Electronics enclosure accomplishes two specific goals, safety and aesthetics. While enclosures are commonly used to keep electronics safe, they keep the user safe from electrical accidents. Enclosures come in various shapes, sizes, and materials. Choosing suitable material and size options for your electronics enclosure can be complicated.

So, to help you in your enclosure manufacturing journey, we have broken down this complex topic into easily digestible bits.

Here is an in-depth guide to the best options for your electronics enclosure.

What is an Enclosure?

Enclosures are outer casings designed to contain, protect and organize electronics. Most electronic enclosures are made of metal for added strength, but some prefer plastic as a cost-saving measure.

The three core elements of any enclosure manufacturing are as follows.

1. Manufacturing Process
2. Material Choice
3. Enclosure Design

A firm grasp of these three elements will help you design and manufacture a successful electronics enclosure.

Electronics Enclosure Manufacturing

Manufacturing is the first and foremost important element of enclosure design. Numerous manufacturing techniques are commercially available for enclosures. 

1. CNC Machining

CNC machining is an incredibly versatile means of production. Here a computer-controlled cutting tool removes material from a block (workpiece) until the desired shape is achieved.

You can machine complex designs with excellent tolerances using CNC. Additionally, you can use almost any material with a CNC machine, as long as you have the necessary cutting tool. 

CNC machining is ideal for early prototypes and quick turnarounds. But this versatility comes at a cost. CNC machining can prove to be very expensive for large-scale productions.

2. Sheet Metal Fabrication

Sheet metal fabrication involves bending, cutting, and forming 2D sheets of metals into a 3D enclosure. This is by far the most cost-effective method of enclosure manufacturing. Sheet metal fabrication takes advantage of metals’ incredible flexibility and elasticity to its full extent.

Sheet metal fabrication is limited to ductile metals.

3. Injection Molding

Injection molding involves injecting hot molten plastic into a mold. This method is particularly popular because the final enclosures are electrically insulated. Enclosures manufactured through injection molding are relatively cost-effective. The most impactful cost factor in injection molding is the design and fabrication of the mold.

Thus, injection molding will be more expensive than sheet metal fabrication for low-volume productions. But as you increase your production size, the difference shifts in favor of injection molding.

In contrast to sheet metal fabrication, injection molding is limited to plastic materials.

4. 3D Printing 

The most common type of 3D printing is FDM (Fused Deposition Modeling). Here a wire of plastic (ABS or PLA) is semi-melted and extruded on a base plate. Once the first plastic layer cools another is deposited on top. Thus, FDM creates continuous layers on top of other layers until a finished design is achieved. 

The best part about 3D printing is that it allows users to create the most complex and intricate designs possible. However, 3D printing is a slow and costly process limited to a handful of plastic materials.

5. Miscellaneous Manufacturing Techniques

A few more uncommon manufacturing techniques can be used for enclosure production. These techniques have their own shortcomings and are generally not recommended.

Laser Cutting

Laser cutting uses a high-powered laser to make precise cuts into a thin sheet of material.

Laser cutting is a slower process than metal forming. However, it supports both thin metal sheets and slightly thicker wood and acrylic sheets.

Die-Casting

Die-casting is a similar method to injection molding. Instead of a powerful injection of molten plastic, you slowly pour molten metal into a mold.

Die-casting results in more robust products but at a much higher cost.

SLS

SLS, or Selective Laser Sintering, involves a high-powered laser selectively melting metal powder. SLS is 3D printing for metals.

It is the most expensive manufacturing technique on this list. SLS is generally limited to aerospace applications, where cost is less of a factor compared to design and performance.

SLA

SLA or Stereolithography uses a UV light projector to polymerize a resin vat selectively. SLA is 3D printing using a liquid base.

SLA is generally more precise than FDM 3D printing. However, it is not suitable for large-size products.

Following is a simple table discussing the advantages of various manufacturing techniques.

Best Materials for Electronic Enclosures

Metal electronics enclosures are typically made from either Aluminum or Steel. At the same time, non- enclosures can use a variety of plastics.

Steel

Steel is a heavy metal with some exceptional properties. It has a high hardness rating and is still malleable enough to be shaped and formed.

Steel alloys can improve the base properties of steel even further. Depending upon the alloying additive, you can double the corrosion resistance, elasticity, or tensile strength of steel.

Aluminum

Aluminum is generally lighter and cheaper, while steel is stronger and more expensive. The key benefit of using aluminum is that it is a lighter metal but one that is still fairly strong.

Aluminum alloys are even more versatile than steel alloys. So much so that aluminum alloys are used for both kitchen appliances but also aircraft parts.

Plastics

Plastics are lightweight materials that are easier to manufacture, resulting in low operating costs. Plastics are a separate industry altogether, using several material bases and even more variations. Some popular plastic options for use in electronics enclosures are as follows.

• PLA & Nylon (3D Printing)
• Thermoset Plastics (Injection Molding)
• Acrylic (Laser Cutting)

Enclosure Material Comparison

Design Considerations for Electronics Enclosure

Design is generally not a primary factor for most electronics enclosures, but it should not be neglected. We hope you will consider the following design considerations for your electronics enclosures.

Mounting Points

Your electronics enclosure should have proper mounting points built into the design itself. These mounting points can be strategically cut holes or protruding tabs.

Ventilation

Most small electronics can be passively cooled. But for more power heavy electronics, you will need vent holes to allow air to flow. Keep in mind that ventilation holes will be subject to dust and water ingress.

Sealing

For outdoor deployed enclosures, proper water and dust seals are imperative. You can seal your enclosures using gaskets and silicone spacers.

Conclusion

Electronics enclosure seems like a complicated topic at an initial glance. But it becomes quite simple when you know the details. As a general rule, CNC and metal forming are preferred for low-volume metal manufacturing. In contrast, 3D printing is ideal for low-volume plastic enclosures.

For most other enclosure manufacturing, you can balance the financial and time costs according to your needs.

If you are in the market for high-quality manufacturing services, we recommend checking out QBH Technology. We offer an extensive catalog of design, manufacturing, and finishing options.QBH has the best electronic enclosure products in the industry. To get a customized quote and get your business up and running, Contact Us Now!

Stainless steel is considered an ideal choice for metal fabrication. Does metal fabrication sound like a new term? Oh, let’s make out the fabrication before jumping to the benefits of stainless steel for fabrication. 

Fabrication is a technical process that includes cuts, mold, and shapes of the metal for the final version of the product. Fabrication produces the product from raw or semi-raw material. It’s used for custom as well as stock products. I hope you get the meaning. 

Albeit stainless steel fabrication costs you an arm and leg yet its benefits are worth your penny. You can even produce your desired masterpiece at home.

 No rocket science is required. Before exploring the advantages we first understand the formation of stainless steel. 

Formation And Alloys Of Stainless Steel

Being an alloy of iron stainless steel has 10.5% chromium (essential to make the steel stainless). Chromium produces a thin passive layer over the surface of stainless steel. 

Furthermore, chromium makes the stainless steel’s surface more durable and steel makes it corrosion-resistant. It saves the outer structure of the metal from corrosion. 

Similarly, the addition of nickel in stainless steel increases the corrosion-resistant properties. It also increases its welding capabilities. 

Copper makes the stainless steel corrosion-resistant and improves its work hardening capacities. 

Uses Of Stainless-Steel

Stainless steel is not only used in the industrial sector but also in various other domestic sectors. Let’s explore its usage. It is used in sheets, plates, coils, bars, tubing, and wire, etc. It’s also used in… 

Culinary uses

• Kitchen sinks
• Cutlery
• Cookware
• grills
• cookers
• saucepans

Surgical tools and medical equipment

• Hemostats
• Surgical implants
• Temporary crowns (dentistry)

Architecture (pictured above: Chrysler Building)

• Bridges
• Monuments and sculptures
• Airport roofs

Automotive and aerospace applications

• Auto bodies
• Rail cars
• Aircraft

Process Of Stainless Steel Fabrication 

Fabrication of stainless steel includes five steps. Let’s explain them in detail. 

Work Hardening

Metal works hardened on cold forming. Grades of 400 series have higher cold working than that of carbon steel. 

But austenitic grades of stainless steel work at rapid speed and that’s the reason it is highly used where strength and resistance to corrosion are required. 

Machining

Grades Of austenitic stainless steels are difficult to machine due to the presence of non-metallic inclusion. This makes them less resistant to corrosion in marine products. 

Welding

Almost all the stainless steel grades have different types of welding properties but Austenitic grades have most readily weld. 

Martensitic grades need deep care during welding while Ferritic grades have excellent weldability. 

Soft Soldering

Soft Soldering includes the use of lead-tin solder, but the use of soft soldering should be used in the transportation sector and food industries. 

Mechanical strength depends on solder joint and is improved by 

• Riveting edges
• Lock-seaming edges
• Spot welding edges

Silver Soldering

Silver Soldering is done where a strong joint is required but without the welding process. Silver Soldering, when used in stainless steel fabrication Silver brazing alloy, is used. 

Benefits OF Stainless Steel For Fabrication Project 

Stainless steel has been widely used in all industries for over 70 years. Due to its plenty of advantages, its usage has taken root everywhere with the passage of time. 

Due to the highest increase in demand, it has become more affordable than ever, even in 2019, its global production crossed 52 million. Also due to the increase in demand, it is available in standard and non-standard sizes. Stainless steel finishes are also available in the market. 

Besides finishes, different colors surfaces are also available that make finding a suitable option for your needs. 

1. Stainless Steel Is Highly Corrosion Resistance 

Being resistant to corrosion the use of stainless steel is extended to indoor as well outdoor applications along with temperature and pressure extremes. 

Owing to resistance to corrosion and availability, stainless steel is a widely used metal in the world. Its 316 grade is widely used in all sectors especially in corrosive environments. 

Grade 304 of stainless steel is highly used in metal fabrication because it is an excellent combination of workability, strength, and corrosion resistance. It is corrosion resistant to chlorine, alkine, and acid solutions, etc. 

2. Surprisingly Stainless Steel Is Eco-friendly 

Stainless Steel Is Highly eco-friendly because of its recyclable properties. It means you can reuse it again and again. 

As it is non-biodegradable in nature therefore it cannot seep into soil and water reservoirs. 

Sustainability with the passage of time has become a hot subject in the industrial sector. As we are depleting the world’s resources, now it is essential to increase recycling. 

It is highly recyclable without diminishing the actual quality. 100% recyclable without losing the strength of stainless steel. As the 50% of stainless steel used in fabrication comes from previous melted steel. 

3. Stainless Steel Is Easy To Fabricate

Stainless Steel Is easy to work with due to its flexibility, machineable, workable properties. Other metals in the fabrication process can break or crack under stress whereas stainless steel excels the race. 

Grades from 400 series of stainless steel contain chromium up to 10-30% which makes them able to bear cracks and stress. 

By using the modern and latest technology you can mold, cut, Fabricate stainless steel in any form and shape. Stainless Steel fabrication can prove difficult if you are using outdated technology or equipment. 

So to avoid this challenge, just use modern techniques and technology. Like CNC Machining and stainless steel laser cutting are also available. 

4. Stainless Steel Is Highly Durable 

When it comes to durability stainless steel is more durable than other metals like aluminum, mild steel, and brass. Moreover, it performs better in higher temperatures than other metals. It has stiffness above 300°C than Carbon. 

Martensitic stainless steel has the highest heat-resistant properties as compared to other grades of stainless steel. As we mentioned above, cold work hardening properties of many stainless steel grades are used to reduce the thickness, weight, and coat of many materials. 

5. Hygienic Benefits

Due to its Hygienic properties, stainless steel is highly used in medical as well as catering applications. It restricts the growth of bacteria and is easy to sterilize and clean. You can even clean it with a swab. 

As stainless steel does not leak in the utensils therefore it is highly used in the Kitchen industry because it prevents bacteria and reduces the risk of diseases. 

6. Stainless Steel Is Temperature Resistance

Stainless steel is well known for its withstanding properties of heat resistance. Therefore it is widely used in welding as well as metal fabrication. 

And resistance mainly depends on chromium presence, and for your pretty concern 310, and 309 grades of stainless steel can bear up the temperature up to 1150°C. Amazing! 

The use of a high alloy of stainless steel having high amounts of chromium and nickel makes it valuable in feed water heaters, boilers, valves, mainstream lines, aerospace, and heat exchanger. Highly resistant to heat and fire. 

7. Easy To Clean And Maintenance Free 

As stainless steel is non-porous therefore any liquid or air cannot pass through it, this makes it the perfect choice where food is processed. It is no wonder that commercial kitchens are full of stainless steel in different forms in utensils, appliances, etc. 

Moreover, the product made from stainless steel can be cleaned with domestic detergent, cleaning liquids, and soaps. Proper cleaning enhances the service life of the product and reduces wastage. 

You should not overlook the long-term value of stainless steel, as maintenance is easy in stainless steel. 

8. Aesthetics Look

Stainless steel is not only strong enough but also gives an aesthetic look to the product. It has a natural grayish color. It gives a sleek look to the product. 

Stainless steel products have a high luster and are exposed to surfaces. It has a variety of finishes including matt and bright. 

Final Verdict 

To wrap the discussion up, when you want to do a stainless steel fabrication process, it’s essential to choose the right fabrication company as all are not suitable and provide quality services for this purpose. 

As a leading name in the fabrication process, we’re always willing to give you quality services and make your project’s goals come to life. 

We excel in laser cutting, welding, CNC turning along with milling, and electronic enclosure. We can use stainless steel in your product and finishing it too. Ready to expel your headache and save time and money? Don’t waste your time just contact our professional team and feel free! 

Related Articles:

• Stainless Steel Types: What Makes Stainless Steel Stainless?
• Stainless Steel Sheet Metal: Everything You Need to Know
• 9 Tips to Optimize Your Design for a Metal Fabrication Project!
• WHAT IS SHEET METAL FABRICATION?

Stainless steel is an eroding -resistance of iron, chromium.  Or it could be iron alloys with a minimum of 10.5% chromium. Simply, stainless steel is any family of alloy steels, usually, that contain 10 to 30% chromium. This metal of stainless steel would be nikal in some cases or maybe other metals.

Usually, stainless steel could be found in many objects that we are using in our everyday life. Stainless steel plays a vital role in an array of industries including energy transportation, building, research, medicine, food, and logistics.

Chromium content could get by the corrosion resistance of stainless steel. Their chromium oxide is producing on the steel surface, in the form of a stable layer.

The size of the oxide layer is approximately 2 nm_3 nm in thickness and extremely thin. It is passive in nature. Although, stainless steel will have oxidizing properties under specific circumstances. Their uniform corrosion would occur. When it is exposed to an acidic solution of strong sulphuric acid or hydrochloric acid.

DFM DFM  stands for design_for_ manufacturing. It is a very significant phenomenon for manufacturing. There are some principles to follow when you are designing sheet metal with. stainless steel.When you are following these principles to design for manufacturing. You could be able to get your desired functionality using stainless steel. It comes on sheet metal from fabrication techniques. In the phenomenon of powder coating, specific stainless steel sheets should be a perfect match. Because stainless steel alloys such as 304 and 301 are not a good match for it. So, stainless steel is not giving a good performance as compared to the matchable stainless steel of 316. Stainless steel of 316 is a good match to perform well in the powder coating process.

Additionally, stainless steel has many significant properties. Such as, there are more than 60 categories of stainless steel. Chromium gives unique properties to standard steel. It also works against rust. Commonly, stainless steel is a non-magnetic material. But in some types of stainless steel, there are magnetic properties. These properties depend on the microstructure of a specific type of stainless steel. Stainless steel also has the significant property of being recyclable.

The interesting fact about stainless steel is it may expand and contracts.

Stainless steel is very significant for nuclear power and aerospace industries. The reason is that there is a high-temperature oxidation resistance of stainless steel.

Comparatively, it is a higher resistance temperature than many other metals. When the temperature varies stainless steel shows interesting properties of expansion and contractions. Due to this property, experts should be very careful while creating steel frames for buildings. For example, during the summer, the Eiffel Tower is almost 984 feet tall. Moreover, in the contrast season of cold, the Tower is 6 inches shorter than 984 feet.

Mechanical properties of stainless steel

Although stainless steel encompasses, huge range of materials. But its mechanical properties are quite diverse. Generally, it has tensile strength, hardness, toughness, creep resistance, and fatigue resistance properties.

Stainless steel shows specific properties in different situations which are applying to it. Such as it’s cold working to elevate work hardening and avoid tearing or cracking.

Stainless steel is also so hot working at specific conditions of 1149_1260°c. Its purpose is a cool rapidly and enjoys maximum corrosion resistance.

Electric and magnetic properties of stainless steel

Stainless steel has electric and magnetic properties such as stainless steel is a relatively poor conductor of electricity. Additionally, the conductivity of 18 wt % cr .8 wt %. Ni stainless steel at 20°c is 1.45 × 106 s/m compare to 5.96 × 107 s/m  for pure copper.

Commonly, stainless steel is classified into four main categories. This classification is occurring depends on their crystal structure, Ferritic, martensitic, austenitic, and duplex.

Difference stainless steels are classified as magnetic and nonmagnetic. Such as Ferritic, martensitic, and duplex are included in magnetic. And austenitic is  non_ magnetic.

Many types of stainless steel show melting properties in an electric arc or basic oxygen furnaces. Then it could be defined in another steelmaking vessel that has the property of low carbon content.

In the process of argon_ oxygen decarburization, and they’re a mixture of Oxygen and argon gas is injected into the steel which is in liquid form.

Stainless steel usage  in industries

Usually, stainless steel plays a vital role in industries. Typically, stainless steel applications include aircraft, diary, and food processing industries.

There are different types of formulations of stainless steel. Each of them has specific properties and unique characteristics to use and handle with precautions. For example, 304 stainless steel is a type of stainless steel that is of higher ultimate tensile strength. Stainless steel is beneficial in the formation of engine and exhaust components, gear components, and superstructures joints. It reduces parts rejection and provides floor space. Therefore, stainless steel plays a key role in the aircraft industry.

Stainless steel is beneficial in automated manufacturing robots.

In the performance and price, all stainless steel for sheet metals is different. The alloy makeup is different in all stainless steel sheets. If you want to choose stainless steel material for your industry use or for any other purpose. Because you should choose the right alloy for your purpose. It will save your cost and gives the best performance by its application.

There are many applications of stainless steel. As it is used to make durable refrigerators and washing machines. It also has capital good applications for example transportation.

In the food manufacturing process stainless steel play a basic role.

Because it is useful In manufacturing the range of materials to stalk convey and process the food products. the food factories, two types of stainless steel are common. These types are 304 stainless steel and 316 stainless steel. Both have different and specific properties and qualities.

Although, stainless steel has a strong quality of resistance. But it is not stain-proof completely. As we know that stainless steel has many types. Each type has a different and specific quality. The resistance quality of stainless steel will depend on makeup which is present specific in each type.

Ranges in thickness.

Stainless steel huge range of thicknesses. It could be quite thin. It could reach 1/4 inch in thickness. The type of stainless steel that is is larger than 1 /4 in thickness, will be a plate. The gauge is useful for measuring the thickness of stainless steel sheets. If that use number would be higher the sheet would be thinner.

Before choosing the right alloy for your application. You should make some research by yourself because it is very important to know about different alloy situations. Misuse may be harmful or can create critical situations. With these precautions, you can achieve your dream of functionality from stainless steel sheets. Your safety must be your priority. If you don’t have enough knowledge about it, don’t use it and consult a specialist.

Stainless steel is present with many configurations

while stainless steel sheets metal comes with many configurations. Each of the configuration-specific advantages and disadvantages to use it. Manufacturers of metal fabrications main offer different grades, finishes, and sizes. But there is a notable difference in specific types of stainless steel sheets.

Many types include:

• Martensitic
• 200 series Austenitic
• Ferritic
• 300 series Austenitic
• Martensitic
• Duplex

Stainless steel play a role in welding

Usually, stainless steel has its application for welding purposes. It plays a very beneficial role in welding. But, stainless steel sheet metal when using in welding its thickness and heat distribution creates difficulties in welding.

Bending

Stainless steel plays a significant role in bending. The thinner sheet is easy to bend. It could be easily bending by using a hand. But when we are bending harder sheets then we should have a bending tool that bands stainless steel.

Cutting

For cutting purposes, stainless steel is significant to cut Hi-Tech lasers. Along with, metal snips, jigsaws, hacksaws, and other band saws.

Other industries with basic use of stainless steel

Stainless steel plays a vital role in industries. It is responsible to perform different duties in industries according to their type and use.

There are some industries in which stainless steel presents to do the best performance.

• Energy
• Diary
• Aircraft
• Architecture
• Food processing
• Construction
• Heavy industries which are responsible to manufacture heavy goods and materials in bulk
• Automotive

It also plays a beneficial role in the dairy industry. As a material of the industries is made of stainless steel, which provides excellent reliability with long-term quality. Stainless steel is a sign to use in the diary because it prevents chemical bacteriological and organoleptic neutrality to the food products. It also has the ability to do cleaning or washing easily. So hygiene and appearance of the product are guaranteed.

Therefore, stainless steel sheet metal is specific material. This material provides choice to a number of industries for its application. It has significant properties of reliable, durable, and resistant properties.

If you have any questions or confusion. You are free to plz ask in the comment box. And leave a reply. We will get back to you as soon as possible.

Fasteners play a critical function in constructing a wide range of products. Suppose you perform a lot of your home improvement.

If that’s the case, you may have utilized fasteners to complete your project. The things in place, reduce the risk of damage from excessive vibration or pressure.

Fasteners come in a plethora of forms. Some variation can be seen among the many varieties.

Various fastener types and subtypes will be discussed in this article. To assist you in choosing the correct fastener for your project, we (QBH Technology) will also provide you with a few pointers. Let’s define fasteners before we get into the nitty-gritty.

What is a Fastener?

The term “fastener” encompasses a wide range of instruments. They all have one thing in common: they’re used to fasten things together. The goal is to make it possible for items to attach.

Subway Fasteners are used to keep things in position or together.

Glue, it is possible to claim, may do this role. If fasteners don’t have glue, then what do they include?

Our initial definition will have to be expanded upon as a result. Hardware fasteners assist in securing two or more items together.

Fasteners can be classified in a variety of ways. These fasteners are divided into two categories: permanent and non-permanent. As a general rule, fasteners are regarded to be temporary joints.

As a result, you should be able to detach two parts that are attached by fasteners. The parts must not be damaged in any way throughout the process. The rivet, a permanent fastening, is an exception to this rule.

When fasteners establish non-permanent joints, it does not state weakness. Your products will be securely fastened if you use fasteners that have threads that are suitably shaped.

This ensures that your thing can withstand a great deal of force. They may be used on a wide range of joints because of their versatility.

Temporary Fastening Devices!

A temporary fastening is a method in which the pieces of a mechanical device can be separated and rejoined at any time. Temporary fastening does not affect the machine or its parts.

Bolts, screws, lock pins, and washers are the most common components used in temporary fastening nut assemblies.

Fasteners are the technical term for these components. Later in the essay, we’ll discuss the primary temporary.

Type#1: Semi-Permanent Fixation

A semi-permanent fastener can be damaged, but it will no longer function.

When re-opening of the joints is unlikely, this procedure is undertaken. Soldering and riveting are two examples of this type of work.

Type#2: A Permanent Fixation

A permanent connection between two materials or pieces is achieved using these one-time-use fasteners.

The pieces will never separate if a permanent fastening is employed. Rivets, welding, soldering, and brazing are examples of permanent fastening.

The Different Types of Fasteners!

Engineering marvels of the modern era may be found everywhere. Engine cylinders in generators’ internal combustion engines, for example, can experience controlled explosions at up to 3600 revolutions per minute.

A two-stroke engine can produce 60 explosions per second, whereas a four-stroke engine can produce 30. It is also common for diesel generators to run around the clock. This means that the machine must withstand long periods under extremely high loads.

When designing a product, another consideration to bear in mind is how easy it is to maintain. After a given number of hours of use, any machinery has to be serviced.

Access to as many sections of the design must be made possible so that engineers and technicians may maintain, repair, or replace them.

As a result, non-permanent methods of securing machinery components are required. As a result sometimes tremendous stresses and flexibility, several fasteners are needed.

To keep machine parts from being displaced by excessive forces or vibrations, these fasteners are designed to be easily removed in the event of non-permanent fastening. To know more about such fasteners, visit QBH Technology.

Type#1: Nuts

A bolt can be inserted into its internal threads. Nuts are frequently used in conjunction with bolts, depending on their position at work.

Type#2: Bolts

Fasteners such as these are commonly used. A thin metal rod is used to create a bolt. To secure them in place, many types of heads are available.

This piece still has some threads on it. Or, a nut and a bolt can be used to secure the item from this angle.

Type#3: Screws

Screws are used to attach various machine components. Screws are threaded in many ways. Helixes can be thought of as spirals wrapped around cylinders.

Bolts have a larger diameter; thus, nuts have a smaller diameter. They can grow up to a quarter-inch in diameter. Screw heads come in a variety of shapes and sizes. There are four major sections to the screw.

Type#4: Washers

It has the appearance of a ring because of its circular form. The stud or bolt must be in place. Tightening nuts and bolts and making it simpler to remove them are two of its primary functions.

While it may be difficult to tighten even with washers, this can be done even with bolts with a greater bore than their diameter.

Type#5: Key-ways and Keys

It is possible to transmit torque by using a key, a machine component that links spinning machine parts to shafts. The key keeps two objects from moving about one another.

The image below shows that the shaft must have a keyway to accommodate the key.

A gear or pulley cannot move on its shaft, but the shaft and gear or pulley move together as one unit. A key connects a shaft and a wheel.

In this case, the shaft and the gear or pulley (or we may use the term “wheel”) are a single piece of machinery.

Type#6: Studs

It’s a bolt without ahead. The term “stud” refers to a long rod with threads on both ends, which may stretch the whole rod’s length. After the stud has been inserted into the hole, a nut is tightened around it.

One of its key advantages is simply opening the nut to detach it from the bottom section and maintain it in place. There are three basic types of studs in this category.

The central section of the round stud is also rounding. The central section of a square stud is square.

Another collar form is built further away from the body’s center. This material is frequently found in the cylinder head of motor vehicles.

Type#7: Rivets

These rivets are used to attach sheets or plates permanently. It is used to make trunks and buckets in boiler and sheet metal operations.

It’s common for rivets to be manufactured of mild steel, but brass, copper, and aluminum are also used. The head, shank or body, and tail of a rivet are all that is required to make a complete rivet.

Type#8: Anchors

Like a ship’s anchor, an anchor is a sort of fastener that serves the same purpose as a ship’s anchor.

In most cases, it’s utilized to fasten anything to a drywall or concrete surface. They stick to the surface and hold the item you’re attaching.

Type#9: Nails

To hold objects in place or to use it as a hook, you insert a metal spike with a wide, flat head into a piece of wood. Because of their widespread use, nails have become an essential component in many people’s lives.

To tell the difference between a screw and a nail, you only have to look at their bodies. Nail kinds are named from the tasks they are used for, so you can use this information to narrow your search.

Type#10: Inserts

Thread bushings, typically cylindrical, are another type of strong thread. For example, they can mend stripped threads or secure long-lasting connections between various materials.

Loads can be transferred from the smaller screw to its bigger insert by using this fastener.

Type#11: Retaining Bands

Fasteners used to hold shafts or components in place include retention rings. They generally come in a variety of forms and sizes. They are employed in a wide range of mechanical applications.

The latch pin of an IC engine piston is held in place by a retaining ring similar to this. A diesel generator’s high-pressure fuel pump also holds the system together.

While most retaining rings are one-time use, others can be reused when the machinery is repaired.

Type#12: The Clevis and Cotter Pinning

Steel pins or a cylindrical shaft are used to make these sorts of fasteners.

A cotter pin is put into the shaft and bent to function as a staple in these. Machines rely on them to maintain their parts in a specific position or alignment.

How To Choose The Correct Fastener?

The most important consideration here is whether or not the fastener is suitable for your application.

Your application may need the use of more than one fastener type. Head, shaft, and threaded end make up the conventional bolt.

Based on the design of the head, there are several types of bolts: hex, socket, screw, and so on.

The proper selection of the bolt head is critical to the bolt’s ability to withstand torque. As a result, length is an important factor in applying the bolt. The flange bolt is an excellent illustration of the value of proper length.

All of these components, plus another washer, the accompanying flange, and its bolt head must be held together by a sufficient length of threaded rod for it to serve its intended purpose.

Additionally, it’s crucial to pick the proper thread. Faster assembly of pieces can be achieved using coarse threads, which are easier to assemble than fine threads.

Know the Use

Before contacting a fastener provider, it is important to establish the intended use of the fasteners. A comprehensive list of all industrial fastener uses is beyond the scope of this document.

However, the types of fasteners and their appropriateness for use in various applications can frequently be the same across various them.

If you need mild steel or Chrome Moly or perhaps something exotic, it will be determined by the application’s demands. It’s also a good idea to be familiar with the fastener-specific standards.

Carbon steel nuts, studs, and threaded rods up to 60,000 PSI tensile strength are covered by ASTM A307, for example. ASTM F593 covers bolts, studs, and hex cap screws made of stainless steel.

ASTM A193/A193M is a standard for high-temperature and high-pressure alloy and stainless steel bolts. These and other standards often describe your application or an application quite similar to yours.

Construction Materials

Carbon steel is used in the vast majority of fasteners. In terms of versatility and strength, it’s the most versatile material. The ASTM 307 Grade B low-carbon steel is utilized for heavy hex bolts and studs intended for use with cast iron flanged joints in pipe systems. Heat treating medium carbon steels can improve their load-bearing capacity.

Bolting materials made of alloy steel and stainless steel are covered. Fasteners for pressure vessels, valves, flanges, and fittings are included in this specification.

Hex head Grades 2, 5, and 8 are the most often used fasteners. Grade 2 is the most common steel used in the construction industry. Fasteners made of this type of metal are the most common and the least costly.

The installation of handrails and pipe clamps and hangers, for example, both demand Grade 2 bolts.

Bolts with hex heads of grade 5 are the most frequent in automotive applications because they have been hardened to strengthen their strength.

Bolts with a grade 8 designation have been hardened more than bolts with a grade 5. As a result, they’re more durable, and you’ll see them in high-stress settings like car suspensions and equipment installation.

Alloy steel is commonly used for socket head bolts. Bolts constructed of alloy steel have a high strength steel alloy as their base and are heat-treated for further durability. A dull black appearance is typical of bolts made of alloy steel that has not been plated.

Despite their high strength, alloy steel bolts are highly fragile. If zinc plating is necessary, care must be given with socket heads. Hydrogen embrittlement, which can lead to fastener failure, is possible when plating these fasteners.

Alloy steels with manganese, copper, and chromium content over 1.5 percent, but less than 4 percent, are particularly helpful for a wide range of strength-to-ductility applications.

With adequate molybdenum or vanadium concentrations, alloy steels can be employed in areas where corrosion is probable, such as heating and boiler equipment.

Final Thoughts

Fasteners exist in a wide variety of shapes and sizes, making it challenging to select the perfect one for your project. We’ve discussed the many types of fasteners and their applications in this post.

To assist you in finding the appropriate fastener for your components, we also provided some helpful advice in this article. QBH Technology’s rapid prototyping services aren’t limited to providing design ideas.

Fastener assembly and sales are also included in our services. We have a wide variety of high-quality fasteners available for purchase. If you need a fastener for whatever purpose, you can rely on us to get it for you.

Introduction

Are you designing for custom metal fabrication? There’s a lot of work cut out for you. However, you can make things easier if you follow the best practices and tips while optimizing the design for fabrication. After all, your custom metal fabrication design will impact the end result, i.e., the product. To keep things simple, you should focus on time, cost, durability, and other factors while optimizing the custom metal fabrication design. In this post, we will dive into the world of custom fabrication design and shortlist nine tips that will ensure that a piece of design successfully translates into the desired metal product.

1.Work with the right fabricator

Assuming that you don’t own a metal fabrication service or workshop, we suggest you spend time finding the right metal fabrication expert or service provider. Indeed, this is quite challenging because every service provider claims to be the best. Here’s what you need to remember. Work only with a fabricator that has enough experience, provides excellent customer service, and has the necessary good-quality tools. We suggest you go for a metal fabricator that delivers designing services and in-house engineering. Such fabricators are known for providing valuable recommendations and design input as they understand what you require from them. In other words, working with the right fabricator will ensure the production of a high-quality and functioning metal product.

2.Choose the right material manufacturer

We cannot press more on the fact that material selection impacts the entire custom metal fabrication process. Not just that, it also affects the design and quality of the project. Therefore, you should know where to purchase the best materials for your product. We suggest you contact metal fabricators as they will help you connect with a local metal manufacturer/supplier. These local manufacturers often provide a wide range of materials to choose from for fabrication purposes. They will provide the required quality and offer the best prices.

3.Keep the design specific

Remember: Never confuse the fabricator. The only way you can ensure that the fabricator understands everything you need from the process is by specifying the design to perfection. This simple move can reduce a significant amount of errors in the end product, i.e., when the design moves onto fabrication. Make everything crystal clear on the design specification page. So, what should you include when specifying the design configuration? We highly recommend double-checking your design specification for tolerances, locations of holes, depth of holes, surface flatness, the radius of corners, material thickness, and overall height/width/length. Most importantly, mention the accurate measurements on the drawing.

4.Simplify the design down to essentials

So, you have clearly marked the drawing and specified the instructions you want the fabricator to follow. Your job doesn’t end here. It’s time to simplify the design to make sure you include only essential elements. Therefore, the next step in optimizing the custom metal fabrication design is to simplify. This editing step will make you look at the design more closely before pushing it to your fabricator. So, what are you looking for here? Identify the elements that don’t add to the function of your design. Do you really need to add or specify the aesthetic elements? You should also look out for elements that are redundant and ambiguous. For example, you don’t need two holes in the design if one hole gets the job done. Adding another hole might add unnecessary expense. Also, make sure you don’t over-detail on the drawing sheet.

5.Choose the right metal alloy

Take your time to choose a suitable metal or metal alloy for your project. Since experts recommend using metal alloys, we will focus on selecting the right metal alloy option that fits your project needs. Materials will impact the cost, design, and fabrication processes required for the project. You will also have to consider whether or not the fabricator has adequate machinery to work on the material. One should have a clear idea of where the end product will be used. The information will help determine the properties the product should possess. In other words, you’d want to use a material that can withstand the environment where the product is used. Ideally, you will want to use a metal alloy that has high durability and can resist corrosion, temperature extremes, and intense force. At the same time, you will want to purchase the metal alloy cheaply to keep the product cost low.

6.Choose right manufacturing way for metal fabrication

We highly recommend learning about different fabrication processes before you present the custom design to the fabricator. If you are designing for a small project, you can go for CNC cutters or metal printing since these are cheaper and quicker to process. While CNC machines provide the best precision, metal printing will help create unique shapes. Using laser technologies for fabrication might result in material wastage. Here are a few basic CNC based fabrication processes:

• Punching

This fabrication technique is primarily used to create a hole in the sheet metal. The material is placed between a punch and a die – both having the same shape.

• Cutting

Cutting tools like plasmas, lasers, water jets, or tin snips are used to perform metal fabrication. This is the most critical process since it is quite challenging to achieve the set design without cutting the sheet metal.

• Roll forming

This process in custom fabrication involves continuous bending of long strip metal in order to create the desired cross-section. Roll forming is useful in waste reduction and can leverage coil-fed processing.

• Bending

Bending involves the use of press brakes. The sheet is bent into the desired V, channel, or U shape.

• Stamping

Stamping involves the use of male and female dies that allow the fabricator to shape the metal sheet.

7.Collaborate with fabricator

Do you know what the ideal fabrication process looks like? Do you know if the simplified or optimized design will help the fabricator get the job done? Well, it’s time to throw the guesswork out of the window and work with the fabricator. Involve the metal fabricator in the early design process. Talk to your fabricator and ask for feedback on the design. Discuss the different fabrication processes (cutting, welding, machining, stamping, casting) and determine the processes your design needs. The fabricator will help you make small changes to your design, allowing you to simplify the overall fabrication process further! Such changes will eventually move your project through the most efficient fabrication processes.

8.Consider metal finishing options

Most of our customers believe that the right material choice is the backbone of a successful custom metal fabrication process. This cannot be further from the truth. Indeed, the choice of material is crucial. But, the custom metal fabrication process is incomplete without the proper finishing. Several finishing options are available for a custom metal fabrication product. You can use powder coating, metal plating, anodizing, galvanizing, and other finishing methods to make your product corrosion-resistant and durable. Moreover, correct finishing will give the product the right color, texture, and shine.

9.Test before mass production

Deal with the custom fabrication design process with patience since several things can go wrong during the process. Most importantly, you should spend time testing the design before pushing it towards production. Most custom metal fabrication designs function well in theory or on paper. However, they fail miserably in real-world conditions. Therefore, we recommend testing the design to figure out whether or not the product meets the specifications. Testing will help understand if the design successfully translates into the desired product. All you have to do is ask the fabricators to provide prototypes and 3D models of the product before production.

Keeping reading!

We all know how intricate a process optimizing the design for metal fabrication is. Therefore, complacency might lead to blunders that will force you to redesign the fabrication altogether. We suggest you use the right tools, skills, and hands-on expertise to create a useful design for metal fabrication. Most importantly, you should follow the nine tips and practices mentioned above. Lastly, we highly recommend working with experts that know what they are doing. Did you find this metal fabrication design guide useful?

Let us know in the comments. Also, don’t forget to read other informative posts on the blog!

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• How to Design a Waterproof Enclosure in Manufacturing?

Introduction

Sheet metal is arguably the most versatile material available as it handsomely meets the increasing demand for customized products. One can transform it into different forms using sheet metal bending processes that are simple and inexpensive. However, bending sheet metal requires a fair amount of knowledge since it involves several critical processes. That’s one reason why we chose to guide you through the process of sheet metal bending. This post will discuss the basics of sheet metal bending, learn about the various sheet metal bending methods, and share tips that will go a long way!

What is sheet metal bending?

Sheet metal is a material that can acquire the desired shape or form when external forces are applied to it. Applying such external forces to change the shape or form of sheet metal is called sheet metal bending. This helps make any manufacturing process efficient and productive. However, the external forces alter the sheet’s exterior features, keeping parameters like length and thickness the same.

But, how does sheet metal bend? It is the malleability of the sheet metal that helps manufacturers run the sheet through different shaping processes. For example, automotive companies work on sheet metal to create automobile parts that can work perfectly as per design. Sheet metal bending also ensures precision which helps manufacture big and small engine parts.

What are the methods for sheet metal bending?

Now that we understand sheet metal quite well, let’s go ahead and discuss the different sheet metal bending methods used in the manufacturing industries. Here are some essential sheet metal bending methods you must know.

• V-bending

Used for most bending projects, V-bending uses a punch and v-die to bend metal sheets at desired angles. In this, the bending punch presses the sheet over the v-die at a required angle. The angle at which the sheet is bent is dependent on the pressure applied by the punch. 

• Air bending

Although known for its inaccuracy, the air bending method is still used as it is simple to implement. There are hardly any manipulations required in the process. You might not even need any tools to bend metal sheets through air bending. The only disadvantage of air bending is that it causes springback of the sheet metal. Stay with us to read more on bending springback.

• Bottoming

In Bottoming, you have a preset die with a defined angle and shape. The manufacturer compresses the sheet metal to the preset die’s bottom. The process doesn’t introduce springback since the punch pushes the sheet metal towards the die with force large enough to give it a permanent structure. 

• Slotting

Bending can become easy if you cut slots at the bending line. Cutting slots weakens the material, and the amount of force required to bend the sheet metal reduces significantly. Slotting is perfect to design custom metal enclosures and frames for projects of all sizes. But, we would not recommend slotting for designing heavy load-bearing parts since this sheet metal bending method weakens the material.

• Roll bending

Do you want to roll or curve your sheet metal? Use roll bending. This sheet metal bending method uses a hydraulic press, press brake, and sets of rollers to bend the sheet metal in the desired curved shape. The distance between the rollers determines the curve of sheet metal. Roll bending is advisable to form cones, tubes, or hollow shapes.

• U-bending

We have already discussed how V-bending works. Well, U-bending is akin to V-bending. The only difference between the two is the shape of the die. Unlike V-bending, here we use a U-shaped die. In other words, the sheet metal is bent in a U-shape form. U-bending is also a prevalent sheet metal bending method.

• Wipe bending

Wipe bending is another sheet metal bending method worth discussing. This is a method where the process entirely depends on the application of wipe die. In this, the sheet metal is pushed firmly onto the wipe die, which is also responsible for determining the sheet’s inner radius.

• Rotary vending

Finally, we have rotary bending. This sheet metal bending method has a significant advantage over other bending methods like wipe bending or V-bending. The advantage is its ability to leave the sheet metal scratchless. You can even turn the sheet metal into sharp corners!

What is bending springback?

The sheet metal springs back when the load during the bending process is lifted. This ‘spring back’ has to be compensated for during the sheet metal bending process. In other words, the sheet metal is bent beyond the required angle – ensuring the sheet takes the required shape even after spring back occurs.

But, why does spring back occur? Well, two different physical processes occur when sheet metal is bent. To be precise, the material on the outer layer is pulled while the inside layer undergoes compression. Since compressive strength is larger than the tensile strength, it is difficult to achieve permanent deformation on the inside layer. Hence the sheet metal tends to regain its original shape.

However, one can reduce the spring back by applying a sharp punch. This ensures a small inner radius – significantly decreasing the bending

Best tips for sheet metal bending

By now, we believe that you have acquired a basic understanding of sheet metal bending and associated processes. However, we suggest you apply a few expert tips that will help you develop better products through sheet metal bending. Check out these sheet metal bending tips before we conclude this post.

• Always check the minimum flange length

Check for the minimum flange length because you don’t want the flange to fall into the crevices. Choose a die with a width that matches the thickness of the sheet. For example, a sheet with 2mm thickness will have an inner bend radius of 2mm. You must ensure a minimum flange length of 8.5mm to create a functional design. Refer to this bending force chart to check the minimum flange length.

• Check for bend allowance

We have already discussed the bending allowance. One should strive to yield precise results when bending sheet metal. Therefore, you must account for the bend allowance. Calculate the bending allowance using the formula mentioned above. It will help achieve accuracy in finished products. 

• Make the chamfer leave enough room

Are you looking to make a flange with chamfered ends? You must ensure that the chamfer stops before the base of the detail. Apply the minimum flange length rule but make sure the chamfers leave enough room for the bends. 

• Don’t make holes close to the bend

Pay attention when making holes close to the bend. Close-by holes may get warped, and you might face difficulty fitting the bolts through them. We recommend making holes at a distance where the bending process doesn’t make an impact. The best way is to refer to the minimum flange length from the bending force chart. Punch the holes farther than the minimum flange length.

• Need symmetry? Make it obvious!

Although symmetry cannot be guaranteed, one should make sure the bending press operator understands if you want symmetry. Give the operator proper clear instructions as to how the sheet should be bent. ‘Almost’ or ‘nearly’ symmetric manufacturing only asks for trouble.

• Rivet nuts before bending

As we mentioned earlier, holes near the bending line generally deform under the bending force. Therefore, it is advisable to rivet nuts before the bending process. This will secure the holes and their functionality. However, make sure the nuts aren’t in the way of the tools during the bending process. 

• Keep the bends on the same line

Lastly, you must keep the bends on the same line. This is helpful when you have several successive flanges. It will allow the bending operator to minimize the number of operations required to create the design. There will be no need to readjust the parts and tools for every bend, which will save the operator a lot of time.

Keep reading!

The incessantly increasing demand for customized metal products requires manufacturers to learn how to bend sheet metal. Sheet metal bending processes are easy to understand, and we hope this post did a fine job at helping you learn the nitty-gritty of the processes. Believe us, the processes aren’t sophisticated enough to consult a professional.

When you are starting in the materials industry you realize that, when handling materials, you have to have greater precision for better quality. That is why we want to show you what is laser technology, how it works, and its advantages in the industry.

Laser technology

In the cutting of sheet metal parts, laser technology is one of the most used in industrial sector processes, mainly due to its precision and speed. Here we explain how laser cutting works, its advantages, and its industrial applications.

How does it work?

Laser cutting is a technique that, through thermal energy, is used to separate pieces of sheet metal.

During the cutting process, the laser beam concentrates the light on a point on the surface of the work material, raising its temperature until it melts or vaporizes. Once the laser beam has crossed the surface, the cutting process begins, redirecting the laser beam at the points determined according to the selected geometry until the material is completely separated.

Laser cutting is used to create patterns and designs on materials by (as the name suggests) cutting them. A high-energy beam of light is responsible for melting, burning, or vaporizing the material.

In essence, laser cutting is a manufacturing process that uses a very concentrated and small beam of light to cut and engrave designs, patterns, and shapes on various materials. This manufacturing process is ideal for certain materials such as wood, glass, paper, plastic, cardboard, and metal.

Once the cutting process is finished, carried out using specialized and highly technological machinery, pressurized gas (oxygen, nitrogen, or CO2) is used to extract the resulting material.

The laser cutter is made up of different parts:

Laser Resonator

The light beam is created from a resonator, which is a closed glass tube with two mirrors facing each other. The tube is filled with CO2 and other gases such as hydrogen, nitrogen, or helium. When the machine is started, an electrical discharge is generated that these gases transform into light.

Cutting head

The light bounces off different mirrors that are positioned so that the laser reaches the cutting head. Once the light beam reaches here, it passes through a curved lens that magnifies it and focuses on a single point (this is similar to using a magnifying glass to make fire with sunlight) that makes it capable of cutting and Record. Normally the cutting head is associated with a mechanical system with a belt or chain, which makes it able to move with precision over an area.

Cutting Distance

A distance is always maintained between the material and the nozzle through which the laser exits. This distance is very important as it determines the focus point. Changing this focus point generally affects the quality of the laser cut.

The light beam from a laser cutter is usually 0.1mm and 0.3mm in diameter and has a power of about 1-3 kW. This power is adjusted depending on the material and its thickness. To cut reflective materials such as aluminum, you may need a laser cutter of about 6 kW of power. This is because metals have a great capacity for thermal conductivity and reflect light, so the heat (and therefore energy) applied has to be very high to overcome these barriers.

Types of laser cutting

There are 3 types or varieties of laser cutting today:

Burned / Reactive: This type of laser cutting uses oxygen as a support gas. This gas is blown over the slit of the cut at high pressures. The material reacts with oxygen, burns, and oxidizes. This reaction produces energy, which helps the laser to have more power. This type of laser cutting is often used on metal.

Fusion: An inert gas such as nitrogen helps the laser blow molten material away from the cutting area. This makes the energy required to make the cut much less. This type is used for metals in general.

Sublimation: a high-intensity laser evaporates (sublimates) the material, making thin sheets that can be cut without the need for a support gas. This type of laser cutting is used for non-metallic materials.

Advantages of using laser cutting

Laser cutting has different advantages and benefits depending on the use that is given to them.

The main advantages are the high precision and production capacity it provides. Also, laser cutting machines are much cheaper than machining (CNC) machines. Finally, they also have the advantage of accepting many different types of materials and of being a process that requires little manipulation by one person, thus reducing the chances of contamination (this is especially true in surgical environments).

Laser technology allows the processing of a multitude of plastic, textile, organic or metallic materials.

Depending on the machinery used and the material of the piece, it can be subjected to different processes such as cutting, engraving, marking, etc.

Laser cutting allows you to process sheet metal parts and metal materials such as:

Steel sheets                                             Precious metals

Stainless steel                                          Painted metal

Aluminum                                               Brass

Anodized aluminum                                 Copper

Chrome                                                    Titanium

The history of laser cutting

The technology of laser cutting has evolved a lot despite being a relatively new machine. It has continued to escalate in the importance of industries such as aeronautics, automotive, medical, and others, and has spread to other small businesses and crafts.

The history of laser cutting dates back to 1954. The Nobel Prize winner in Physics, Charles H. Townes invented the maser and later, in 1960, the laser. And although at first it was described as “A solution looking for a problem” since in reality, it had no real use at that time; And it wasn’t until 1965 that the laser was used as a drilling tool. This was at the Western Electric Engineering Research Center, in the United States, and was used for the purpose of making small holes in diamond dies, which were used to make electrical cables.

Initially, laser cutting was used to measure distances, calculate the density of materials and was used mainly in the naval and aerospace industries. Later they spread to the chemical, medical, pharmaceutical, and engineering sectors.

Currently, we have a wonderful fiber laser cutter, these laser machines can cut materials such as steel and iron. Revolutionizing many sectors due to its intricate and precise cuts.