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Author Archives: Jody Key

  1. Building Charging Systems for Electric Vehicles

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    Building Charging Systems for Electric Vehicles

    Charging systems are used in many different settings to power electric vehicles. They can be built for a number of purposes, from overnight charging to high-speed charging for long-distance travel. This blog will discuss the growing need for efficient EV charging systems and detail the types of EV charging systems users can choose from.

    Importance of Charging Systems for Electric Vehicles

    As the number of electric vehicles on the road increases, so does the need for efficient EV charging systems. Having reliable access to charging systems provides added convenience and flexibility for EV owners. It also removes fossil fuels from the equation, which is essential to achieving long-term sustainability goals and supporting the continued adoption of electric vehicles.

    Types of EV Charging Systems Explained

    When building charging systems for electric vehicles, there are two primary challenges to address. The first is logistics, with many consumers expressing a desire for more charging stations. As of now, there are far fewer charging ports than are needed to achieve carbon-free energy systems by 2050.

    The second issue involves concerns regarding travelable distance with each charging cycle. Currently, several main types of charging systems are available for electric vehicles:

    • Level 1. These are slower systems that many homes use to charge vehicles overnight, with each hour of charging supplying enough power for a five-mile driving range.
    • Level 2. Many public facilities and workplaces use these faster chargers, which supply enough charge every hour for 25 miles of range.
    • Level 3. Ideal for gas stations and other locations accommodating long-distance travel, these are the fastest chargers, supplying sufficient power for up to over 200 miles of range after 30 minutes of charging.

    Building high-quality electric vehicle charging stations promotes a strong charging infrastructure that can meet the varied needs of EV vehicles.

    What Makes up an EV Charging System?

    Electrical vehicle charging systems rely on a number of components, connectors, and systems:

    Power Sources and Compatibility

    Charging systems need to be able to draw power from reliable sources and must work with multiple types of EVs. The electric grid is a primary source for EV power. Power lines in the grid transmit electrical power to charging stations, transitioning the power into direct current (DC) electricity to supply the charge.

    Due to the external installation of many charging stations, power sources often require an EV power distribution cabinet. This provides ongoing protection from harsh weather and other environmental conditions.

    Connectors and Cables

    Charging systems typically use one of two types of connectors:

    • Alternating current (AC) connectors for slower chargers running on AC
    • DC connectors for faster chargers using DC

    In North American markets, you can obtain two primary charger plug types, including CCS 1 for DC charging and SAE J1772 (Type 1) chargers for Level 1 and 2 AC charging.

    EV Charging Connector Type EV Charging Connector Type

    Software and Monitoring Systems

    These systems also require management and monitoring tools to maintain efficient energy use. Innovations in software allow for intelligent infrastructures that effectively track energy usage. For instance, systems may use cloud-based solutions that offer features like remote real-time monitoring and management or in-depth data analytics. These solutions help meet drivers’ needs while also optimizing the user experience.

    Building Charging Systems for Electric Vehicles

    Site and Power Requirements

    EV charging systems must perform according to several critical requirements:

    • Power Requirements. Different electric vehicles will require varying power levels. While most home chargers use up to 7,200 watts (W), this fluctuates based on the charger and charging mode.
    • Site Setup Needs. While indoor installation will provide better protection from the elements, some may prefer outdoor-rated systems for parking lots and other exterior sites. Regardless of the placement of charging systems, they must connect to a nearby building’s power supply.
    • Safety Compliance. Chargers also need to be dependable and safe, from the conductor used during installation to the amount of overhead space they provide. It’s important to consult the manufacturer’s instructions for details about proper usage, storage, and charging, as any unauthorized modifications could render charging systems unsafe.

    Charging Systems for Electric Vehicles at H&S Manufacturing

    Selecting the best charging station for a given area ultimately depends on build and charging requirements. AT H&S Manufacturing, we are familiar with the evolving charging needs of our customers. We provide custom metal fabrication services for a variety of applications, including automotive, aerospace, electronics, and medical devices.

    For help with an EV charging system build, turn to the experts at H&S Manufacturing. Request a quote today to learn more about our capabilities and get started on a custom build.

    Public Charging
    Home Charging Stations
    Public Charging
    Fast Charging

  2. Emerging Market of Electric Vehicles

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    Emerging Market of Electric Vehicles

    As the automotive industry continues to adopt electric vehicles (EVs), PwC analysts predict the market could expand almost tenfold by 2030. This projection is supported by an increase in consumer interest and the willingness of automakers to go all-in for the expansion of the U.S. electric vehicle market.

    Substantial government funding has also played a significant role in the growing EV sector. The 2021 Infrastructure Investment and Jobs Act allocated $7.5 billion to EV charging infrastructure, and the Inflation Reduction Act introduced tax credits for those purchasing new and used commercial and passenger EVs.

    Considerable investments are still needed to build a national charging network for the estimated 27 million U.S. electric vehicles expected on the roadways by 2030. While such an undertaking will prove challenging, it is necessary to ensure the future viability of EV transport. U.S. manufacturers throughout the EV supply chain—from battery manufacturers to metal part fabricators—are ramping up production of EV components and charging infrastructure parts to support these electrification trends.

    Electric Vehicle Market Trends

    PwC’s recent study highlights the main U.S. electric vehicle market trends to expect in the coming years. Since 2021, over 20 electric vehicle charging startups in the U.S. and the EU have been acquired, many by major energy companies. In the past four years, at least five EV businesses have gone public through special purpose acquisition companies (SPACs), and funds raised from initial public offerings (IPOs) have given these businesses the cash to acquire other EV businesses.

    Analysts expect the workplace segment to be the fastest-growing charging segment, with anticipated growth from around 0% of the total EV market to approximately six million charge points (or 17%) by 2030. Multi-unit residential apartment buildings are another fast-growing sector, also expected to expand from nearly 0% to 17% of the market by 2030. This rapid growth will task construction and engineering firms with integrating charging points in new and existing garages and parking lots.

    Meanwhile, EV sellers (like dealerships and OEMs) will dominate 70% of the market for residential chargers in single-family homes. Integrators and installers are predicted to serve 80% of all other EV charging market segments.

    Key Takeaways From the EV Supply Equipment Market

    The electric vehicle supply equipment (EVSE) market has the potential to grow at a 15% compound annual growth rate (CAGR), from $7 billion in the early 2020s to $100 billion in 2040. Here are some insights into the future of the following key areas in the EVSE market.

    Hardware Manufacturers

    Product developers of EVSE face high upfront costs for manufacturing, research, and development. These costs are necessary to remain competitive in the EV market, and hardware providers can expect considerable long-term gains from the rising demand for EVSE services and products.

    Software Providers

    To generate a revenue stream from EVSE applications, software companies must develop customer-facing and back-end solutions. Profit margins are expected to increase as fleet management solutions are integrated into existing on-the-go systems.

    Installation Services

    Despite being a lower-margin business, installation services are expected to grow quickly as the need for public charging infrastructure continues to increase. As federal government funding gets disbursed, installation service companies may find relief from the reduction in new installations and start experiencing a significant increase in retrofitting outdated infrastructure.

    Charge Point Operators (CPOs)

    Today, many charge point operators (CPOs) are burdened by low utilization rates and hefty capital expenditures. While these businesses are in it for the long-term payoff, a successful CPO business model will be challenging to execute. However, companies that manage to ride the wave may reap substantial dividends when charging stations become as common as gas pumps.

    As EV adoption rates become mainstream, integrated charge point operators (CPOs) will have the chance to improve their bottom lines by bundling offerings such as:

    • EVSE Financing
    • Operation
    • Utility Charging
    • Maintenance

    Creating Jobs in the EV Market With the Infrastructure Act

    The $1.2 trillion in funding from the Infrastructure Investment and Jobs Act aims to tackle the following challenges facing the expanding U.S. electric vehicle market:

    1. Address the repair backlog in transport systems
    2. Modernize and secure existing infrastructures
    3. Support the transition to a clean economy

    Part of the funds from this long-term federal investment includes the expansion (by thousands of miles) of the electrical grid’s high-voltage transmission network across the U.S. This expansion will help facilitate the efficient delivery of renewable energy through transmission corridors marked high priority, supporting the nation’s transition to an integrated grid that can help regions share power and control electricity shortages and pricing volatility.

    The Infrastructure Investment and Jobs Act comprises a variety of grants, loan financing programs, and technology development incentive payments that businesses need to understand to take full advantage of the available offerings while anticipating the reporting obligations and conditions that come with them.

    Automotive Metal Fabrication by H&S Manufacturing

    To keep pace with the rapid acceleration of EV adoption in the U.S., EV charging infrastructure builders need to scale up their operations accordingly. H&S Manufacturing has the expertise and equipment to help EVSE businesses meet the challenging supply needs of EV charging stations. Since 1968, H&S Manufacturing has provided custom metal fabrication services for the automotive, electronics, medical device, aerospace, defense, and other critical industries. Our experienced team can help you select the best material for your application and deliver high-quality custom components for your project.

    Contact us today to connect with a team member about the specific demands of your EV project.

  3. Sustainment: Building a Nation of Builders

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    Sustainment: Building a Nation of Builders

    Building a sustainable future means building sustainable practices across the U.S. manufacturing industry. Sustainment is a public benefit corporation dedicated to fostering this mission.

    We make sure that American manufacturers have the technological tools they need for profitable manufacturing, streamlined supply chain management, and long-term partnerships with defense, federal, and state organizations within the government.

    Public benefit corporations stand apart from other corporations in their singular commitment to public benefit. At Sustainment, our team’s mission is to support yours. Learn more about how we can help you meet your organization’s goals and strategically collaborate with suppliers, clients, and business partners.

    What Sets Sustainment Apart?

    Sustainment helps manufacturing organizations implement successful domestic manufacturing projects. Our next-generation technology platform connects local and regional suppliers with manufacturers, building a strong manufacturing sector that lowers our country’s geopolitical risks on an international front.

    Mission-Driven Approach

    Our mission-driven approach centers on domestic manufacturing capabilities.

    When you choose to incorporate Sustainment into your processes, you gain access to our unique mission, technology, and cost management tools. We help our clients harness these technologies to find continued success in an evolving industry.

    Streamlined Manufacturing

    We build and develop the technology manufacturers need to simplify production and create profit. Our platform cuts down on waste and time-intensive processes, increases efficiency across key processes, and creates cleaner, faster workflows from start to finish.

    Profitability and Cost-Effectiveness

    Trimming down costs and achieving profitability requires the right tools. Sustainment is focused on helping US manufacturers reach their financial goals by implementing cost-effective processes and partnerships while maintaining high-quality production standards.

    Reimagining American Manufacturing

    Creating a strong core of American manufacturing is important to Sustainment’s mission, as well as contributing to a sustainable domestic production pipeline and creating economic resilience.

    Our team is committed to transforming the American manufacturing landscape by creating a secure, streamlined ecosystem that fosters collaboration, fast transactions, and progress.

    Hyperconnected Ecosystem

    Sustainment’s platform supports security through connection. Local, regional, and nationwide suppliers and manufacturers can easily find qualifying contacts, negotiate on project specifics, and complete transactions with minimal waste or delays. We facilitate instant and mutually beneficial communication between producers and commercial and defense organizations.

    Secure Transactions

    Financial security is a growing concern for every sector. Creating secure payment channels for every vendor can also be highly manual and prove burdensome for manufacturers waiting to begin their work.

    Sustainment’s secure transaction platform creates a space where buyers, suppliers, and government organizations can securely complete transactions and streamline procurement. Together, we are building a more efficient supply chain.

    Core Values

    Since Sustainment is a public benefit corporation, our mission and values are at the core of what we offer. We operate based on these core values:

    • Integrity. All of our endeavors and services are transparent, and we operate with a strict code of honor.
    • Innovation. We are continuously innovating to help our clients access relevant technologies.
    • Expertise. Our team members have years of experience in both technology and manufacturing.
    • Service. We’re committed to supporting our clients so they can continue to serve theirs.
    • Commitment. Our mission is central to every decision we make.
    • Collaboration. We foster collaboration between business entities, integrating technology and products the American manufacturing industry needs to thrive.

    Join the Mission

    At Sustainment, we are focused on fostering the ongoing success of manufacturing in the U.S., providing tech solutions that empower our manufacturers. As the industry evolves, so do our efforts to support the larger industry.

    If you’re also committed to the growth of the American manufacturing industry, reach out today to join Sustainment. We’re currently looking for individuals with technology or manufacturing expertise who are dedicated to furthering our mission.

  4. Importance of Trade Shows

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    Importance of Trade Shows

    Trade shows play a crucial role in manufacturing. Industry conferences and trade shows provide a venue for professional networking. They also promote business growth and foster collaboration.

    This blog will cover the primary advantages of attending DIBCON, Design2Part, and other events. Read on to uncover the importance of trade shows and the critical role they play in the larger industry.

    Networking Opportunities

    Trade shows typically attract a range of industry professionals, including buyers, engineers, manufacturers, and suppliers. One reason trade shows are worth it is the unique networking opportunities they provide. Participants get the chance to exchange ideas, explore partnerships, and explore new business ventures.

    Brand Exposure and Visibility

    Showcasing products and services at a trade show can help exhibitors:

    • Enhance Brand Recognition
    • Gain Exposure
    • Attract New Customers

    At a trade show, attendees can focus on a particular industry. This provides a meaningful way for exhibitors to connect with their target audience.

    Face-to-Face Interactions

    Meeting potential clients in person can build significant credibility and trust, giving them the opportunity to:

    • Answer Questions
    • Demonstrate Products
    • Directly Address Concerns

    Insights Into Market Research and Trends

    Trade shows also allow professionals in manufacturing to gather valuable insights into the following:

    • Current Trends
    • Emerging Technologies
    • Innovations
    • Market Research

    Attendees and exhibitors can identify knowledge gaps, learn from their competition, and adapt their product strategies accordingly.

    Lead Generation and Sales

    Collecting leads at trade shows can jumpstart valuable business relationships. In addition, following up promptly after an event can convert those leads into meaningful sales.

    Educational Sessions and Workshops

    Industry conferences can often include the following:

    • Panel Discussions
    • Seminars
    • Workshops

    These informative breakout sessions can help attendees gain invaluable industry knowledge, learn from experts, and stay updated on current trends.

    Showcasing New Products and Services

    Trade shows are the perfect platform for launching a new product. They can attract potential new customers and generate buzz on the exhibition floor. Whether you are a buyer, exhibitor, or OEM engineer, trade shows can offer considerable value for professional growth.

    Trade Shows We Participate In

    Understanding the importance of trade shows, H&S strategically participates in both the DIBCON convention and Design2Part show to attract new clientele and professional growth opportunities.

    DIBCON Convention

    • Industry Insights. DIBCON provides valuable industry knowledge, helping H&S uncover the latest developments for better-informed offerings and strategies.
    • Face-to-Face Connections. Personal interactions at DIBCON help us build trust with potential and existing clients. Receiving direct, unfiltered feedback helps us improve our products and services.
    • Professional Networking. At DIBCON, we can develop lasting business relationships, explore partnerships, and collaborate with other industry professionals.
    • Educational Opportunities. Conventions such as DIBCON provide workshops, keynotes, and educational sessions that allow H&S to remain adaptable and informed in the industry.

    Design2Part

    • Targeted Audience. At the Design2Part show, H&S team members connect with industry professionals seeking advanced manufacturing solutions. Attendees include buyers, managers, and decision-makers looking for top-quality services and suppliers.
    • New Sales Leads. Design2Part provides a valuable platform for finding potential customers and clients. H&S can collect important contact details and nurture qualified leads to explore future sales potential and opportunities.
    • Product Launch. As an exhibitor, H&S can offer hands-on demonstrations to showcase new products, allowing attendees to visualize the benefits.
    • Brand Awareness. H&S uses this event to enhance brand recognition and communicate our values to a targeted audience.

    Learn More with H&S Manufacturing

    Understanding the importance of Design2Part, DIBCON, and other industry events has helped H&S become a vital player in the manufacturing and fabrication market. We have gained valuable brand exposure, built lasting professional relationships, attended many educational workshops, and showcased our products and services to our intended audience.

    Contact us today with any questions or concerns and we will respond as soon as possible. You can also request a quote based on the specific needs of your application. We look forward to working with you and meeting your team at the next industry event.

  5. The Importance of Precision Medical Device Manufacturing

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    The Importance of Precision Medical Device Manufacturing

    Medical instruments, equipment, and devices have strict specifications for materials, dimensions, tolerances, and finishing processes. They must be safe for critical healthcare applications and meet US and international standards in order to be brought to market.

    Manufacturers serving the medical industry use several processes to achieve highly precise and accurate parts and components. Here, we’ll take a closer look at precision in medical manufacturing and some of the tools and operations used to achieve the highest quality components.

    What Is Precision Manufacturing?

    Precision is how closely parts match each other in terms of their finished dimensions. High precision means parts have little to no variation within a batch or production run. Achieving high precision is possible in manufacturing with computerized and automated equipment, such as laser cutting, programmable CNC equipment, and laser welding.

    Ideally, components will also have a high level of accuracy, meaning the finished parts very closely match the design on the part print and correspond to dimensions and tolerances. Achieving both high precision and accuracy is the goal in medical device machining and manufacturing, regardless of the equipment and processes that are used.

    The Importance of Precision Manufacturing for Medical Devices

    Manufacturing for precision and accuracy is critical in medical applications to ensure proper function, long service life, patient safety, and compliance with regulations and standards.

    Whether part of an assembly, instrument, enclosure, or other medical component, the more accurate it is, the better it will function in the real world. Likewise, higher precision makes it more likely that all finished devices or equipment in a batch or production run will function correctly.

    Precision and accuracy come into play in every aspect of medical manufacturing. Some examples include removing small amounts of material to achieve hole diameters, forming proper bend angles and minimizing springback, or correctly locating welds in critical components. In most cases, the machines’ movements are controlled by computer programs. This makes each process highly repeatable and efficient because it avoids human fatigue, error, and variation.

    Some examples include:

    • CNC medical precision machining: Subtractive operations, such as drilling, boring, cutting, milling, or turning, remove material from a workpiece to achieve part features and dimensions. All movements, blade angles, and operations are based on a computer-aided drafting (CAD) file of the part that is translated into coded instructions the CNC machine follows over and over.
    • Electromechanical Discharge Machining (EDM): An electrical discharge, or spark, between the electrode and workpiece creates thermal energy to remove material, forming complex or intricate shapes that are hard to achieve with standard CNC machining.
    • Laser cutting: The high heat of the laser cuts through and vaporizes substrate material to form an exact shape. The laser can be programmed for accuracy and efficient material use. This process leaves a clean edge that requires little additional finishing.
    • Laser welding: A high heat laser beam is concentrated to a small point to make accurate welds with a minimal heat affected zone (HAZ) on the material. It produces clean joints that rarely need additional grinding or polishing.
    • Additive manufactured prototyping: A special printer deposits a stack of very thin layers of polymer or powdered metal to create a test model of a part. This is an effective way to test design functionality and identify possible points of physical stress or failure prior to full production.

    Benefits of Using Precision Machining for Medical Devices

    Advantages of precision machining include:

    • Improved part uniformity: CNC and other computerized machining, laser cutting, and welding use the same operations and parameters on each cycle so there is very little variation between cycles.
    • Enhanced speed, efficiency, and production volumes: High-speed equipment performs operations more quickly than a person can and does not become fatigued.
    • Minimized human error: CNC machines use computers programmed with instructions so that all movements, cuts, and dimensions are consistent from part to part. This minimizes the risks of human error or inconsistency.
    • Minimal waste: Computer-controlled manufacturing processes can be programmed to use material efficiently for less waste. Their high precision and accuracy also result in less scrap and rework.

    Precision Machining for Medical Devices From H&S Manufacturing

    At H&S Manufacturing, we work with a variety of tools and techniques for automated and semi-automated medical device machining, including CNC and EDM machining, laser cutting, laser welding, and additive manufacturing. Our capabilities also include mechanical and electromechanical assembly, sheet metal fabrication, and several secondary and finishing services.

    Contact us to discuss your next medical device machining project or to request a quote.

  6. CNC Lathe Machines — What You Need to Know

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    CNC Lathe Machines — What You Need to Know

    Automation technology plays a substantial role in modern industrial production. Computer numerical control (CNC) machining has long been one of the driving forces of automation in the manufacturing sector, as the various CNC processes allow businesses to produce large volumes of high-quality, accurate, and repeatable goods in complex shapes. Learn more about lathe machining and the advantages of the process for diverse industries.

    How CNC Lathes Operate

    While manual lathing processes require an expert machinist to make high-quality cuts, CNC lathe machining achieves unmatched precision and repeatability. In CNC lathe operations, a computer translates a part’s design into highly detailed instructions that the automated lathe machine will follow exactly. Directing the movement of the rotating workpiece and cutting tools, these pre-programmed instructions detail the required cutting path of the tool, along with the proper depth, velocity, and other factors to generate a part per your specifications.

    CNC lathes are quite versatile, facilitating the following processes:

    • Cutting and shaping. Lathing machines apply one or more stationary cutting tools against a rotating workpiece. As part of the subtractive manufacturing process, the tools carve away excess material with precision to leave behind a cylindrical part in the exact desired shape, with a central axis of symmetry. Common examples of lathed components include shafts, gears, and axles.
    • Drilling. When you secure a drill bit to a lathe, you can then drill circular holes in a workpiece. These holes are useful for fasteners like screws and bolts.
    • Facing. Facing tools on the lathe’s mounting system generate uniform cuts on the surface of a workpiece, generally decreasing the part’s length.
    • Knurling. Utilizing a roller with raised spikes, knurling processes pierce holes in a workpiece to texturize its surface.
    • Sanding. This finishing process creates a smooth surface on a part by rotating a workpiece pressed against an abrasive material or tool.

    Materials

    The CNC lathe machining process is compatible with a wide range of materials, including:

    • Stainless steel
    • Galvanized steel
    • Cold rolled steel
    • Hot rolled steel
    • Aluminum
    • Brass
    • Copper
    • Plastics
    • Reinforced epoxy (FR4)

    Applications of CNC Lathe Machines

    CNC lathe machining is a versatile, effective production option across major industries. Some of the markets that use CNC lathing to produce high-quality components include the following:

    • Aerospace. The aerospace industry demands tight-tolerance components to safely fulfill the needs of mission-critical applications, and CNC lathing can successfully achieve that.
    • Automotive. Pistons, gears, brake drums, and shafting parts for vehicles are all components that CNC lathe machining can create uniformly.
    • Electronics. The small and intricate components within electronic devices require precision manufacturing. CNC lathing makes heat sinks, shafts, and more.
    • Medical. Precision devices are essential for healthcare applications, and CNC lathing is capable of producing everything from surgical tools to implants for the medical sector.
    • General manufacturing. CNC lathing supports the manufacturing market by creating cylindrically shaped parts in high volumes for diverse industries.

    Advantages of CNC Lathe Machines

    Some of the key benefits of using CNC lathing are:

    • Superior accuracy. One of the main benefits of CNC lathing is that computer-controlled lathes generate precise, repeatable, high-quality parts with tight tolerances.
    • Enhanced productivity and efficiency. Automated CNC lathes operate at high speeds without needing breaks or vacations like human workers, making lathing a good choice for high-volume projects. Lathing streamlines production, delivering optimal efficiency and throughput.
    • Complexity. CNC lathing equipment can produce components with highly complex designs and shapes as well as intricate details, especially compared to manual alternatives.
    • Cost-effectiveness. Automated machining is more precise and less reliant on manual labor, which means you’ll benefit from decreased labor costs and material waste.
    • Safety. As automated CNC lathes only require minimal human intervention to operate, they are much safer and less likely to cause worker injuries.

    CNC Lathe Machining From H&S Manufacturing

    Providing high-quality contract manufacturing services since 1968, H&S Manufacturing Co. specializes in precision CNC machining, sheet metal fabrication, laser cutting, testing, finishing, final assembly, and more to create innovative, comprehensive solutions for our clients. Our ITAR-compliant, well-equipped facility features advanced, specialized machinery to support our custom manufacturing capabilities, integrating CNC and laser cutting. In addition to CNC lathes, we operate vertical and horizontal CNC machining centers, lasers, and brake, drill, and punch presses. Our expert team produces CNC-machined parts in dimensions of up to 24″ x 24″ x 12″ with tight tolerances of ±0.001″ (0.0254 mm).

    Contact us to learn more about our extensive CNC capabilities, or request a quote on our lathe machining services today.

  7. What Is Tapping in CNC?

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    What Is Tapping in CNC?

    The tapping process fulfills many important functions for industries that depend on precision-engineered threaded parts. Computer numerical control (CNC) machines enhance the accuracy and consistency of tapping in manufacturing, improving quality and making finer threads and tighter tolerances possible, even at mass-production volumes. Learn more about this versatile process, its benefits, and the markets that CNC tapping supports.

    What Is CNC Tapping?

    Tapping is a manufacturing technique for cutting threads into the walls of rounded drilled holes using a tap. CNC tapping follows pre-programmed computerized instructions to operate and precisely control the tap, making accurate internal threads per the needs of your application. The hole will be chamfered to eliminate rough edges and allow for an optimal fit with other threaded components like bolts and screws.

    Benefits of CNC Tapping

    In manufacturing, CNC tapping delivers numerous advantages for parts production. Primary benefits of CNC tapping include:

    • High-quality replicability and consistency. The CNC tapping process achieves consistent internal thread quality, reducing part variability and meeting tight tolerance windows. It’s also possible to save and reemploy a tapping program on a later production run for optimal repeatability.
    • Heightened productivity. Automated CNC tapping machines operate at much higher speeds than manual processes, resulting in maximum throughput and threading rates.
    • Flexibility. This process is capable of generating many types of threads in holes with various features and dimensions, making tapping highly versatile for achieving most tapping application requirements.
    • Minimized errors and scrap. CNC machines are highly precise, making accurate and controlled movements. Their capacity for repeatable production minimizes errors during manufacturing, equating to less part rework and scrap waste.
    • Safer operations. Controlling tapping machinery with computers minimizes human-machine interaction and keeps operators safe from hand tapping accidents.

    Common Applications of CNC Tapping

    CNC tapping fulfills the needs of numerous industries’ manufacturing applications, for products such as the following:

    • Aerospace parts. The aerospace industry demands repeatable, precision products for mission-critical applications. CNC tapping is capable of achieving identical threads with tight tolerances for landing gear, engine parts, aircraft structural components, and more.
    • Optics devices. CNC tapping in engineering can achieve precision down to the micron level, making it a suitable process for creating various casings, lens mounts, and adjustment devices for everything from prisms and lasers to microscopes and telescopes.
    • Automotive components. Accuracy and the ability to create high volumes of uniform components are important qualities for automotive manufacturing. CNC thread tapping is indispensable for transmission housings, cylinder heads, and engine blocks at full-scale production.
    • Telecommunication and electronic devices. Threading for sensitive or miniature electronic components, devices, connectors, and housings requires the precision that CNC tapping provides.
    • Healthcare devices. The medical sector often requires that its devices feature fine threads of exact dimensions. Many prosthetics, surgical devices, and MRI components benefit from precision CNC tapping.
    • Oil and gas components. Precise and reliable tapping is important for ensuring the safety and effectiveness of threaded oil and gas parts like pumps, valves, pipes, and meters at extraction sites and refineries.
    • Hydraulic and pneumatic cylinders. Creating threaded connection points and part ends for large amounts of hydraulic and pneumatic cylinders is more efficient with CNC tapping.
    • Valves and pipe fittings. Plumbing manufacturers rely on CNC tapping to quickly and accurately produce high volumes of threaded valve bodies, pipe fittings, sprinkler heads, and related components.
    • Dies and molds. Forging dies, injection molds, and other manufacturing tools and equipment rely on CNC tapping to apply threading to fitted components like core bolts and ejector pins.

    Precision CNC Tapping Services From H&S Manufacturing

    The CNC tapping process is essential for numerous precision engineering and mass-production manufacturing applications. Achieving quality results with the correct thread depth, pitch, and chamfer depends on the precision control made possible through advanced CNC tapping equipment.

    Since 1968, H&S Manufacturing Co. has specialized in producing custom components to meet the exacting specifications and unique needs of our client base. For demanding industries ranging from aerospace to medical, we’re proud to offer high-quality threaded parts tailored to your application. In addition to CNC tapping, our diversified contract manufacturing and precision machining services extend to milling, boring, drilling, lapping, welding, plating, heat-treating, painting, and silk screening.

    To learn how we optimize products for quality, reliability, appearance, innovation, and cost reduction, contact us or request a quote on our CNC tapping services today.

  8. What Is Milling?

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    What Is Milling?

    Milling is one of the most popular fabrication methods used across a range of industries because of its unique advantages. With milling, companies can create high-quality custom components made with various materials to meet their needs.

    Milling involves the removal of material from a stock workpiece using a rotating cutting tool. In this subtractive fabrication process, the workpiece forms the desired final shape after the removal of enough material. Modern milling machines often work in conjunction with computer numerical control (CNC) technology to increase automation, precision, quality, and consistency of the produced parts.

    Here we’ll discuss the benefits and applications of milling operations across a diverse range of industries.

    Benefits of Milling

    Many applications require milling solutions because of the specific benefits they offer over other types of processes. These advantages include:

    • Versatility: This manufacturing process offers more versatility, with the ability to create many types of shapes out of varying materials. Other processes like additive manufacturing or 3D printing have material restrictions that limit design flexibility.
    • Precision: Medical, aerospace, and other industries require high-precision designs in their components and end products, which CNC milling can produce.
    • Efficiency: Milling is also highly efficient, allowing you to develop top-quality parts and components much faster than you could with alternative manufacturing methods. As such, this process is ideal for large-volume production runs.
    • Superior Quality: Milling operations offer better quality than what you would get with less precise and accurate processes, eliminating the need for additional finishing.
    • Automation: With the assistance of programmable CNC machines, the milling process can be completely automated, which reduces the need for manual intervention while increasing productivity.
    • Greater Consistency: Another advantage of milling is more repeatability to produce parts of consistent quality.
    • Cost-effectiveness: The reduced need for human labor and increased productivity translate into overall cost reduction, making the end product more profitable.
    • Ability to Machine Hard Materials: CNC milling equipment can work with many types of materials of varying hardness, including Inconel, steel, and titanium. These materials are much more difficult to effectively machine using other types of fabrication techniques.

    Industries Served

    A wide range of industries and applications use milling to manufacture parts and components, including:

    Aerospace

    CNC milling helps manufacture many components that allow for safe flight while adhering to weight restrictions. Applications for milled parts in this industry could include everything from prototypes and replacement components to manifolds, transmissions, and aircraft frames. CNC milling helps fabricate even the most intricate parts using lightweight, high-strength materials such as aluminum.

    Energy

    This industry often relies on milling operations for producing large volumes of parts for oil and gas equipment, natural gas pipelines, nuclear energy plants, and more. Additionally, energy suppliers may use this process to develop parts for use in solar, wind, and hydropower systems, allowing for more efficient energy production.

    Agriculture

    Farming components such as incubator parts, gearboxes, and transmission housings depend on CNC milling for fabrication.

    Automotive

    Automotive manufacturers and OEMs often use CNC milling to manufacture water pumps, cylinders, piston rods, engine blocks, vehicle headlights, and interior lighting.

    Medical

    Manufacturers of medical equipment often need complex designs fabricated with high precision, which CNC milling offers. Parts made with plastic and metal materials benefit from CNC milling’s efficiency and precision, helping produce equipment and instruments of all types.

    Military

    Pistol locking mechanisms, drones, weapon components, and many other military applications frequently utilize CNC milling in their fabrication.

    Reliable Milling Services from H&S Manufacturing

    Want to benefit from high-quality CNC milling services for your application? H&S Manufacturing offers custom manufacturing solutions, specializing in milling operations, sheet metal fabrication, mechanical and electromechanical assembly, and testing. Whether your project is for a military, medical, aerospace, or other application, we can design and fabricate products to your unique specifications.

    Contact us today for more information about our capabilities, or request a quote to get started on a new project with our team.

  9. Aerospace Foreign Object Damage – AS9146 Compliance

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    Aerospace Foreign Object Damage – AS9146 Compliance

    Foreign Object Damage (FOD) is a major concern in aviation, aerospace, and defense craft and operating environments, including maintenance facilities, airfields, and aircraft manufacturing plants. FOD can risk the safety of personnel and cause serious damage, including direct damage to aircraft parts like sensors and engines. Indirect costs of FOD include delays, increased maintenance, and risk of injury to personnel.

    Managing FOD effectively can minimize operational interruptions, prevent safety breaches, and minimize repair costs. Read on to learn more about how you can protect your aircraft, personnel, and facilities from unforeseen damage.

    Understanding FOD

    FOD is any object, particle, substance, or agent that could cause economic or physical damage to an aircraft. The acronym “FOD” can refer to foreign objects or the damage caused by said objects. This includes wildlife strikes during operation, debris on the runway, or maintenance tools inadvertently left in the aircraft.

    Minimizing and managing FOD can take many forms. Best practices include taking proactive measures to control wildlife near airports, utilizing strict tool control protocols, and meticulously cleaning work zones.

    AS9146 Standard and FOD

    The FOD Prevention Program requirements defined by AS9146 standards provide guidelines for organizations involved in the development and design of defense, space, and aviation products and services. Under this standard, organizations must conduct thorough risk assessments for FOD, establish mechanisms for continuous monitoring, and encourage a culture of awareness and prevention.

    AS9146 compliance increases safety and operational integrity by addressing FOD risks systematically at each stage in product development, handling, and delivery. The AS9146 standard is intended to complement common customer specifications and their applicable regulatory and statutory requirements, rather than replace them.

    FOD in Manufacturing

    FOD risks can significantly impact the efficiency of production processes and product quality in manufacturing. Proper control and management of FOD in manufacturing are critical in reducing the risk of product damage and avoiding unintended costs or delays.

    FOD management protocols to integrate into manufacturing procedures and processes include:

    • Routine inspections of the facility
    • Using the proper equipment
    • Personnel training
    • Strict tool and part controls
    • Organization and cleanliness
    • Work area oversight

    Some valuable best practices to prevent FOD in aerospace manufacturing include using protective coverings during sensitive part assembly, utilizing magnetic sweepers to collect metal debris, and establishing clean zones to carry out critical operations.

    FOD Detection Systems

    The Federal Aviation Administration (FAA) evaluates various detection technologies as they serve to elevate safety standards in aerospace applications. Major U.S. airports use automated FOD detection systems to detect and remove hazardous foreign object debris before they can damage aircraft. Optical sensors and radar help teams monitor surfaces at the airport for FOD, providing real-time monitoring and alerts to airport operation centers.

    The FAA highlights the critical nature of integrating technology in FOD management protocols to maintain airport operations and enhance airfield safety.

    Take Action Against FOD: Join Us in Leading Aerospace Safety and Compliance

    A preventative approach is critical to safeguard operations and ensure compliance with AS9146 standards. Implementing FOD management practices with a trusted partner can help you manage risk and remain competitive in the aerospace industry.

    H&S Manufacturing offers various solutions to meet your organization’s FOD management and control needs. Our services include precision forming, shearing, punching, extruding, bending, notching, welding, and graining, as well as assembly and finishing.

    Contact us or request a quote to learn how our expertise in aerospace manufacturing can help you reduce costs and maintain the highest quality and safety standards.

  10. The Uses of Custom Sheet Metal in the Aerospace Industry

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    The Uses of Custom Sheet Metal in the Aerospace Industry

    In the aerospace industry, precision and consistency are critical to manufacturing and assembling safe, reliable aircraft. Aerospace parts must provide long-lasting performance while tolerating humidity, extreme temperatures, and high mechanical stresses. At H&S Manufacturing, we leverage our precision machining capabilities to produce custom sheet metal fabrications that comply with the aerospace industry’s rigorous safety and quality standards. Our AS9100D and ISO 9001:2015 certified facility is equipped to handle everything from prototyping to full production, with services like shearing, punching, precision laser cutting, extruding, notching, and other fabrication techniques.

    In this blog, we’ll highlight the applications and benefits of our precision sheet metal fabrication services in the aviation & aerospace industries.

    Sheet Metal for AerospaceAerospace Industry

    Metal materials used in aircraft construction are selected based on several factors, including durability, strength-to-weight ratio, and corrosion resistance. The metal’s structural integrity must also be capable of withstanding exposure to the high pressures and extreme temperatures encountered during flight. Three commonly used sheet metals in this industry are aluminum, stainless steel, and brass. 

    Aluminum: Aluminum is a lightweight, electrically conductive metal that can be strengthened and enhanced through the addition of various alloying elements. The most popular aluminum alloys in aircraft construction are 7075, 7475-02, and 6061, all of which exhibit excellent resistance to fatigue resistance and damage. Specific aerospace applications of aluminum sheet metal include: 

    Click to Expand

    Sheet Metal Uses In Aerospace Industry

    • Wing panes
    • Fuselage
    • Rudder
    • Doors and floors
    • Engine turbines
    • Cockpit instrumentation
    • Seats
    • Exhaust pipes

    Stainless steel: Stainless steel is a group of corrosion-resistant iron-carbon alloys containing 10-30% chromium. Because they maintain superior mechanical properties over a wide temperature range, stainless steel alloys are ideal for enduring the harsh conditions of continuous flight. Applications of stainless steel sheet metal manufacturing in the aviation aerospace industry include: 

    • Airframes
    • Landing gear
    • Jet engines

    Brass: Brass is a copper-zinc alloy with excellent hardness, workability, corrosion, and temperature resistance. This alloy performs well in harsh settings, making it ideal for aerospace environments. Applications of brass sheet metal manufacturing in aircraft construction include:

    • Wheel and brake components
    • Landing gear
    • Cargo doors
    • Casings for electrical components

    Benefits

    Aviation sheet metal fabrication is an intricate process that requires precision equipment and close attention to detail. Custom metal stamping and forming techniques are particularly well suited for sheet metal fabricated products since they allow for precise cutting and shaping while eliminating surface defects. Other benefits of metal stamping and forming include:

    • Affordability: Metal stamping and forming are highly cost-effective, especially for large-scale production runs where the dies can be reused.
    • Quick setup: With short setup times, metal stamping and forming processes ensure quick turnaround times for sheet metal manufacturing and fabrication.
    • High accuracy: The custom dies and tools used for metal stamping ensure excellent precision and tight dimensional tolerances. Cold forming can achieve superior levels of precision since it eliminates any heat-related warping.

    To maximize the benefits of sheet metal fabrication, it is important to choose materials that meet the functional and environmental requirements of a given aerospace application. Aluminum, stainless steel, and brass each have distinct advantages: 

    • Aluminum
      • Excellent strength-to-weight ratio
      • Resistance to corrosion, UV radiation, and moisture
      • Malleability
      • Low cost
      • Well-documented properties
      • Simple to inspect
      • Easy to replace or repair
      • Recyclable 
    • Stainless steel
      • Corrosion resistance
      • Generally stronger and more durable than aluminum
      • Low maintenance
      • Aesthetically appealing
    • Brass
      • Performs well at high temperatures
      • Great conductor of heat and electricity
      • Spark resistance
      • Corrosion resistance

    Sheet Metal Fabrication Services at H&S Manufacturing

    For over 50 years, H&S Manufacturing has built employee trust, earned customer loyalty, and improved our sheet metal fabrication processes. By investing in the latest sheet metal manufacturing methods and equipment, we ensure cost-effective, compliant, and reliable sheet metal fabrications for a range of mission-critical aerospace applications. To complement our core manufacturing capabilities, we also offer secondary services to optimize your sheet metal fabricated products for their intended environment.

    To learn more about our sheet metal fabrication services and other capabilities, please contact us today.