Volumes of production
The process can be used for manual production or for an automated CNC high-volume production.
Unit price vs. capital investment
Tooling costs can be reduced, or eliminated, by the use of existing punches or cutters, allowing for high-volume production to be achieved with low capital costs.
Speed
Varies greatly, but typically 1,500 soda-can pull tabs can be produced per minute.
Surface
In terms of finishing, these cutting techniques will generally need deburring.
Types/complexity of shape
Mostly used in the production of small components, and thickness is restricted to available standard sheet.
Scale
Restricted by the standard sheet dimensions.
Tolerances
High tolerances are achievable.
Relevant materials
Restricted to sheet metal.
Typical products
Cooling fan blades for electronics, washers, keyholes, and watch components.
Similar methods
Laser cutting (p.46) and water-jet cutting (p.42) are two non-chip-forming methods that can be set up to produce designs from CNC programs, without tooling costs.
Sustainability issues
Each of the various cutting processes is based on the removal of material, which results in a significant amount of waste material. However, metals can be melted down to form new sheets that can reused in the process to reduce material consumption and the use of virgin resources. Aluminum is one of the most widely recycled materials.
Further information
www.pma.org
www.nims-skills.org
www.khake.com/page88.html
Industrial Origami®
Product |
Jack-stand made with Industrial Origami® |
Materials |
12-gauge cold-rolled steel |
Manufacturer |
Industrial Origami |
Country |
USA |
Date |
2004 |
A typical component showing the cutlines and construction method of Industrial Origami®. This jack-stand demonstrates the structural strength that can be obtained using the method.
There is something fascinating and inspiring about watching a simple, flat sheet of paper being transformed into a complex form through origami. In much the same way, this patented process takes the principles of origami but applies them on a much more industrial scale, using metal in place of paper to create usable products.
This folding innovation has many benefits over traditional metal-forming methods such as stamping and press breaking, as it reduces the number of operations required to shape the metal and the whole process can therefore be completed in much less time and at a much lower cost. The component is created from a net, much like a flattened cardboard box. A stamping technique or a laser is used to cut the outline of the shape from a metal sheet and to produce a series of lines and smile-shaped curved cuts along the edges to be folded. A set of straps pulls at the smile shapes from either side of the sheet, to create contact between two of the sides. This leverage causes the sheet to bend along the fold lines with only a relatively small amount of force. It is the small smile-shaped cuts that control and determine the folds as they direct the stresses during folding to make everything align perfectly.
The process allows for the integration of several parts into a single piece, and removes the need for welding and joining as it uses a number of folding clips to secure the folds, which significantly reduces material consumption. The process enables the rapid creation and fold-up of prototypes, which allows designers to experiment with and test prototype configurations quickly, and make any necessary changes.
– Reduced joining, fixing, and processing.
– Integrating multiple parts into a single sheet means material consumption is significantly reduced.
– Fast construction and assembly relative to alternative methods of construction.
– Allows for effective prototype testing.
– Lower labor costs.
– A great deal of planning is required to make a design suitable for the process.