Solution-oriented manufacturing capabilities
Manufacturing Capabilities & Services
IntriPlex consistently produces components to the most exacting tolerances and geometries. Our personnel are experts in all types of metals including stainless steel, aluminum, copper, nickel, and titanium, and have extensive experience with polymeric materials and sub-component assemblies that integrate these materials. We have expertise in forming, coining, and stamping austenitic alloys and specialty metals with feature tolerances of less than 10 micrometers. IntriPlex offers a wide variety of manufacturing capabilities and services to meet today’s higher levels of compliance and performance demands:
Precision Forming Technology
Our precision forming technology is a fast and cost-effective solution for manufacturing large quantities of complex products. We can mass produce intricate metal components with very consistent results. It is well known that high-speed stamping is among the most efficient manufacturing processes, but not every part can be stamped. The core of our innovation is finding ways to stamp the traditionally "un-stampable."
At IntriPlex, we utilize a wide assortment of in-house processes to remove burrs or conduct surface modification to the metal parts. We can chemically and mechanically deburr, as well as perform polishing and etching prior to ultrasonic cleaning. We can produce exceptionally clean parts in our clean rooms.
Tool & Die Design and Development
Tool & Die Design
IntriPlex Tool Designers are also Tool and Die Makers with production precision forming experience. They work with Product Research & Development and Product Engineering to understand the component design and performance requirements. They team up with the Tool Makers responsible for producing components, to develop initial strip layout and stamping concepts. In some cases, Research & Development will assist Tool Design with analyses to help develop innovative precision forming processes.
More radical stamping development utilizes rapid prototyping capabilities in the toolroom to create and test strip/blank and stamping processes for critical die progressions. The results from these studies are incorporated into the full die design to help expedite the completion of a fully functioning production die. Detailed die assembly and component prints are generated from the die design.
Final die fitting, timing and part development is completed by Tool Design and by lead Tool Makers during qualification of the completed stamping tool. Solid modeling, CAD/CAM and FEA software is used in this process.
Companies turn to IntriPlex for heat treatment of their small precision parts. It is our objective to bring value to our customers in unique ways by understanding and responding to their challenges through becoming a direct extension of their team. Our proprietary heat treatment techniques process parts in a manner that can help reduce or eliminate distortion. Our furnaces employ nitrogen and hydrogen gases as protective atmospheres, resulting in clean, bright parts. These processes are ideal for high production volumes and enable us to provide expedient, cost effective heat treatment. All production is monitored per product-specific process control plans, using statistical process control and data systems.
IntriPlex excels at precision cleaning by leveraging our advanced technology and environmentally friendly processes. IntriPlex follows the most stringent product quality testing standards for both particulate and chemical cleanliness.
Utilizing multiple ultra-pure aqueous cleaning lines located in Class 10K clean rooms with Class 100 final process environments, IntriPlex manages cleaning to the highest level of compliance. Our standards include 18 Mohm DI water and ultra-pure plumbing along with multi-frequency ultrasonic treatment and Ultraclean optimized part handling. The result is that IntriPlex produces the cleanest parts available, a requirement for Data Storage and Medical clients.
IntriPlex has installed dedicated testing labs staffed with chemical engineers and full-time lab assistants to provide production quality support. These tests include:
✓ Liquid Particle Count (LPC)
✓ Ion Chromatography (IC)
✓ Liquid Particle Analysis (LPA)
✓ Atomic Absorption Spectroscopy
✓ Passivation Testing
✓ Scanning Electron Microscopy (SEM)
✓ Energy-Dispersive X-Ray Spectroscopy (EDS)
✓ Tape-Particle Analysis (TPA)
Material conversion involves the receipt of tape, liner and adhesive products from key suppliers, followed by the transfer of these tapes and adhesives to other components or materials. For example, IntriPlex creates dampening products by accurately transferring viscoelastic adhesives to stamped metal constraining layers. IntriPlex is an approved converter of materials from 3M, JDC and others.
Our technical team, including multiple PhDs and many engineers on-staff, employs state-of-the-art engineering, modeling, testing and inspection techniques to monitor products throughout the development and production phases. In addition, our world class Innovation Center is available for collaboration and development of complex parts, and addressing material and engineering challenges.
IntriPlex uses various drying processes depending on part size, part fragility and cleanliness requirements. One process uses HEPA filtered hot dry air introduced to flat baskets of parts which are oriented toward the air stream by a robot such that part-to-part impingement is minimized. This prevents damage to fragile parts as well as the generation of particles.
IntriPlex develops material specifications that are stricter than industry standards to ensure the best part quality and part performance. Incoming inspection confirms that supplier certifications conform to these specifications, and performs critical parameter audit testing, including in some cases in-house tensile testing of materials. In-process and final inspection utilizes IntriPlex-developed metrology, including 25 nm resolution contact gages, interferometer-based profile measurements and camera and laser CMMs. Visual inspection is done at multiple stages per customer and internal AQL levels. Critical parameters are tracked using an SQL database with electronic alarm notifications to production and engineering staff for out of control conditions.
Our packaging is designed to meet customer needs and to ensure that no damage occurs during shipping and delivery. Solutions have included parts in heat sealed double cleanroom bags in clamshell trays with bubble wrap, parts stacked in custom tubes for integration into customer automation, tape and reel, and vacuum packing.
Innovation is at the Heart of What We Do
The primary difference between IntriPlex and other manufacturers is a willingness to stretch the limits and explore “what’s possible” versus “what’s simple.” Tough challenges are the norm not the exception.