IS PRECISION FORMING TECHNOLOGY?
The increasing demand for precision metal parts is found in many industries, pushing precision forming technology to the forefront of manufacturing. IntriPlex’s version of precision forming, which is akin to ultrahigh precision stamping, is a high-speed process (~10 parts/second) that has the capability of replacing traditionally machined or turned components. What used to take multiple seconds to produce using material removal processes can be done 25 times faster.
IntriPlex was founded on the idea that transitioning products from traditional removal processes to high-speed stamped methods meant lower costs and better capability, and we continue to prove this every day. The adaptability of IntriPlex’s precision forming technology, with custom tooling tailored to exacting requirements, has allowed us to displace many traditionally machined products with high-speed stampings. Thanks to its speed and cost-effectiveness, our precision forming technology is an ideal solution for manufacturing large quantities of intricate complex products.
DOES PRECISION FORMING TECHNOLOGY WORK?
Our precision forming technology uses precision presses and custom progressive dies to form metal into complete parts via automated processes well-suited for high-volume applications. A strip of metal is fed through a press and a custom die which cuts and forms the material in successive steps to produce your parts at a speed of 200 – 1,000 per minute. The raw material is manipulated to create specific geometry and then formed to create the extremely repeatable final shape and size to exacting precision. Through this single process, we produce more than 2.5 million parts per day.
CHOOSE PRECISION FORMING TECHNOLOGY?
Precision forming technology offers a fast, efficient, repeatable, and affordable solution for businesses requiring large-scale manufacturing of small (less than a cubic inch) precision metal components. Not all component designs lend themselves well to stamping, and it is common for design engineers to assume machining or another type of material removal method is the only option. IntriPlex’s success is built on being the first company in the world to stamp many industry-changing innovations, displacing the traditional methods.
IntriPlex provides precision formed products utilizing in-house die design, engineering, prototyping, performance testing, manufacturing, post processing, quality control, and support. Each project is customized to meet your specifications and requirements.
- ✓ COST EFFICIENCY
- ✓ PRODUCT CONSISTENCY
- ✓ QUALITY AND ACCURACY
- ✓ HIGH VOLUME CAPACITY
We Bring Solutions
What can be achieved when science, intellectual curiosity, and years of extensive manufacturing experience and process technology come together?
At IntriPlex, every challenge is treated as an opportunity. A sense of pioneering innovation prevails. We deploy advanced engineering and science, metrology, precision cleaning and automation.
IntriPlex has a deep passion for precision, a focused attention to detail, and an unwavering commitment to excellence. This culture is ingrained in our people and evident in the quality of our products and services.
The continuing story of innovation at IntriPlex begins with the discipline of design focused on delivering products that drive solutions for high customer expectations. We invite you to explore some of our recent successes that have made an impact on the telecommunications and data storage industries.
Our customer needed a crimp for a fiber optics application that could be made with high precision for lower cost at high volume. Machining technology was not adequate, so the customer investigated to see if metal stamping could provide an answer. They inquired with many metal stamping companies and were told that what they were asking for was simply not possible.
We were contacted to develop a solution. Our highly specialized engineering team at our Innovation Center along with our master Tool and Die Engineers collaborated to develop an innovative metal forming process that delivered a more consistent, higher quality, and high-speed stamped fiber optics crimp.
- Size dimension control better than ±8 µm with Cpk>1.5.
- Form dimension control better than ±6 µm with Cpk>1.5.
- Selectable material properties for component performance, such as high elongation for crimp rings and high yield strength for bodies.
- Salt spray corrosion resistance (GRE-326-CORE, EIA/TIA-455-16A) without plating or anodizing for increased surface quality and lower cost.
- Optimized surface finishes for performance improvement, such as friction optimization and reflectance.
- Production capacity of 500,000 units per week, per stamping tool.
Hard Disk Drives
The customer wanted a swage mount that was more consistent, less expensive, and could be manufactured in high volume quantities. Machining technology was failing to perform on any of these deliverables. Other metal stampers did not engage because the obstacles to finding a solution seemed insurmountable.
Our select team of engineers and tooling craftsmen put their heads together and we became the first company able to figure out how to stamp a swage mount through an innovative manufacturing process. The result was increased consistency, higher volume manufacturing quantities, and lower pricing.
- IntriPlex PowerPlate™ surface optimization technology boosts swage mount assembled joint strength up to 100%, enabling volume and mass reductions through component miniaturization.
- IntriPlex swage mount flanges are manufactured and controlled with micron-level cupping and tip height biases to provide optimum assembly performance.
- IntriPlex components are manufactured with controls on material particle cleanliness counts for particle sizes down to 200 nm.
- Swage mount manufacturing efficiency of 10 parts/second and capacity of 20 million parts/week.