MetalUrgency^sm

Contact Information
E-mailing RFQ’s & Attachments
Complete Data/File Transmittal
Feedback during Quoting Process
Delivery Guidelines for Quick Turn Order
Data Input
DFM Guidelines
Fabrication Tolerances
Typical Design/Documentation Problems
Plating and Painting Guidelines for Quick Turn Orders
Case Studies/Samples of our work

MetalUrgency^sm means Rapid Prototyping of Fabricated Sheet Metal

The MetalUrgency^sm service regularly supplies “Rapid Quick-Turn” prototype or short run sheet metal parts with compressed lead times in 5 business days or less with quoting in hours for single detail parts.

We do not limit this service to only the simplest parts.  The majority of our manufacturing from this “Cell” is fabrication of multiple parts, multiple part assemblies to include plating, painting and silk screening.

The shortest lead times and lowest costs are achieved with the input of 3D CAD data of a quality that optimizes the sheet metal fabrication process.  However we have in many cases worked with input a simple as “Napkin” sketches or other drawings that we process into usable manufacturing format.

Gain a competitive advantage through time compression; get your product to market sooner

Dedicated in-house services and equipment include:

• Sales-Engineering-Manufacturing Team
• Laser Cutting Technology
• CNC Punching/Turret Punch Press
• Press Brakes
• Hardware Insertion
• MIG, TIG and Spot Welding
• Powder and Liquid Coating
• Silk Screening

MetalUrgencysm  was established in January 2000 in response to requests from our customers to provide time critical sheet metal manufacturing services.

Unlike other Rapid Prototyping technologies which can create a “reasonable” facsimile from 100% customer data the fabrication of a sheet metal prototype requires the same processing as a production part.  The short lead times are accomplished by “Fast Tracking” the processes.

Simply the process lead times are shortened by a dedicated team of Engineers, Programmers and Manufacturing Technicians who manage projects to ensure minimum lag time between each process

MetalUrgency^sm  has delivered over 55,000 quality parts, with a 100% on time deliver since 2000

MetalUrgencysm Contact Information  

Alan Denny, Quick Turn Manager
adenny@amf1.com
562-596-4740 x136

Gary Sawyer, Vice President Business Development & Marketing
gsawyer@amf1.com
562-596-4740 x116

MetalUrgency Request for Quote

E-Mail all RFQ’s and Attachments to metalurgency@amf1.com

The type and quality of customer input is directly related to the amount of time required to engineer and program parts for fabrication.

If a quote is requested using a drawing submittal the type of input that will be submitted for manufacturing should be stated as is will be reflected in the quoted cost.  For example if a “PDF” drawing is submitted for quote and Solidworks native data will be supplied for manufacturing it should be noted.

If data received with an order is not of the type or quality referenced in the quotation Accurate Metal Fabricators reserves the right to re-quote before proceeding with the order.

It is assumed for purposes of quotation that data input for manufacturing will be consistent with RFQ input and is of a quality as described in “Guidelines” for Quick Turn Orders”.

Complete Data/File Transmittal

Many times “Assembly” files are transmitted that are incomplete.  This usually results in iterative transmission of missing files before the assembly file has all the references necessary to properly re-generate.  This process is inefficient and results in lost productivity for both the sending and receiving parties.

When transmitting CAD “Assemblies” please ensure that all references are included.  The process we suggest is to open the “Assembly” and save to a new directory using the “Find References” or similar command in your specific CAD Application.  Once this save is complete re-open the “Assembly” and verify that NO ERROR MESSAGES appear indicating that a “Reference” cannot be found.  If an error message appears copy the necessary references to the new directory and again verify completeness.  When complete compress the file (zip) and for transmittal.  File naming should include “Part Number” and “Revision”.

For example:

XYZ CO_206941-001_A

**Use of “nouns” for file names is problematic due to the number of files processed by Metalurgency

Feedback during Quoting Process

During the quoting process you will be contacted with any questions we have regarding producing your part(s).  If we feel there are issues regarding the manufacturability of the part(s) we will contact you regarding changes before continuing with the quote or producing the prototype part(s).  If issues are deemed minor they will be noted as exceptions on the quotation.

Delivery Guidelines for Quick Turn Orders

If you feel your situation almost fits within the rules, call a MetalUrgencysm salesperson (562-596-4740 x136) and we’ll see what we can do.

An “Order” is dependant upon a MetalUrgencysm Quotation

A confirmed order must be received by 9:00 AM PST on the day you order with the applicable quote referenced.  Orders received after that time will start on the next business day.

All orders will ship using customer specified shipping method and account supplied with purchase order

Scheduled delivery of orders will be confirmed at time of order.  Scheduled delivery is based upon the feature complexity, quality of data input, Quantity and finishing requirements.

The type and quality of customer input is directly related to the amount of time required to engineer and program parts for fabrication.

If a quote is requested using a submittal a drawing the type of input that will be submitted for manufacturing should be stated as is will be reflected in the quoted cost.

If data received with an order is not of the type or quality reference in the quotation Accurate Metal Fabricators reserves the right to re-quote before proceeding with the order.

MetalUrgencysm Data Input

3D Data with Drawings
The preference for parts and/or assembly data input is Native Pro/E or Solidworks.  Processing time/cost is directly related to the quality of the input.  Part data supplied as “Sheet Metal” that will generate a flat will typically yield the shortest delivery and a lower cost than data supplied in other formats.

• Pro/E (Native Format)
• SolidWorks (Native Format)
• Parasolids _xt
• IGES (International Graphics Exchange Standard)
• STEP (Standard for the Exchange of Product Model Data, ISO 10303)
• SAT (ACIS Industry Standard file format)

3D Data part files without Drawings
When submitting 3D CAD part data without drawings a separate instruction must be included defining material, finishing and other requirements.

2D Intelligent Drawings
2D drawing information can be used and is superior to non-intelligent drawings in that interrogation for missing dimensions can be accomplished.  As with any input the process will be optimized with complete information in the original submittal.  Drawings must be fully annotated.

• AutoCAD drawing file (*.DWG)
• Pro/E drawing file (*.DRW)
• CADKEY drawing file (*.PRT)
• DXF (Data Exchange Format) drawing file scale 1:1
• IGES (International Graphics Exchange Standard)
• Other exchange formats may be accommodated, inquire

Hard Copy Drawings (non-intelligent data)
Input in the form of Hard Copy Drawings is acceptable but is the least desirable.  With this type of input any missing information must be requested which can result in delays.   As with input in any form the process will be optimized if complete information on manufacturing requirements is in the original submittal.
Drawings should include the following:

• Complete Annotation
• Material Specifications (Material and specific alloy)
• Finishing Requirements (Plating, Painting, Silkscreen, Polish, Graining, etc)

SILKSCREEN DATA INPUT & SPECIFICATION

Data in put can be input in several forms.  Dependent upon the input form different costs and schedule will apply.

Input in the form of Corel Draw “.cdr” format or Adobe Illustrator “.ai” files will yield the best lead time and lower the cost of the service.  When sending these formats protect your “fonts” by converting fonts to “curves” or “protect fonts” as applicable to the application.

“Art Work” supplied in PDF or other non-intelligent 2D form will be converted in Corel Draw or Adobe Illustrator format before process film and screens.

All artwork must be 1:1 with “shoot to” targeted dimensions included.

These files should carry a Part or Document Number and Revision as part of the artwork

For silkscreen “Colors” other than Black use Pantone Matching System (PMS) color number for reference

DFM (Design for Manufacturability)

Designing for Manufacturability DOES NOT necessarily translate into a part design of the lowest manufactured cost.  Each part design should be reviewed for its “cost performance” as part of the overall assembly.
However, for purposes of understanding process cost implications the following design suggestions are offered.

• Minimize Processes and Feature Complexity
• Use no tapped holes
• Use no extruded holes
• Use clinch nuts and clinch studs
• Use self-locating techniques such as tabs and slots, Pop rivets and “Cleco Clamp” holes for aligning mating parts.
• Use slots for alignment of mating parts
• Length tolerances for rectangular slots, both round and square end, should be ± .02, or greater whenever possible.  Width tolerance should be ± .01.
• Eliminate need for secondary operations, such as reaming, by using standard hole sizes and tolerances.
• Specify welds on inside of corners, instead of outside, whenever possible.
• Specify 45° ± 5° chamfer instead of a radius on corners whenever possible.
• When a radius is absolutely necessary on corners, .125” radius is preferred.
• All bend angle tolerances to be specified as ± 1°.
• Do not specify locations of spot welds unless it is critical to the design.
• Specify all paint masking dimensions with a Ref. callout.
• Recommended bend radii for materials with a thickness under .120 should be .07R MAX.
• Use pre-plated such as “EZC” electro-zinc CRS, eliminate plating
• Eliminate masking for paint requirements
• Eliminate painting requirements

TOLERANCES

The following sheet metal tolerance information is based upon standards for soft tooled sheet metal to meet high yields from the process.  Tolerances outside these standard can possibly be achieved with special tooling or process.

Fabrication Tolerances

Hole to same size hole in same plane	± .005
Hole to different size hole in the same plane	± .010
Hole to Punched Edge	± .010
Punched Edge to Punched Edge	± .010
Hole to Bend	± .010
Bend to Edge	± .010
Multiple Bends per Bend	± .010
Standard Feature Size (Hole, Ob-round, Square)	± .005
Punched Feature	± .005
Angle	±  1º
Special Features that are a result of a single tool hit	± .010
Special Features that are the result of multiple tool hits	± .010
Dimensions that locate features that are the result of a single form	±.012
Dimensions that locate features that are the result of 2 separate forms	± .020
Dimensions that locate features that are the result of 3 separate forms	± .030
Dimensions that locate features that are the result of 4 separate forms	± .040

Webbing/Punching

Related to large areas of high % open perforations Min Web Thickness	1.5 Mtl Thk
Minimum Punch Opening	.060 Dia

Assembly Tolerances

Dimensions that locate features that are the consequence of a single assembly process (Welding, riveting, staking)	± .012 Minimum, otherwise use RSS calculated tolerance
Dimensions that locate features that are the consequence of a 2 assembly process (Welding, riveting, staking)	± .02 Minimum, otherwise use RSS calculated tolerance
Dimensions that locate features that are the consequence of a 3 assembly process (Welding, riveting, staking)	± .03 Minimum, otherwise use RSS calculated tolerance
Dimensions that locate features that are the consequence of a 4 assembly process (Welding, riveting, staking)	± .04 Minimum, otherwise use RSS calculated tolerance

Critical to function (CTF) is the characteristic whose variation has a significant on the fit, performance, or reliability of the component or system

Dimensions that are NOT CTF should not have tolerances tighter than the default tolerance rules

TYPICAL DESIGN/DOCUMENTATION PROBLEMS
Poor Modeling/Design Practices

• Parts are modeled in the flat and do not allow bend adjustments without time consuming changes to the models/data
• Hardware modeled as “Extruded Features” instead of as an “Assembly”
• Suppression of hardware feature in assembly eliminates mounting hole features
• Suppression of hardware feature in assembly eliminates mounting hole features
• Part files will NOT generate a “Flat”
• Unnecessary multiple bend radii
• No Bend Relief
• Countersinks not designed to the sheet metal minimum thickness tolerance.  Countersink designs should have a 10% material thickness “barrel”.
• Material thickness modeled to theoretical maximum
• PEM holes sizes not modeled correctly (should be -.000, +.003)
• Flange widths are less than 3 ½ material thicknesses
• No systems of numbering for data files.  Creates problems with traceablility.

Data Submitted for Fabrication

• Part Assemblies (sheet metal with “PEMS” or other hardware) are missing “part” files (all references)

Drawing Issues

• Tolerances are not within the process capability for soft tooled sheet metal
• Missing dimensions
• Material specification is missing or incomplete
• Finish specifications are incomplete
• Drawing does not show bend relief and/or note for allowable use missing
• Ordinate dimensioning is used over multiple bends (tolerance accumulation issue)
• Use of tooling holes for assembly purposes is not shown or noted
• Drawing views are not properly oriented and/or rotation noted
• Hardware call outs are not specific (vendor name and part number should be referenced)
• Critical appearance of surfaces in not indicated
• 3D data does not match drawing (typical when parametric features of modeler are abandoned)

PLATING AND COATINGS

Platings & Coatins are available and typically add 2 business days to the fabrication process.
Electroplating is a process whereby an object, usually metallic, is coated with one or more relatively thin, tightly adherent layers of some other metal.  Electroplating is specified when there is need for surface characteristics that the basis metal selected does not possess.  Whatever the purpose (improvement of appearance, corrosion protection, and the like), the plating operation is an important and necessary part of the manufacturing process and should be planned for with the same care accorded to the fabrication operations.
It sometimes happens, however, that designers, intent upon achieving a fresh, new look with sales appeal for their product, and production engineers striving for low fabrication cost for component parts, inadvertently create configurations and situations that make it difficult and expensive to accomplish the plating objective.
These limitations are basic and to a degree, self-evident;

• Surfaces to be plated must be wetted by all solutions and rinses in the plating sequence
• One must be able to make electrical contact without resulting defects
• The amount of metal deposited on a given portion of a surface will be proportional to the current that flows to that surface portion.

It is not intended nor desireable, that designers be unduly influenced by the above or that the plater be relieved of his need for ingenuity in the process.  On the other hand, in this practical world it is necessary to be aware of the great influence that part configuration can have on the cost of plating and on the quality of the finished product.

LIQUID AND POWDER COATING

Powder and liquid coatings are available in the MetalUrgency^sm process limited only by cost and availability.  Please contact Metalurgency@amf1.com for a list of available standard powders.

The application of a coating either as wet paint for powder coating is usually either for decorative purposes such as adding color, gloss and texture for functional value for protection from corrosion.  The preparation and cleaning of surfaces to be coated is the key factor in the adhesion of the coating.

Powder coating is an advanced method of applying a decorative and protective finish to a wide range of materials and products that are used by both industries and consumers. The powder used for the process is a mixture of finely ground particles of pigment and resin, which is sprayed onto a surface to be coated. The charged powder particles adhere to the electrically grounded surfaces until heated and fused into a smooth coating in a curing oven. The result is a uniform, durable, high-quality, and attractive finish.