Even for high temperature gaskets, Gasket Engineering is always looking for the most profitable part production for its clients and always considers multiple processes in order to recommend the best methodology that will help the client find the most economical process possible. Albert Diederiks, Inside Sales Account Manager explains, “It’s our responsibility to give our clients options so that they can choose the best way to go forward.”
A Heavy Duty Vehicle manufacturer recently came to the experts at Gasket Engineering recently with an interesting challenge. They needed high temperature gaskets for the right and left sides for the exhaust of a Class C truck. This was a new product for them, so they reached out to us to help engineer the product in the best way possible. They were looking for the most profitable part production for their new part. Because the gasket would be used in an extremely high heat situation, they needed something that would provide appropriate buffering capabilities while still maintaining its ability to hold up to the high heat of the engine.
MetalTech makes fibrous gasket facing materials that are bonded to a starburst- or rectangular-style perforated steel core or have special coating like Teflon™ or other materials. These provide excellent sealability, good load retention, crush resistance, lateral stability, more bonding points or more conformable materials that are excellent for use as exhaust gaskets, manifold gaskets, head gaskets, heat shields or other high temperature gaskets that are subject to frequent thermal cycling. These are highly engineered materials that can be difficult to cut.
Gasket Engineering provided them with one option to diecut the material to create the high temperature gaskets. The engineers determined that method would produce a very clean-cut, but they also conceded that the yield would be lower and that there would be a lot of waste created using a traditional die cutting process. As they are always looking for profitable part production, that led our experts to recommend a flash cut that allowed for much closer nesting (and therefore less waste) for this expensive material.
Samples were sent to ensure that the edge was clean enough for the process required, the samples passed testing and the client was very happy with this money saving solution for their high temperature gaskets.
Do you need more profitable part production for your next project? Give us a call at 813-363-8333.
Have you designed an un-manufacturable part? A good production engineer should be able to design any part, but a great engineer needs to make sure they don’t forget to consider all the production process consequences of their otherwise perfectly-designed part.
“A lot of times an engineer designs a part for a specific application but they don’t always take into account the assembly method or the production method. Yes, the part might work in the final application but that part might cost precious time and money if the part is cumbersome or hard to handle in assembly. He or she needs to make sure they don’t forget to consider the production process consequences of an otherwise perfectly designed part.
Fortunately, Gasket Engineering can provide guidance and solutions. One of the most common problems we solve has to do with manufacturability. Gasket Engineering staff help customers with the design of manufacturability, rather than just the functionality of the part itself. There are several aspects of any job that need to be evaluated.
After we assess the material itself, we ask the customer about the assembly process. Is it automated or by hand? Do they have housings that the part is going on (for placement)?”
The questions are vital because all materials are different and some may need some sort of backing or some type of rigidity to facilitate manufacturing.
We’re always looking for ways to be more efficient in the materials that we use and in the way those materials are put together. Some engineers are proficient only with the materials themselves and this can lead to less than optimal product design. This is the way you end up with an un-manufacturable part. You have to take into consideration the whole production process when you’re developing a part.
Smooth Assembly Versus Higher Yield: Which Is More Profitable In The End?
All of these questions are meant to help our engineers determine the best way to produce a part that will maximize the client’s overall profitability, not just the cost of the individual part.
One element we think about is: “what is more important, speed of assembly or yield?” For example, it may be wiser in some circumstances to sacrifice the number of parts (lowering yield efficiency) in exchange for greater efficiency in assembly (increased speed of production). If there is minimal difference in the waste, it might be wiser to alter how the part is produced.
At first blush, a particular job might appear to be most efficiently produced as ten pieces lined up across from each other, but when considering the manufacturing process, we might discover that the parts are getting pulled through and assembled by a robotic arm right into the fixture. In that case, it might make more sense to produce them in a straight line with a quarter-inch gap in between. We might add a perforated liner or peel tab which makes the part itself more expensive but could save the customer assembly time and lower their overall scrap rate. This could increase their overall profitability, which is the ultimate goal.
In that case, the trade-off of potentially higher waste still saves the customer money on the production flow.
With more than 60 years of experience serving customers in the aerospace, alternative energy, automotive, heavy equipment, electronics, industrial, marine and medical fields, our experience leads us to ask the right questions to help you avoid designing an un-manufacturable part and help you make the right decisions to maximize your profitability.
By thinking through the entire production process and working closely with Gasket Engineering, a customer can expect a more robust product for their specific manufacturing needs, as opposed to just a designed part. The part will work in your application, with your manufacturing, but will also provide increased productivity, increased throughput, less waste and ultimately, higher profitability.
Although the finished product will not be edible, rotary cutting can stack a variety of “ingredients” and make them as palatable to a manufacturer as the best multi-layer dip is to a party guest.
Typically used for high-speed, high volume projects that require anywhere from two to seven substrates to be joined to form a part, rotary cutting has been part of Gasket Engineering’s offerings since the 1990’s when the company made nearly 60 percent of the US-based intricate parts needed by Motorola.
What’s so great about rotary cutting?
Gasket Engineering’s advanced rotary cutting capabilities have the ability to process multiple substrates in one harmonious pass. This type of process makes a nice, clean homogenous part out of multiple materials.
But it’s much more complicated and intricate than just laminating seven layers together. You can also remove and introduce liners, use different adhesives on different sides of the materials and stack different materials on top of each other.
Clients bring us incredibly complicated and intricate parts that need to be made–ones with voids and adhesives and liners and precision requirements from every industry imaginable. That’s probably why we ask so many questions–because we want to get it right! We know that there are so many elements that need to be considered in properly making an effective part. Our expertise in designing the proper processes is just as important as our knowledge of materials and production methodologies.
Sequencing is important.
Our knowledge of the right process design is only secondarily critical to the finished product itself. For example, it would not be uncommon for a customer to request to have a conductive material sandwiched between two insulatory materials and then have another adhesive that is put on a liner. That material could have multiple cuts so that some of the conductive material is exposed while some of it is covered.
For these types of intricate parts, those layers have to be processed at different times and in different ways in order to be properly laminated or delaminated and have the appropriate cut patterns and adhesives laid down. That process needs to pull off scrap at the right time and make multiple cuts in multiple materials.
That’s how we make the intricate parts that are customers bring to us. Our engineer has to be my knowledgeable about the materials themselves and how best to convert them, as well as how to properly process them through one of our machines. It has to be sequenced properly so that it doesn’t negatively impact other layers or aspects of the part production. That’s why we say that the sequence is as important as the material placement.
Our experts also need to be familiar with which machines should be used for different jobs. We run our rotary cutting projects through one of two different types of machines. Our Delta presses are software driven so each station can run at independence speeds, while the Allied presses all run at the same speed. Depending on the types of parts being made and the particular requirements of those intricate parts, our engineers will recommend the right machine for the job.
No matter which machine you use, we have optic registration on all machines for maximum precision.
Have you got ayn intricate parts or tricky problems that you’d like help with? Feel free to give one of our engineers a call at 813-363-8333. If you’d like to read more about our rotary cutting capabilities, download our free ebook about The 10 Most Important Considerations for Rotary Cutting here
Gasket Engineering Company poised to expand into specialized wind turbine, aerospace and marine composite repair markets
KANSAS CITY , MISSOURI, UNITED STATES, September 19, 2016 — Gasket Engineering Company, known for its extensive gasket manufacturing capabilities, quick turnaround times and superior quality is poised for market expansion. The Company continues to invest in state-of-the art technology to meet the growing demands of its diverse client base. With its disruptive technology, Gasket Engineering Company has earned a stellar reputation in such industries as Aerospace, Automotive, Heavy Equipment, Wind Energy, Marine and Industrial.
The US Gasket and Seals market is forecasted to expand 3.8% annually until 2018, according to The Freedonia Group. The Company will continue to leverage its large selection of state-of-the art, ISO-9001 certified technologies to capture a larger share of this growing market.
The Company is also modifying its distribution strategies to accommodate the specialized repair and servicing niche of select industries. Due to the size and intricacies of their composite structures, Aerospace, Alternate Energy and Marine industries face significant logistical challenges when it comes to blade and composite repair.
“A major challenge facing these companies is that materials are shipped in enormous and costly rolls when only a fraction of the roll is needed to do the repair. In addition, onsite logistics make it impossible to access the precision technology needed to cut with accuracy , which results in spoilage and substandard quality” explains Boyd Comfort, Director of Sales and a Principal Partner of Gasket Engineering Company. “To address these complex problems, Gasket Engineering Company has designed custom crafted repair kits, which are cut, batched and shipped according to client specifications. Materials are always on hand and the quality is top-notch making this a complete turnkey solution”, Comfort continues.
With lightning quick response time and precision cutting using its CNC cutting tables and patented nesting software, Gasket Engineering Company is able to strategically nest multiple geometries out of a like material so that there is absolutely no waste.
Gasket Engineering Company plans to capitalize on the market need for leading edge composite repair services and will continue to innovate and provide the market with custom solutions that are cost efficient, flexible and long lasting.
Gasket Engineering Company is a service-oriented, experienced partner that provides “one-stop shopping” and quick turnaround for the broadest range of high-quality parts and materials. Founded in 1942, this third generation family-owned business has grown into a worldwide leader in rotary and flat bed die-cut parts.
The Company’s facilities include two major manufacturing buildings (one 60,000 square feet and the other 80,000 square feet) located in Kansas City and serving clients nationwide.
Extremely tight tolerances.
That’s what one of Gasket Engineering’s aerospace customers needed for some polyester backed tape that was being cut for use on one of its military vehicles, this part was quite intricate for several different reasons.
- First, the project included 30 different shapes that need to be cut.
- Second, the parts included voids (or areas that needed to be masked off so that there would not be adhesive material in certain sections).
- Third, these pieces needed to be arranged together properly and sent to the manufacture in a certain configuration
As with all aerospace part construction, consistency, precision, and exact edges are required. Because of these tight tolerances needed, the customer was cutting these intricate pieces by hand. Each of the 30 pieces was cut using a razor blade and a cardboard template. This process insured precision but naturally took a great deal of time and care.
This aerospace customer was referred to Gasket Engineering because they are a 3M Preferred Converter. Gasket Engineering worked with the customer to transfer this intricate, Tier Two Boeing application project from a painstaking, time-consuming process to a streamlined, exact, repeatable process on Gasket Engineering’s state of the art laser cutting equipment. They were able to load the customers AutoCAD drawings of the part into one of their precision laser cutting machines and produce the polyester backed tape components with extremely clean edges in a fraction of the time that it used to take to do it manually. Tight tolerances every time! We asked 3M’s Jason Christopher about Gasket Engineering, and he had this to say: “Gasket Engineering has a broad range of excellent capabilities that not all of our 3M Preferred Converters has. They are highly creative and willing to do whatever it takes to do the job well. They are a partner who is continuously improving, adding the equipment necessary to exceed customer expectations.”
If you have a challenging component that has requirements for tight tolerances or would like help in figuring out how to streamline your production process, feel free to give one of Gasket Engineering’s sales engineers a call. You could also check out more about Gasket Engineering’s laser cutting capabilities here.
Director of Sales Boyd Comfort is a guest on this week’s edition of Composites Weekly, a podcast that brings the latest news and information in the world of composites to listeners, discussing new technologies & emerging markets within carbon fiber, 3-D printing and FRP (fiberglass reinforced plastic). This particular episode highlights how Gasket Engineering is helping customers eliminate waste, save on material shipping costs, shrink downtime and provide kitted materials exactly suited to customers’ needs. You can listen to the podcast here.
In this interview, Boyd talks about the company’s history of making gaskets via traditional die cutting and how they expanded to rotary die cutting and dieless cutting, building expertise all along the way. He talks about how we supply custom gaskets to a wide variety of industries, including aerospace, alternative energy and marine applications, converting and binding virtually any raw material into the exact shape, dimensions, and thickness required for your manufacturing needs.
- Gasket Engineering is ISO 9001:2015 Certified!October 28, 2017 - 4:14 am
- We’re in the press (again)!May 25, 2017 - 6:41 pm
- Got Thin Wall Widths? Laser Cutting To The Rescue!May 11, 2017 - 7:26 pm
- Engineered Coated Fabric Or Diaphragm MaterialApril 13, 2017 - 11:14 pm
- Innovation and the Founding of the Gasket Fabricators AssociationMarch 27, 2017 - 7:27 am