 , GRCop-42)
Iron-Nickel base superalloy (NASA HR-1)
Aluminum Alloys (AlSi10Mg, AlSi12Mg, HRL-7A77, SiC reinforced AlSi10Mg,
3D printing has become a popular manufacturing method for parts made from specialty alloys for a couple of key reasons:
Intricate and unique features. 3D printing can achieve intricate features that are difficult or impossible to achieve with conventional CNC machining—especially when hard specialty alloys are involved.
Minimal material waste. Specialty alloys are expensive. As an additive manufacturing process, 3D printing wastes considerably less material than subtractive CNC machining processes, saving customers money.
Using EDM Services to Finish 3D Printed Parts Made from Specialty Alloys
Ask any CNC machinist about their experiences machining Inconel, rhenium, or other specialty alloys, and they’ll tell you stories about broken taps and cutting tools and how difficult it can be to machine traditionally.
EDM manufacturing is an excellent alternative to CNC machining when finishing 3D printed parts made from conductive specialty alloys for these primary reasons:
Non-contact process. The EDM manufacturing process is non-contact, meaning a) there are no tools to break, and b) we can cut through hard materials without the risk of mechanical stress or chatter.
Highly precise. EDM is highly precise and capable of achieving tight tolerances and smooth surfaces for precision parts like our customer’s missile/rocket parts.
Trust Micro-Tronics to Finish Your 3D Printed Parts
At Micro-Tronics, we have 50+ years of CNC machining and EDM manufacturing experience. We regularly machine various unusual alloys for our customers and have perfected our processes to deliver superior results every time.
If you could benefit from EDM services for your 3D printed parts, please don’t hesitate to reach out. Request a quote to work with us!
Custom Molded Rubber Products for the Oil and Gas Industry
High-performance custom molded rubber products play critical roles in oil and gas applications. Parts such as rubber valves and fabric reinforced diaphragms are often required for equipment that will be submerged deep underground. And these parts can be incredibly expensive一if not impossible一to maintain or replace.
At Micro-Tronics, we know that when it comes to such parts, “I think it’s going to work” simply won’t cut it. That’s why we’ve cultivated the expertise and capabilities to supply our oil and gas customers with parts they can count on.
Molding Top Materials for Oil and Gas Applications
Micro-Tronics has extensive experience molding elastomers that perform exceptionally well in long-term oil and gas applications. We can help you choose the best material for your design and price point. These materials include:
Nitriles
Hydrogenated nitriles
Fluoroelastomers
Neoprenes (occasionally)
Enhancing Our Injection Molding Services
To serve oil and gas customers effectively, a shop must have the requisite capabilities to produce high volumes of parts efficiently and consistently. Micro-Tronics recently enhanced our injection molding services, enabling us to fulfill high-volume orders for custom molded elastomer parts (between 10,000-20,000 per order).
Providing Supplemental EDM and CNC Machining Services
With our in-house EDM services and CNC Services, we can create valve stems and other metal mechanical components. We have the capabilities to machine variable flow adjustable valves and custom sealing rings tailored to the type of fluid, temperature, and pressure they will encounter.
Will your equipment process refined oil or crude oil? Purified natural gas or a mixture of gas and another substance? No matter your application, we can create an elastomer compound that promises exceptional performance and durability.
Micro-Tronics Is Your Full-Service Manufacturer for Oil and Gas Parts
When you need high-quality custom molded rubber parts that will meet your timeline and budget requirements, it’s beneficial to work with a single company like Micro-Tronics that can provide top-of-the-line elastomer molding services, machining, and EDM services.
If you choose a shop that only has machining capabilities and plans to outsource the other services, chances are they’ll send your parts to a vendor like us anyway一and you’ll pay a premium price. So why not bring your oil and gas projects to us in the first place and save valuable time and money? You’ll also benefit from better end results since just one shop will have full control of the manufacturing process.
Did you know we also do assembly work? In addition to manufacturing the components for your valves, we can assemble and ship completed parts to you. Depending on the volume needed, vendor-managed inventory may also be an option.
The Value of Collaboration during the Stage Gate Process
When manufacturing a new product, it is in your best interest to consult your manufacturing partner about your design early in the process. In these early-stage conversations, your manufacturing partner can identify potential issues and help you optimize your design for manufacturing to save you time and money in the long run.
The stage gate product development process is a model that allows product developers to track a products development and launch across different manufacturing stages. As the illustration demonstrates, the cost of changing your design steadily increases as you progress through the stage gate process and those changes become harder to implement.
To put it simply: modifying a design in the initial gates or final design stages is relatively easy and cost-effective; modifying a design in the fabrication, production, or final product stages is increasingly difficult and costly.
The Benefits of Design for Manufacturing Guidance
Design for manufacturing (DFM) is a practice that fosters design collaboration between engineers and manufacturers. Because Micro-Tronics is a build-to-print shop, customers often don’t enlist our services until the fabrication stage. But we encourage customers to seek our DFM guidance much earlier—specifically, in the design stages.
This collaboration is especially useful for Micro-Tronics customers because we specialize in two relatively niche manufacturing areas—elastomer products and EDM manufacturing—that aren’t as broadly understood among engineers as traditional machining methods. Whether you’re working on an initial design or modifying a final design, contact us! We welcome the opportunity to save you time and money with our team’s DFM expertise.
5 Key DFM Considerations for Early in the Stage Gate Process
Here are five key factors to consider early in the stage gate process to set your project up for manufacturing success.
1. Manufacturing process
First, consider the big picture: the process. What’s the best method for manufacturing your part? When you proactively think through your entire workflow before beginning any design work, you can optimize your design for fast and cost-effective manufacturing.
Cost is often the driving force in choosing a manufacturing process. But the cost per part can vary widely depending on certain factors. For example, if you only need a few parts, investing in custom tooling isn’t ideal; but if you need a high volume of parts, an initial investment in custom tooling could yield a lower overall cost per part.
Our team can help you think through these essential considerations.
2. Design
Once you’ve identified the optimal manufacturing process, it’s time to focus on your part’s design. What are the critical tolerances? Can you build a radius into the internal corners, or are square corners necessary? Will the part require finishing, and if so, which finishing process?
Your manufacturing partner can help you identify possible opportunities to simplify your design. For instance, you may find that machinable features will work just as well for your application as the more complex features you designed for EDM manufacturing.
3. Materials
Selecting the right material is vital to your part’s success. Does your desired material have the characteristics required by your part’s application (e.g., chemical resistance or flame protection)?
If you’re unsure which material is best for your needs, our material selection chartis a great place to start your research.
4. Environment
Will the part be used indoors or outdoors? Will it need to withstand extreme temperatures or exposure to salt water? Environmental factors can influence the material and finishing processes you select, so it’s important to consider these factors early in the stage gate process.
5. Testing
Finally, selecting the proper testing methods for your part prior to production is crucial. You must be confident that the test will reveal any points of weakness in your design. The last thing you want is to discover an undetected flaw during fabrication or production.
Case Study: Troubleshooting Fabrication Issues for a Customer
Recently, a customer brought in a failed part that had been supplied by another manufacturer. However, before fulfilling the customer’s request to produce the part at a high volume, we needed to understand what had gone wrong the first time.
We recommended starting with a prototype mold, so we could work through fabrication issues in a cost-effective manner before advancing to production with a costlier mold. The prototype mold cost $10,000, while the production mold would cost 4x that amount and take much longer to build.
Ultimately, we saved our customer time (3 months) and money with this approach. We prototyped the part in a few weeks. Application testing was done, and revealed the true cause of field issues being an improper bonding process by the original supplier. In addition, we proved the materials ability to support injection molding and hit the target price.
The key to successful manufacturing is open communication throughout the stage gate process. Use our materials and manufacturing engineering experience to reduce your product launch risk.
