Why Hydroforming? We’ve Got Your Answers.
Lots of different types of machining methods are familiar to manufacturers. Even if you don’t deal with all of them or maintain a factory full of every machine that’s out there, you can probably rattle off quite a few different types: CNC machines, EDM, waterjet cutting, and so on. Of course, for us at Helander, one type invariably comes to mind first: metal hydroforming.
In late 2011, the Association for Manufacturing Technology released this summary of the manufacturing outlook for 2012. With Q1 (and fiscal Q2) drawing to a close for many companies, we’re revisiting their assessments and sharing some benefits of hydroforming with you, our readers. One of the major factors behind the growth of hydroforming? As older machinery breaks down to the point of replacement rather than repair, shops are looking into new technologies to increase efficiency and expand their customer base. Of course, at Helander Metal Spinning, we’ve been hydroforming for over 35 years, so you can be assured that we’re not a new kid on the block. We combine the benefits of experience with the assets offered by the process.
As the article mentions, some of those assets include distortion- and deformation-free manufacturing thanks to the precision inherent in the technology. Other benefits include greater complexity in forming drawn shapes than traditional stamping, as well as decreased tooling costs. For answers to any questions you may have, please contact Helander today!
As Manufacturing Expands, So Does Helander
With so much talk of U.S. manufacturing in the news lately, it’s difficult to understand how some pundits can continue to roll their eyes at the return of factories an industry to a key role, if not a backbone position, in our economy. As this Tulsa World article discusses, the purpose of committing to strengthening and supporting U.S. manufacturing isn’t to instantly transform manufacturing from an afterthought back to the behemoth that it once was. Rather, politicians and corporations are taking notice of the fact that though overlooked, in many ways, U.S. manufacturing never truly went away. More difficult to overlook? The fact that in the face of still-discouraging overall unemployment, manufacturing has led the way as a source for jobs and a way to spur vocational training. In fact, in January 2012, manufacturing accounted for a full 20% of all new jobs created.
We at Helander Metal Spinning have been watching –and participating in – these developments with great interest. In fact, we’re riding that wave of expansion by opening up a new CNC machinist and maintenance technician position, which we’re still looking to fill. As specialists in hydroforming, we offer a great way to get involved in one of the most exciting machining technologies, working on components for projects like the Boeing Dreamliner. As U.S. manufacturing continues to expand, Helander is following suit. Want to get involved or learn more? Contact us at service@helandermetal.com or 630.268.9292.
Helander Metal Spinning’s Fabtech Canada 2012 Preview
One Fabtech show in a year is quite an event. But all the metalworking expo action isn’t in Chicago. This year’s Fabtech Canada 2012 expo, happening in Toronto from March 20 – 22nd, 2012, promises to be just as exciting and informative as its stateside counterpart. We found the January show to be overwhelmingly helpful, and won’t be attending Fabtech Canada this year. We will, however, point you in the direction of some of the most promising panels and events at the conference.
Don’t Miss: The Keynote Speaker, race car driver and TV star Andrew Comrie-Picard. Andrew will be discussing his varied career – from attorney to racer to TV-host-of-all-trades – and talking about thinking outside the box in manufacturing, from materials to processes. One way to do that? Look into hydroforming instead of other processes.
Get Involved: Wednesday’s Toen Hall discussion will allow you to pose some questions or share some answers, recognizing that the expertise at Fabtech Canada is among all attendees, not just speakers.
Look Ahead: Thursday’s presentations will focus on the future of welding and manufacturing as a whole, including a talk on using technology to close the machining skills gap. In the pursuit of young, talented engineers and machinists to fill and ever-growing number of positions, there are a number of ways to find them. One of them? Social media, meeting them on their level. This is just one of the many reasons Helander has initiated our extensive social media outreach.
We hope to hear from any and all Fabtech Canada 2012 attendees! Share your stories or advice here.
Dreamliners, Hydroforming and Helander
The new Boeing 787-9 Dreamliner is like nothing you’ve ever seen. It’s a super-efficient airplane that uses 20% less fuel than any other plane in its class. Did we mention that it does this with a range of 8,500 nautical miles while carrying up to 290 passengers? It’s the plane of the future because it saves fuel while helping handle the ever increasing number of domestic and international air passengers. It sounds so exciting that it might even be worth planning a vacation around riding in one.
It should come as no surprise that everyone at Helander is excited about the new Dreamliners. Our excitement not only comes from how cool the new planes sound, it also comes from the fact that we’re experts in hydroforming and it just so happens that hydroforming is one of the best ways to produce parts for aerospace products. Because of the recent growth in larger aerospace projects like the 787-8 and 787-9 Dreamliners, Helander has been busy upgrading our already impressive hydroforming capabilities. On February 15th, we will be adding a 20” hydroform machine – our third hydroform overall, and our very first 20” one – which will give us the ability to handle an even larger volume of orders. Keep checking our blog and website to learn more about our new completely custom rebuilt 20” hydroform machine and how it can help you stay at the forefront of aerospace technology. And if anyone gets to take a ride in a Dreamliner, take some pictures and we will share them with our readers!
Helander Metal Spinning Going Green(er) in 2012
Being able to bring our industry-leading metal spinning together with today’s green energy boom is on the top of Helander’s 2012 to-do-list, but we also know that we can make a difference right here in Lombard, Illinois.
Most of us have become familiar with recycling at home – bottles in one container and paper in another. It’s pretty simple, and, added bonus: we’re giving our children a better future.
At Helander, we are beginning the process of turning our 30,000 square foot facility into a more environmentally friendly and green workplace. For a metal spinning company, “going green” is about more than just recycling pop bottles; it involves a multi-step plan aimed at change.
First, we are embarking on an ambitious new recycling initiative. This initiative is aimed at recycling 100% of our scrap metal, waste oil, paper, and wood products. To achieve this high recycling rate, we plan on using a combination of common sense changes including an employee awareness program, and more recycling bins of all sizes throughout the facility.
Our second big initiative involves our facility’s lighting. We are currently getting quotes to replace all of our incandescent lighting with high efficiency LEDs and fluorescents. This complete overhaul of our lighting will not only shrink our environmental footprint, but it in the long run, it will also lower our power bills. Lower overhead for us means cost savings for our clients.
Saving our customers money and helping out the environment: a combination you can’t beat.
We have set ourselves some pretty lofty goals, but if they allow us to continue bringing our customers outstanding metal spinning while helping give our kids a better future, all the effort will be worth it.
Spinning into 2012 With Green Energy
You don’t have to be an industry insider to know that green and alternative energy have been a hot topic of conversation for several years. What you might not know, though, is just how far the reach of this paradigm shift extends. Manufacturing companies play an important role in constructing the components that play a key role in harnessing power sources like solar energy and hydrogen fuel. There are also indirect ways in which manufacturers contribute to the viability and sustainability of such operations. This week’s blog explores one of each.
Working with a major fuel supplier, Helander Metal Spinning was contacted to produce several prototypes for pressure vessels to transport hydrogen fuel for a number of forklifts. Because of the highly sensitive nature of hydrogen – and the extremely high energy potential which it holds – these vessels needed to be designed to exacting safety standards. Producing 20 of these 6-foot long vessel prototypes, Helander was approved to be the main supplier to the company for this type of fuel transport. Our ability to spin especially sturdy, ¾”-thick aluminum was a major factor in aiding this customer in expanding the role of sustainable fuel.
For a project in which metal spinning actually produces components used on energy-harnessing devices, we look to the example of solar panels. One major source of solar energy in North America is an array of solar panels with a total radius of one mile. These panels harness and focus the energy of the sun on a water reservoir, producing massive amounts of steam energy strong enough to provide substantial power to a community. The base of each of these solar panels is manufactured through metal spinning, exhibiting the versatility and strength of the process.
Keep an eye out for more blogs describing Helander’s role in alternative energy, including our own efforts to go green!
Why Choose Metal Spinning?
Perforated Filter Basket 20gage 304 7.70” long X 5.00” diameter made on CNC metal spinning machine
So, you need a metal cylinder. Maybe it’s an enclosure, maybe it’s for piping or tubing, maybe it’ll even end up in someone’s kitchen as a fire extinguisher. First things first, though, you need to figure out how you’re going to get your hands on that cylinder. But wait: actually, you need more than one. You need thousands. So you’re probably going to want to have them made for you, rather than bought off the shelf. Now we’re getting somewhere, and this is where this blog may come in handy. Basically, there are two methods of producing cylinders like these: metal spinning, or deep-drawn stamping. As expert metal spinners, we’re here to tell you why this process is superior.
- Economics: The main benefits of metal spinning are lower costs nearly across the board, in aspects from tooling costs, preproduction, and initial investment, to overall energy efficiency and in-process secondary operations.
- Part strength: The specifics of the metal spinning process, as compared to stamping a part, lead to greater ductile strength in a finished piece, and a lower chance of crack propagation if a defect does occur.
- Shape versatility: For non-uniform hollow shapes, like concave or convex parts, elliptical shapes, or cones, metal spinning is the clear answer over deep-drawn stamping.
See the PMA metal spinning Design Tips PDF and website for more information, or contact Helander Metal Spinning with any further questions about process selection, material selection, and efficiency.
