Metal Forming of Brackets in Bulk Requires Progressive Power Presses

Metal brackets are the unsung heroes of countless structures and devices we rely on daily. Whether holding together pieces of furniture, supporting electrical enclosures, or stabilizing building frameworks, these seemingly simple components play a crucial role in our everyday lives. The importance of efficient and precise manufacturing processes for metal brackets cannot be overstated, particularly when it comes to high-volume production.

Diverse Uses of Metal Brackets

Metal brackets serve a multitude of functions across various industries. Here are ten examples showcasing their versatility:

1. Furniture Assembly: Brackets are used to connect and support furniture components, such as shelving units and cabinet fittings.

2. Electromechanical Equipment: Brackets hold and position electronic components within devices like computers and appliances.

3. Building Materials: They are integral to constructing frameworks for walls, ceilings, and other structural elements.

4. Automotive Parts: Brackets secure components within vehicles, such as engine mounts and suspension systems.

5. HVAC Systems: They support and stabilize heating, ventilation, and air conditioning equipment.

6. Signage: Brackets are used to mount and display signs in various commercial and public spaces.

7. Plumbing: They hold pipes and fittings in place, ensuring a secure and stable installation.

8. Electrical Installations: Brackets support electrical panels, conduit, and other wiring infrastructure.

9. Shelving Units: They are critical for creating stable and functional shelving systems in both commercial and residential settings.

10. Structural Reinforcement: Brackets add strength and stability to structural elements, such as beams and columns.

The Importance of Good Bracket Design

Designing metal brackets involves more than just creating a functional piece; it requires a deep understanding of the forces and stresses the bracket will encounter. Engineers and product designers are responsible for ensuring that brackets meet specific strength, durability, and aesthetic requirements. Good bracket design considers factors such as material selection, load-bearing capacity, and compatibility with other components.

The Role of Metal Stamping Power Presses

Metal stamping power presses are essential in transforming flat sheets of metal into fully formed metal brackets. These presses use high pressure to shape metal into desired forms through various stamping operations. The process allows for the creation of brackets with precise dimensions and often complex geometries, catering to different applications and specifications.

Manual Fed vs. Progressive Sheet Metal Stamping Presses

There are significant differences between manual-fed metal stamping presses and progressive sheet metal stamping presses.

• Manual Fed Metal Stamping Press: This type of metal forming press requires the operator to manually feed individual cut sheets of metal into the press for each stamping operation. While suitable for small production runs or prototyping, this method is less efficient and scalable for large volumes due to its slower pace and higher labor costs.

• Progressive Sheet Metal Stamping Press: In contrast, a progressive stamping press automates the entire process. A length of sheet metal is fed continuously through a series of die stations, with each die station performing a different stamping operation as the strip of sheet metal progresses through the press. This method allows for high-speed, high-volume production and ensures consistency and precision across all steps.

The Manufacturing of Metal Stamping Dies

Metal stamping dies are critical tools in the stamping process. A die is essentially a custom-made mold that shapes the metal into the desired bracket form. The die-making process involves designing and machining the die to achieve the precise shape and dimensions needed. Die makers for metal stamping presses use various machined metal parts to create dies that can handle multiple forming operations, including punching, bending, and embossing.

Why Progressive Stamping Is Ideal for Bracket Production

Stamping metal brackets often requires multiple forming operations, including cutting, bending, and embossing. Using a single die to complete all these operations in one go can be highly efficient and cost-effective. Companies that perform progressive metal stamping in PA are particularly well-suited for stamping tasks because it streamlines the production process by combining several operations into one continuous sequence and their proximity to major thoroughfares, rail lines and port facilities. Progressive stamping processes speeds up production but also reduces material waste and ensures high precision across all parts.

The Benefits of High-Volume Production

For manufacturers, producing metal brackets in higher volumes can significantly lower the per-part costs. By leveraging the capabilities of metal stamping shops and partnering with experienced metal fabrication companies near me, businesses can achieve greater efficiency, consistency, and cost-effectiveness in their bracket production. Investing in a metal stamping shop with advanced equipment and skilled die makers for metal stamping presses ensures that you get the best results for your high-volume needs.

In summary, whether you’re looking for progressive metal stamping in PA or seeking a reliable metal stamping shop, focusing on bulk production can help you reduce costs and improve your product’s overall quality.

Metal Brackets Are Used Everywhere But Are Not Easy to Make

The production of metal brackets through sheet metal stamping is a critical process in manufacturing, involving meticulous design and powerful machinery. The journey begins with the mechanical design process, often carried out by mechanical engineers or industrial designers. These professionals use computer-aided design (CAD) software to create detailed blueprints of the bracket, specifying dimensions, material type, and any special features such as holes, bends, or slots. The design must ensure that the bracket can withstand the mechanical stresses it will encounter in its final application while being cost-effective to produce.

Metal brackets are ubiquitous in various industries due to their versatility and strength. Here are five industries that extensively use metal brackets in their equipment:

1. Automotive Industry: Metal brackets in automobiles secure various components such as engines, transmissions, exhaust systems, and interior fittings. These brackets must be robust to handle the vibrations and stresses of vehicle operation.

2. Construction Industry: Metal brackets are essential in building frameworks, supporting structures like beams, and securing pipes and electrical conduits. They ensure structural integrity and safety in both residential and commercial buildings.

3. Electronics Industry: In electronics, metal brackets hold circuit boards, components, and assemblies in place within devices like computers, televisions, and mobile phones. They need to be precisely manufactured to fit intricate designs.

4. Aerospace Industry: The aerospace sector uses metal brackets to secure and align critical components within aircraft. These brackets must be lightweight yet strong enough to endure extreme conditions during flight.

5. Medical Equipment Industry: Metal brackets in medical devices and equipment secure parts, supports, and assemblies, ensuring reliability and safety in demanding medical environments.

The production process begins with sheet metal stamping, a method favored for its efficiency and precision. Metal stamping presses mold and form metal brackets by applying high pressure to a sheet metal blank between a die set. This process is preferred due to its ability to produce complex shapes with tight tolerances at high volumes, reducing the need for additional machining or finishing.

A metal stamping power press differs significantly from a typical press brake. A press brake is used for bending and folding operations, manually or with CNC control, to form parts from sheet metal. In contrast, a metal stamping power press can perform a variety of operations such as punching, blanking, embossing, bending, and flanging, all in a single stroke or series of strokes. This versatility makes it ideal for producing intricate and high-volume parts like metal brackets.

Within metal stamping, there are two primary types of presses: manual sheet-fed stamping presses and progressive sheet-fed stamping presses. A manual sheet-fed stamping press requires an operator to manually feed the sheet metal into the press for each cycle. This method is suitable for low-volume production or simple parts but is labor-intensive and less consistent.

On the other hand, a progressive sheet-fed stamping press uses a continuous roll of sheet metal that feeds through the press automatically. The strip of sheet metal passes through multiple stations, each performing a different operation, resulting in a completed part by the end of the line. This method, known as progressive metal stamping, is highly efficient for high-volume production and complex parts, as it reduces labor costs and ensures consistent quality.

Most metal stamping companies in PA and beyond often leverage these advanced techniques to offer their custom sheet metal fabrication services. They can take over sheet metal stamping projects from design to production, ensuring seamless execution and high-quality results. Companies like FBF Inc specialize in this area, providing reliable and efficient production of metal brackets and other stamped parts.

In conclusion, the sheet metal stamping process is vital for manufacturing durable and precise metal brackets used across various industries. Whether it’s the automotive, construction, electronics, aerospace, or medical equipment industry, the need for high-quality brackets remains constant. FBF Inc stands out in this competitive field, known for their fast turnarounds and competitive pricing, making them a go-to choice for businesses needing custom sheet metal fabrication. If you’re looking for expert metal stamping services, consider FBF Inc for your next project.

Cut Complex Geometries With Speed and Precision Using Fiber Laser Cutting

Precision is essential when cutting thin metal used in medical instruments, industrial equipment and parts for the electronics industry.The quality of the cut can have a significant impact on the effectiveness of the part, and negative consequences if tolerances are not adhered too. As a result, metal fabrication companies place quality and precision as a top priority, but also need to consider other factors to ensure their business thrives. A fiber laser cutting machine can produce high precision of metal cutting for some very complex shapes while contributing to business goals of cost reduction and improved lead times.

3 Dimensional Cutting

One of the most significant ways laser technology stands out among metal fabrication methods is its ability to work in three dimensions if necessary.A custom laser cutting machine using solid state processing can can cut intricate shapes in one pass with amazing precision, which is often an impossible feat for wire electric discharge machining(EMD), the next leading method. To create a three-dimensional shape using wire EMD requires additional equipment and software, which means higher costs and longer processing times. A CNC turning mill utilizes a 3-5-axis motion package, allowing it to cut in two or three dimensions with specialized cutting tools. A solid state fiber laser cutting service uses a beam of light, no investment in specialty cutting tools.

Speed

When it comes to speed, nothing compares to a fiber laser cutting service cranked up for speed.We have done over 7 different metal parts from one sheet of 108 inch metal. The computer onboard arranges the shapes to make the most economical use of the metal sheet, minimizing waste.  Other fabrication methods require several passes to achieve the same level of precision and take much longer to complete the 7 different parts.

Laser technology also includes the option to utilize fusion cutting, which introduces gas to the cutting zone during the process. When oxygen is added, the speed can increase up to 50% without detrimental effects on the quality.

Accuracy and Quality

Metal fabrication with lasers can provide the cleanest edges of any method. The intense focus of the laser also allows for incredible precision. Laser technology can create products that have:

• Exit sides with minimal dross/burr
• ±0.001 in. dimensional accuracy
• Less than 0.002 in. cut width
• Less than 0.3 µm “as cut” roughness

Fusion cutting can also be used to increase the quality by using nitrogen instead of oxygen. Although this is a slower process, the mobility and power of a laser ensures that fusion cutting with nitrogen is still a quicker process than a turret punch press for example.

A laser cutting service proficient operating their equipment can produce high quality metal blanks while ensuring a quick turnaround. Metal fabrication with lasers is transforming the way metal fabrication companies in Philadelphia and meeting the demands of their clients. Custom laser cutting of metal is slowly replacing the way complex metal parts are made today. The additional option of fusion cutting with oxygen, nitrogen or argon as an assist gas can speed up production times but should be allowed specialized jobs due to controlling gas emissions.

Cutting Complex Metal Blanks Just Got Easier, Faster and More Affordable

There are thousands of products that are manufactured using metal parts cut the old fashion way. This article is focused on laser cutting technologies that are faster and a more affordable way of cutting metal parts. Almost all kinds of metals such as the mild steel, aluminum, and nickle alloys can be cut using the advanced laser technologies that are available.

Laser cutting achieves high precision cuts as well as improved production speed compared to punch presses and shears. Lasers are highly programmable and don’t require any tooling.

The laser cutting helps get more complex parts done with less waste.There are two primary types of laser technologies that are available for cutting complex parts, One is CO2 lasers and the other is solid state fiber laser cutting machines. One of the major benefits of fiber lasers is the minimized energy consumption compared to CO2 laser machines currently on the market.

Fiber Lasers

Fiber lasers tend to do a better job with thinner metal sheets. TruDisk solid-state lasers enable you to work quickly, particularly in thin sheet metal. This is possible because they emit abeam with a wavelength of approximately 1.03 µm, which is absorbed significantly more intensely than the wavelength of CO2 lasers: these lasers transfer more energy to the sheet metal, enabling cutting to be carried out more quickly.

CO2 Lasers

CO2 lasers are particularly effective for any applications that require especially smooth and high-quality cut edges. They are the right choice for cutting edges that will be visible and where smooth edges matter for the further processing of your part. CO2 lasers are an older type of laser technology, which means that in general, the price to acquire them has come down over time.  Yet, it’s a technology that has continued to evolve beautifully, even as prices fall. CO2 lasers, while not as fast as their fiber cousins, are extremely flexible and adaptable for use on the most common types of materials, such as aluminum and steel, and on a range of material thicknesses.

When investigating a laser cutting service for your next fabricated metal part, it would be wise to quote out a few companies that do metal fabrication with lasers and ask them about the quality of the cutting surface for the metal parts you are making. If you are just doing a laser cut for metal blanks that don’t require any forming, you may not be concerned with the type of machine. But if you are doing some custom laser cutting of more complex parts that need additional forming, then we recommend that a fiber laser cutting service get involved in the project. Not every metal fabrication shop in Philadelphia is created equal.

5 Steps to Improve Press Brake Productivity

Let’s face it. When it comes to your metal fabrication shop needs, your main focus is on producing high quality results cost effectively. Equipment productivity is key to reducing internal costs and raising the margins of profitability on each job. If there are areas within your production process that slow down productivity, let’s identify them and find a few solutions that tend to bog down a fabrication flow. There are five steps you can follow to improve the productivity when it comes to the press brake operations.

Step 1: Organize the Workstation

Organization is important in any metal forming company with welding capabilities. If your operators must stop to find tools, this takes him or her away from focusing on operating the press brake. A cluttered workstation is also a safety hazard. There needs to be a place for everything within easy access. Operators should be trained to put tools back to specifically assigned spots so that they and others can access them anytime.

Step 2: Handling Tools Effectively

There are ways to do things that can have a huge impact. Most fabrication companies have a solid inventory of press brake tooling, each tool is relevant to a specific type of bend. Cutting corners on tool selection or not putting the time into choosing the right tool can add extra steps into the forming process. Stage-bending, for example, helps reduce the need to adjust or change die heights. Sometimes the decision to do stage bending instead of swopping out for the right tool can add more time than originally allocated in the estimate. Reducing overall set up time for each bending stage and lead to dollars in the bank. This all also leads to easier change outs and helps increase productivity.

Step 3: Take Advantage of Precision Tooling

Getting operators into better productivity habits is important. Have them work smarter and training them on the right tooling for each task is part of that. Segmented tooling allows the operator work with precut pieces to reduce waste and save time. That may require the blanks to be cut on a turret press or fiber laser cuttingmachine before it arrives at the press brake first. Furthermore, such operations reduce press brake tool wear, improves quality and lets you put less experienced operators on the job while reserving your more experienced operators for much more complex work.

Step 4: Use Power Clamping

A great way to reduce setup time is with power clamping. Operators can load and unload in front of the press, which goes faster than loading at the ends of the brake. It also saves space since front loading requires less space around the press brake. Up time for the machine is increased because it allows for clamp and seat tooling in one step.

Step 5: Use Control Technology Innovation

Finally, you should make use of any CNC programming installed on the press brake. If your operator is not fully trained on the full capabilities of the machine’s computer, let’s get them trained ASAP. Many of the CNC machines today can do so much more that they are currently being tasked with. Most machine manufacturers offer the training but require your operators to fly to a remote location. Our metal fabrication shop in Philadelphia brings the trainers to us and operators are trained on our machines. Don’t become one of those sheet metal fabricators that accepts the status quo as good enough. Continuous improvement should be part of the company culture.

Press Maintenance and Safety is Important

Stamping metal components uses very large equipment that has often been around for a few years. To fill orders and reach new customers, managers must work to reinforce a safe metal stamping environment. Everyone who works on or around the press at the metal stamping company must be committed to press maintenance and safety.

Training the Individual

Before anyone can work on a large power press, he or she must receive and understand stamping equipment training. The type of training delivered should include information about wearing personal protective equipment like goggles, steel tipped shoes and learn how to operate the press safely. It should also outline procedures for identifying hazards and reporting risks. Progressive metal stamping requires everyone to commit to both initial training and retraining. With a comprehensive training program, supervisors are confident employees know the safety rules.

Having a Zero-Tolerance Policy

Metal stamping power presses are incredibly powerful machines. They are also very dangerous if someone operates them in a way they were not intended to be used. Metal stamping company supervisors realize they must have a zero-tolerance policy for press misuse or unsafe behavior. Workers also must conduct press maintenance evaluations truthfully, pledging never to overload presses or misuse equipment.

Using Die Blocks and Cable Covers

When trying to stay on track to complete an order, workers may be tempted to use die blocks for other purposes outside of their intended purpose. Simply put, the original die blocks for a project are company assets just as the equipment itself. Die blocks should not be used to stand on, raise bins off the floor or turned in a press to hold it open. When not in use, they should be returned to the tool and die inventory room. Likewise, no safety cable should be exposed. Instead, supervisors must be certain all necessary covers and other protective pieces are securely in place.

Identifying Hazards

To avoid accidents, the press must be free from all hazards, scrap, foreign debris or anything not part of the safe operation of a power press. Everybody on the floor must be responsible for identifying all risks without exception. Tripping hazards, sharp objects, and other dangerous items should be removed as soon as possible. If the hazards are fixtures, they should be clearly marked and included in safety briefings and with yellow or orange markings.

Making Repairs

Keeping the press in good shape is not only good for business, it is essential for keeping employees safe. Machines that have missing safety guards or tendencies to malfunction are ticking time bombs. Managers, shift leaders and supervisory personnel must take safety as a number one priority including all employees who work around the press. If equipment is not functioning properly, it is everyone’s responsibility to submit a work order for repairs. Progressive metal stamping company supervisors should also have the authority to stop work until the completion of a repair. No timeline or due date for a custom metal stamping project is more important that the safety of an employee. If you work for a metal stamping company in Pennsylvania, you probably have an independent 3rd party that helps oversee the safety environment of your metal fabrication shop.

Press safety and maintenance are inextricably intertwined. For stamping companies that are committed to reducing injury, there is no substitute for a safety and maintenance plan.