Portfolio 1

Project Name & Description

Powder Metal Precision Gear

Capabilities Applied/Processes

 Multi-level compaction tooling, sinter hardened powder

Equipment Used to Manufacture Part

Compaction Press, Sintering furnace, automated handling

Overall Part Dimensions

Tightest Tolerances

Run out specification is 0.00267 inch, overall length held to +/- 0.00196 inch, total composite error held well within the upper and lower limits of AGMA level 7 standards

Material Used

Sinter hardened powder

Material Finish

Industry for Use

Automotive

In Process Testing/Inspection Performed

SPC throughout the manufacturing process

Volume

In excess of 300,000 units per year

Delivery/Turnaround Time

Two-year development time,  delivery at 100% of customer demand

Delivery Location

USA, China, Mexico

Standards Met

AGMA level  7, IATF

Why did you pick this piece?

Example Answers:

• Highlights our design and engineering capabilities

• Highlights high volume capability

• Demonstrates ability to combine multiple pieces into a single product.

• Focus on the benefits of sinter hardened material for heat treatment vs conventional oil quench heat treatment

• Demonstrates the “no human hands “ approach with automation

Why did the customer choose you to do this job?

Example Answers:

• Provide full service (design, manufacturing and installation)

• Local vendor

• Previous experience in metal fabrication of custom outdoor shelters

• Engineering and manufacturing capabilities to produce this complex gear

• Responsiveness to customer-driven changes and demand fluctuations

• IATF Certification

• Superior quality, customer service, and On-time delivery

Were there any difficulties you had to overcome to complete the job?

Example Answers:

• Needed to meet government safety codes

• All materials of construction were specified for food industry compliance and ready for marine duty.

• Creating a very complex and tightly tolerance component in high production volumes.

What positive feedback did you receive from the client upon completion?

Example Answers:

• The customer was pleased with every aspect of our work and has come back to us for additional project partnerships

• We are the customer’s best supplier, we go above and beyond.

• Awarded the next generation of the gear

What would you like to point out about this piece/process? (Special features, processes, materials)

Example Answers:

• Part is an unconventional size for an aluminum enclosure

• Complete machining capabilities are featured in these products including: Precision CNC Turning, Sinker EDM, Laser drilling, and TIG welding for final assembly

• Compound gear, tight tolerances, high volume

Describe the title/role of the employees involved in the project?

Example Answers:

• Certified welder

• Design engineer

• Sales engineer, new product development engineer, manufacturing team, quality manager, employees on the floor who make the product