''Do you want to give your product an enhanced aesthetics?" Obviously...and you are not alone....everybody wants their product to be perceive appealing to their customers .... But why they are not able to achieve it? Due to low volume production and less investment cost for their business, they could not go for tooling and ended up with compromising on the appearance and switching to alternative materials and processes.
Have you ever thought? What if there is no need for customized tools to give your low scale product the desired look and feel ...yes, it is possible for a company to provide a beautiful piece of machine without making high investment on tooling.
Importance of an Aesthetic look for a product:
Sometimes, a good functionally sound product is not very well accepted in the market due to its look. Hence, an Aesthetic design is critical for consumer acceptance and the market success of the product.
Low-Volume part production needs are usual in some industries such as Medical equipment, Aerospace, Defence, Instrument, Shipbuilding and also in prototyping of a new product development.
Aesthetics plays a crucial role in the perception of the product which directly associate with the overall satisfaction of a customer and it also substantiate the innovation, quality and reliability of the product. So, from the initial stage of development itself, the product aesthetics should be kept in mind and work towards achieving that.
Using Sheet metal for product development:
Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the fundamental forms used in metal working and can be cut and bent into a variety of shapes and thicknesses. (source: Wikipedia)
Because of its characteristic features like pliability, malleability, ductility, temperatures tolerance, collision resistance and long life span, etc., today, sheet metal applications are huge and present in many kinds of industries with a variation in the uses.
But then what is the problem with sheet metal?
When we use plastic, it can be easily molded to give the desired look and feel to the product. But the metal components are not that easy to manufacture. It must go through die-cast, sand cast, or forged, where sheet metal is stamped into complex forms, and this results in a very expensive tooling.
If the sheet metal is needed to be bent it has to go through common die hence, can form only sharp 90º curve bend. To get the desired shape the die tool has to be customized and made which can cost you lakhs for tooling.
So, sometimes to save money from customized tooling, a good part turns into a scrap metal and the machine looks nothing but a box because of only 90º curve bends in it.
And to deal with this problem, Srushty offers the desired curve bend with progressive bending technique to get the ideal curved shape without customizing any tools.
Progressive bending by Srushty
Ways to get an Aesthetic design:
In prototyping, the innovative products are made by mostly focussing only on the functionality, but not in the look and feel. The reason is the cost involved in providing an aesthetic look by tooling is too high and unfeasible for low-volume production.
But in Srushty, this legacy belief has been broken by making an aesthetically pleasing product with sheet metals by using the methods such as Hydraulic pressing, 3D acrylics, print acrylics, metal powder coating, bending without customized tooling, CNC router, Laser cutting etc., to bring the same aesthetic as it is done for the mass production.
"From a sheet of metal to an ornamental looking machine without spending on tooling"
It is a computer-controlled cutting machine related to the hand held router used for cutting various hard materials. A CNC router is very similar in concept to a CNC milling machine. Instead of routing by hand, tool paths are controlled via computer numerical control which enable the machine to function. CNC routers reduce waste and increase productivity, producing various items in a much shorter amount of time than using other machines.
A CNC router can reduce frequency of errors, and the time for taking the finished product to market.
Laser Cutting gives a high-quality surface finish. It is used to cut complex shape with perfect finish and even for a smallest cut this process is very precise and uses less energy. Also avoids the need for a Blanking tool which is otherwise necessary for sheet metal fabricated parts.
It is a device which uses a hydraulic cylinder to generate a compressible force. Hydraulic presses are commonly used for forging, clinching, molding, blanking, punching, deep drawing, and metal forming operations. (Source: Wikipedia)
Acrylic print used directly for metal finish to give high gloss and color retention. Acrylic print is very durable and ideal for the materials which cannot be heated. It provides a wider range of colors options, and result into a very light and thin finish.
Metal powder coating:
To give the aesthetic look to the product, it is powder coated at the end of part development in which a coating is applied electrostatically to a surface as a free-floating dry powder after which heat is used to melt the powder and completes the coating process. The coating is thick and more durable than spray paint and gives an even finish to the product.
Some of the successful and beautiful products manufactured by Srushty.
In this vending machine, not only the purpose of the machine has been achieved but also the aesthetic look which is given by vinyl stickers, acrylic fixture and powder coating to give the machine a beautiful ornamental look.
This machine is engineered with beautifully curved edges with powder coating to give it an adorn look and feel with the mechanism to perform its desired functions.
This Machine is very aesthetically pleasing and capable of performing several medical diagnostic tests. The bend curves of sheet metal are sublimely finished by progressive bending and with the methods such as CNC laser cutting, powder coating and silk screen printing, etc., it results in an elegant piece of work.
In Srushty, we give the best engineering solutions without compromising on the aesthetics of the machine, in spite of low volume requirement for the product.
There is a significant expansion and growth of large and medium sized MNC's own Captive Engineering and R&D centers, as well as large and medium sized Outsourced Engineering and R&D centers.
As part of this growth there are also small and highly focused Outsourced Engineering and R&D center catering to Small and Start-Up organization across the globe from India. These service providers form the pool of Nano Outsourced Engineering and R&D centers.
The need for small and start-up organization is significantly different from that of the established OEMs.
The smaller companies require,
- One-stop-Shop for end-to-end product development covering Mechanical, Electrical/Electronics, Firmware and Software
- Ability to complement the core technological strength of the company with expertise and experience
- To support organizations who sometime have zero or very little technological know-how, but have a market potential idea
- To start with the ability to quickly prototype the concept to validate market and drive for funding for next stage
- And eventually the ability to take the engineering design to production with minimal budget and timeline, in a global setting
This demands the Nano Outsourced Engineering and R&D center to be flexible, nimble, ability to scale and versatile.
The effectiveness of such Nano Outsourced Engineering and R&D center depends on,
- Experience in developing end-to-end products
- Ability to bring in Global Subject Matter Experts (SME) from relevant domain into product development cycle on-demand
- Frugal Engineering Practices to do More with Less
- Cost effective in-house prototyping capability to quickly validate concepts
- Eco-System of partners for Industrial Design, Prototyping, Tooling, Manufacturing and Assembly
- Manage early stage low volume production
- Ability to take the product to compliance and certification
- Provide effective technical support after product launch
Srushty is glad to be part of this growing space of India's Outsourced Engineering and R&D Services, focusing on serving and supporting the Small and Start-up organization as a Nano Outsourced Engineering and R&D center.
Srushty in collaboration with Progress Consulting offered GD&T Training at SMR Automotive Systems India Limited on 10th and 11th October 2014.
The 2 full day intensive workshop covered GD&T concepts in practitioner’s perspective. The workshop was anchored by Maruthachala Mandiram, Director, Srushty Global Solutions.
The course covered right from basics of Tolerance, and to Why, What and How of GD&T Techniques. Thanks to enthusiastic 40 odd participants from SMR Automotive, the training included real life project examples and study of GD&T usage in them.
The training covered the theoretical aspects, as well as Design Intent, Manufacturing Impact, Part Inspection and Qualification aspects.