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[Project Success Story] Integrated Appliance Hinges + Powder Metal

 

Hinges may seem like simple concepts. However, a little ingenuity can add stability, support, movement, and durability to a product.

That includes household appliances, where high-precision components and design are musts for success. The top three qualities necessary in an appliance hinge are:

  • Accuracy – repeatable & precise operation to mitigate safety hazards
  • Functionality – an easy & simple user experience
  • Durability – able to withstand repeated use over time without wearing out

Is your part manufacturing method making the grade? Or might another process offer better results or lower costs ... or both?

In this Project Success Story, learn how one supplier turned to Atlas to convert its component to powder metal. This conversion helped integrate an appliance hinge more effectively into a roller assembly. As a bonus, the solution improved the product's aesthetics too!

(You Might Also Like: Project Success Story – Hand-Tool Assembly)

Application Hinge Conversion (1)
THE PROBLEM – Integrating a Better Appliance Hinge

  • Industry: Appliance
  • Product: Hinge for roller assembly
  • Project Type: Process conversion
  • Original Method: Machining, wrought stainless steel

The original hinge was a sub-assembly that required stacking (laminating), aligning, and riveting three stampings to achieve the required thickness of 0.360". The cam form was machined to smooth the edge.

The process of stacking stampings in the original hinge assembly process presented misalignment issues, creating inconsistent hole features.

Altogether, the existing process added undue challenges, time, and secondary operations.

However, choosing a powder metal conversion made all the difference! 

THE SOLUTION – Converting the Hinge to Powder Metal

  • New Method: Powder metallurgy
  • New Material: Stainless steel PM grade with high resistance to corrosion & wear

Application Hinge Conversion

It was quickly apparent that the current hinge needed a more efficient manufacturing process. Enter powder metallurgy.

The advantages of the powder metallurgy process over the original process are:

  • Net-shape precision
  • Enhanced aesthetics
  • Tighter tolerances & more consistent features

The new, converted hinge design was pressed to net shape. In other words, we were able to manufacture the part to its final density and dimensions without machining, while also eliminating the need for subassembly components. This allows us achieve a lot in a single step:

  • Holes
  • Mounting plates
  • Edge details

The powder metallurgy process also improved part-to-part consistency, hole feature tolerances, and running surface for the part. 

Atlas also supported the appliance component company's testing and validation process. By providing production-intent "pucks" out of the desired material, the customer was able to fine-tune the final shape before tooling up the part design. 

THE RESULT – More Time, Money, & Quality in the Buyer's Pocket

  • What the customer said:

"We designed an appliance mechanism component where the laminated stamping approach was not working adequately. The PM part that Atlas helped us convert provided superior structure, functionality, and far more repeatable performance."

While a process change sounds daunting, a PM-suitable part can actually accelerate the journey toward efficient production. By converting production to powder metallurgy, the customer solved several issues at once:

  • Switching to powder metallurgy reduced production costs by eliminating assembly and machining operations. Pressing the part with PM met all geometry requirements in a single stroke.
  • The net-shape forming process created a smooth-running surface for the hinge in the roller structure. As a result, the converted part has a cleaner, more streamlined look than the original hinge design. 
  • The integration of additional features improved installation time for the final assembly. 
Understanding PM's diverse capabilities, the buyer now relies on Atlas for many types of components. Whether it's a kitchen appliance hinge or a door hinge elsewhere in the house, powder metal often offers more for less.


Reimaging Your Integrated Appliance Hinge (or Something Else?)

Are you an appliance part manufacturer ready to assess your design for conversion potential? Or do you simply want to learn more about powder metal for a different application?

Either way, visit our Appliance page to start unlocking the potential of powder metal:

See Appliance Solutions

 

 

(This article was originally published in January 2023 and was recently updated.)
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