Miniature Four-Slide Stampings
One secret to cold-headed parts manufacturing efficiency and reliability is to build dual functions into a single part to reduce the number of assemblies and create fewer opportunities for failure. MW Components collaborates with its customers to accomplish this. As seen in some of our product examples, you will find electronic parts diode cups that combine mount and heat sink, for LED with mount, heat sink, and reflector functions, or reflector and wire lead components, or mount and terminal. All these features are produced as an integral part of a cold forming process.
Custom Manufacturing
Custom Micro-components
We specialize in producing components with non-standard dimensions and geometries, using specialty materials and manufacturing processes. We also offer added value services that include design, prototyping, and tooling assistance.
Some of the shapes we can accomplish include tubular structures, like specialized rivets and out-of-round shapes and features that are not radially symmetric, such as ears on the ID. Ordinarily, a deep draw-house will be asked to produce this part but may not be able to do it without secondary operations, leading to problems in conductivity or strength properties.
To send us your specs or configure a part, request a custom quote.
Examples of Custom Solutions
Material: Kovar per ASTM F-15 (glass to metal seal quality)
Manufacturing Method:
- Wire formed in a slide machine.
- Complete off the machine. No secondaries.
Notable Features:
- Extreme small size & tightly toleranced: (a) .012" (.3 mm) diameter wire diameter (b) bent in 3 dimensions.
- Extremely high surface finishes attainable.
- No indents/marks in the sealing area.
- No longitudinal draw lines that would introduce a leak path.
- Good Straightness over each of the three-dimensional lengths.
Material: 304 stainless steel (glass to metal seal quality).
Manufacturing Method:
- Wire formed/coined/pierced in a slide machine.
- Complete off the machine no secondaries.
Notable Features:
- Extreme small size & tightly toleranced: .035" (.88 mm) hole diameter, .175" (4.4mm) overall length.
- The hook loop is very tight to the shaft.
- Very short terminal.
- No indents/marks in the sealing area.
- No longitudinal draw lines that would introduce a leak path.
Advantages:
- Material waste is minimal. The part is formed from stainless steel round wire. No machining (no waste) or secondary used.
- Highly toleranced dimensions are precisely controlled for reduced variation (ie: high CpKs).
Material: Expansion Alloy: 52 alloy (nickel/iron alloy) per ASTM F-30 glass-to-metal seal quality.
Manufacturing Method:
- Formed & pierced on a slide machine. Complete off the machine.
Notable Features:
- A very good surface finish present on the sealing surfaces. No leak paths.
- Hole (oval) diameter is centered inside the terminal flat area.
- Hole diameter held to +/- .002" (+/- .05mm).
- The flat end is trimmed perpendicular to the lead axis.
Advantages:
- Material waste is minimal.
- Cold forming the pin eliminates the presence of spiral machining lines.
- Production speeds are high allowing for low production costs on high volume production runs. Much faster than machining/much less material cost than machining.
Material: Glass Sealing Alloy 42-6 (42.5% Nickel/5.75% Cr/Fe)
Manufacturing Method:
- Cut & formed from slide machine with a CNC secondary for pointing.
Notable Features:
- Very smooth surface on a pointed portion of the part
- No machining lines or machining tit present at either end of the part.
- A very good surface finish present on the sealing surfaces. No leak paths.
- The pointed tip is held to a consistent sharpness specification.
Advantages:
- Surface finishes are smooth for good hermetic sealing characteristics. No machining marks/spirals/inclusions are present.
Material: CDA 102 copper (oxygen-free; high conductivity copper).
Manufacturing Method:
- Coined & trimmed C-Bend: on a slide machine.
- Complete off the machine.
Notable Features:
- The coined area is formed into a precise S-Bend.
- A large coined area for brazing attaches to the platform.
- Smooth top head surface (RMS 32 and better) with zero voids or inclusions or folds on the braze surface.
Advantages:
- Material waste is minimal. The part is formed from copper round wire.
- The S-Bend section provides a braze platform for die attachment and the S-Curve provides give to provide stress relief.
- Production speeds are high for this high-volume piece allowing for low production costs.
Material: CDA 102 oxygen-free high conductivity copper.
Manufacturing Method:
- Produced from coiled wire.
- Manufactured complete from slide forming machine - no secondaries.
- Tooling designed & built in-house.
Notable Features:
- Surface finishes better than 32 RMS.
- Note the thin web of material between the hole diameter (.150") and the outside edge of the fault.
- Burrless.
Advantages:
- No machining lines or cut-off deformations present.
- Cost. Much less expensive than machining.
Material: Kovar per ASTM F-15 (glass to metal seal quality).
Manufacturing Method:
- Wire formed in a slide machine.
- Complete off the machine; no secondaries.
Notable Features:
- Extreme small size & tightly toleranced: .020" (.5 mm) wire diameter, 1.2" (30.5mm) overall length.
- The hook loop is very tight to the shaft.
- Extremely high surface finishes attainable.
- No indents/marks in the sealing area.
- No longitudinal draw lines that would introduce a leak path.
- Good straightness over the entire length.
Advantages:
- Material waste is minimal. The part is formed from pure Kovar round wire. No machining (no waste) or secondary used.
- Highly toleranced dimensions are precisely controlled for reduced variation (ie: high CpKs).
Have Questions?
Have questions about small metal parts manufacturing? Talk with our experts today and let us help you figure out the best solution.
