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| ORION is frequently asked to help in the design and material selection of the parts we produce. How do these initial discussions help our customers? BY PRODUCING A BETTER PART AT LESS COST! By discussing the part and its application before a design is finalized, we can produce the most cost-effective part. Over the years we have produced thousands of parts from many different materials. We know just how each material reacts to die-cutting, and it is this experience that enables us to produce the most economical part. Parts should meet the criteria of form, fit and function in the final assembly. Designs should minimize cost through consideration of the materials and processes to be used in the fabrication and assembly of the part. | |
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Material Selection guide Cost-Effective Tolerances Utilize the expertise of your supplier |
Design for form Design for fit Design for function |
Early ORION Involvement |
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| Get ORION involved as early as possible. We are most familiar with the opportunities and limitations of the manufacturing process. Whether the processes are to be internal to your company or from an outside source, we are eager to meet with you and match our experience with you ideas. Early feedback from ORION can help to reduce costly engineering changes later in the project or prevent locking your design into more expensive tooling or manufacturing processes. | |
Cost-Effective Tolerances |
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| Loosen the tolerances. Tolerances that do not provide gains in form, fit, or function will increase costs of tooling, processing, and assembly. Tolerances determine what type of equipment will be used in inspection, what secondary operations may be needed, and how simple the assembly process will be. Most shields, insulators, seals, and screens are not structural parts and may be designed to simply drop into place during assembly. Typically, tolerances of ± 0.015" on feature location and ± 0.030" on feature size are adequate and preferable for the design of shields, insulators, seals, and screens. Such tolerances will trim tooling and part costs and make the assembly process more fluid. Of course, we can achieve tighter tolerances, although they may increase tooling costs. | |
Material selection guide |
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To address the concerns and interests of engineers and purchasing agents in the cycle of designing, quoting, and purchasing parts for their assemblies, this article offers assistance in the material selection process. Selecting the right material is a design activity that can not be underestimated. The finished part consists of material that has been transformed with processing and labor, guided by the concepts of the design team. the part must be designed to meet function requirements and endure the environments of shipping, storage and service. Because of the interdependent relationship between a material and the form, fit, and function that parts must fulfill, the selection of material is a dynamic decision. A well structured selection process draws on past experience to fully satisfy customer requirements by saving time, reducing cost, increasing yield, and reducing or eliminating the number of redesign activities and part revisions.Top |
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Design for form |
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| To properly design for form, these types of questions need to be answered: Will the part required bending or forming? If so, are perforations at the bends acceptable? PVC and polypropylene will form relatively easily, while polyester tends to crack and split at sharp folds. If flatness is a concern, then material should be selected to avoid the curvature associated with roll stock. | |
Design for Fit |
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| What part thickness does your application require? Does thickness relate to function? Thicker and softer materials will show greater deformations when cut with a steel rule die. Do thickness tolerances reflect the function of the part, or are they assigned by habit? It is important to know the material manufacturer's thickness tolerance. If you are designing a foam part, keep in mind the fact that you material will deform during the compression of cutting as well as during service. Most vinyl nitrile and blended neoprene expanded rubbers will shrink up to 5% over several months of storage, while some insulation materials will shrink or grow with changes in humidity. | |
Design for function |
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| To design for function, know your part's thermal, dielectric, hardness, hydroscopic, dimensional stability, and other requirements. Keep in mind any agency approvals you will need (UL, C.S.A.,etc.). Save time by specifying any flame rating requirements early. Knowing your material's limitations will save time and help avoid unpleasant surprises. | |
Utilize the expertise of your supplier |
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If your supplier is not interested in your application, you are not getting full value-added service. ORION has engineers who are eager to put their experience to work on you applications. Enlisting our help is a great way to get your product to market faster. Back to Top |
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