Breakthroughs in aluminum extrusion technology by Exact Manufacturing, Inc., are helping companies achieve greater efficiency and more profits.
Called Ultra Precision Extrusions(reg), the process allows the production of parts that were previously considered impossible to manufacture without machining. The process can potentially replace a number of other traditional practices, such as roll forming, drawing, and carbon EDM machining. And it also eliminates a number of secondary machining operations such as drilling, broaching, milling, and surfacing operations.
The secret is an ability to produce 'near net shape' extrusions. Predictability and reliability are built in so that tolerances of ± 0.001 inch can routinely be achieved. Wall thicknesses of 0.008 inches and surface finishes as fine as 10 (mu) sec are possible. The products also have superior concentricity and the variety of shapes that can be produced is virtually unlimited.
Some of the products Exact has produced for customers include a tape housing for an ATM machine, a toner applicator, and a computer clamp.
Exact was able to produce the camera slide shown in the figure and attain ever tighter tolerances than the previous EDM process. The wall thickness was reduced to 0.02 inches, while still maintaining the integrity and quality of the part. The total savings for this part was over 95%.
In addition to consistent quality, ultra precision extrusions can reduce the amount of scrap--up to 95%, particularly with complex product shapes and profiles. Inspection costs can also be reduced, and there is less setup time and a shorter lead time for parts.
For more information from Exact Manufacturing, contact Product Development at (612) 551-8601 or fax (612) 557 9442.