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Fuel Tank Sender Cover: One
piece, deep drawn stamping replaced a two-piece, welded “flange
and skirt” design. Currently supplying
twelve different versions; more than 2,000,000 pcs/yr.
Saved 15% Per Part |
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Fuel Fill Restrictor: Assisted customer by accepting the
transfer of a competitor’s tool. Improved dimensional
integrity of the part, which in turn improved the
fit and function of the mating part in assembly,
saving
our customer thousands of dollars. |
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Fuel Fill Neck: Difficult
filler neck had been made in two processes, stamping
and secondary thread forming. Drawform’s tooling
design fit everything into the main tool, eliminating
the secondary operation.
Saved: 14% |
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Proportional Power Solenoid
Shell : Once
stamped and machined due to strict tolerances, Drawform
redesigned the part to be completely deep drawn.
A true success
in terms of quality and performance on the assembly
line, Drawform’s process equated
to several million dollars saved over the life of the
program.
Saved 80% |
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Cell Phone
Battery Cover: By
stretching the limits of 6061-T6 aluminum, a brittle
and unforgiving material, the battery door for a very high
volume cell phone model was re-designed to a one-piece,
eliminating multiple individual pieces and sub assemblies,
with no additional sub-assembly needed and a greatly
improved robustness.
Saved $2MM+
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Door Lock Latch
Housing: Our
transfer press technology and tooling allowed us to
replace a flat stamped and wrapped component with a
full featured deep drawn cylinder. Improved dimensional
integrity created considerable savings during assembly,
while improving the overall function of the final part
for the customer.
Saved 15-20% |
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Air Bag Diffuser: Working
with the
advanced engineering team of a major airbag manufacturer,
Drawform was able to help re-design a heavy walled
machined
part into a deep drawn stamping, including
wall thinning (previously machined) of almost 50% complete
off the press. |
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Stator Sleeve: High
volume part required ID and OD machining to meet dimensional
tolerances. Previous supplier also demanded surcharge
for fallout. New Drawform tooling met ID tolerance
in press, eliminating one machining and resulting in
dimensional integrity for less fallout in customer
assembly.
Saved 32% |
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Fuel Filter End Plate: Replaced
a five-piece assembly with a one-piece deep drawn plate
with tube. Eliminated four parts (2 braze rings, washer,
and tube), the brazing requirement and the leak / braze
integrity test as the part is now leak checked in line.
Saved $.35 per part |
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Airbag Manifold: Replaced
an aluminum extruded can (left) with multiple secondary
operations with a CRS deep drawn shell with features
introduced in the press (right).
Saved over $6 per part |
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Fire Protection Sprinkler
Pip Cap: Replaced
a solid machining of 304 stainless steel (right) with
a two-piece design that incorporates a brass shell
and stainless insert (left). Assembly is completed
in the press.
Saved over $.28 per part |
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