Mechanical Designs of Virginia was recently contracted by a railroad industry client to custom manufacture a mounting bracket that would be used within a transportation application. Based off a customer supplied print, we laser cut the part to measure precisely 30 inches in overall length and 15 inches in height. The unit possessed an overall plate thickness of .375 of an inch and weighed 80 pounds.

The mounting bracket possessed the following components: a left and right side frame measuring 14 inches long and 1.94 inches high, a leveling shim measuring 11.5 inches long and 1.5 inches wide, a gusset measuring 9.63 inches long and 3 inches wide, and a manifold block measuring 23.25 inches long, 4.5 inches wide, and 2 inches thick. All of these components were fully manufactured and welded together (using our MIG/TIG welders) in-house to meet exact client specified dimensions.

Constructed from durable carbon steel, we employed our CNC milling technology to skim cut any excess material, drill all holes, and tap all threads. We then formed two 90 degree bends, each containing a .375 of an inch bend radius. During production, we were able to uphold an overall precision tolerance of (¡¾) .005 of an inch, with a flatness tolerance of .0025 of an inch, and a perpendicularity tolerance of .015 of an inch. After all mount bracket components were fully manufactured and welded together, we then deburred the finished bracket, creating a smooth, 125 RMS finish, and painted the part using quick dry steel primer.

To ensure that this high-quality part met with precise customer requirements for design and functionality, Mechanical Designs of VA performed a series of product inspections using thread gauges, dial calipers, a height indicator gauge, and feeler gauges. Only after we were fully assured that we fulfilled all of our client's exact specifications did we deliver this product to our customer.

By combining our advanced laser cutting, press brake, and TIG welding technology, Manufacturing Designs of VA was able to successfully fabricate two coupling guards used within a pump/fluid handling system, while meeting a ±.010 of an inch precision tolerance. We first laser cut all components to shape from 14 gauge HRP&O steel sheet metal. We additionally cut logos into this sheet metal. We then TIG welded all components together and provided two 90 degree bends at the base of each unit for product stability.

Once the units were successfully built to print, we then deburred the coupling guards until they possessed a smooth, 1.5 millimeter finish. We finally applied a safety yellow powder coating to each product. Once completed, the coupling guards measured precisely 6.5 inches long and high, and 4 inches wide. The parts additionally weighed 2.32 pounds.

Manufacturing Designs of VA performed a variety of in-process inspections in order to ensure the high-quality of our products. First, we checked all measurements in flats. We then inspected the first bent unit and the first welded unit of each coupling guard. We also completed a final, comprehensive examination of the products before shipping the finished units to our buyer's facility. Fulfilling all customer product requirements, the coupling guards met with high client satisfaction.

Recently, a food industry client contracted Mechanical Designs of VA to fabricate an outer tank wrap used within a grease removal unit. Meeting tolerances as low as ±.015 of an inch, with an angular tolerance of +0º/-2º, we combined our laser cutting and TIG welding technology to build this component, based on a customer supplied 2D print.

To begin this project, we first laser cut all components to shape from sheet metal, and then bent the material based on client requirements. We first made a 90º main bend and then created 4 additional 90º bends over sides. We finally TIG welded all tank wrap components together, including joining all latches onto the outside of the unit. After manufacturing was complete, we deburred the completed product, giving it a #3 bright material finish.

Constructed from 24 gauge 304 stainless steel, the tank wrap measured 25.6 inches long, 17.6 inches wide, and 10.1 inches high. The part also weighed 2.32 pounds. In order to ensure the tank wrap met precise client requirements, we performed a variety of product inspections. Testing included checking the first unit in flat, examining the first bent, and inspecting the latch after installation.

Successfully manufacturing this product to meet exact print specifications, our tank wrap fulfilled all client expectations for design and quality.

Mechanical Designs of Virginia was contracted by a furniture industry client to reverse engineer an aluminum planer head from an already existing component. This planer head is used within a wood working application. In order to begin this process, we first obtained all proper part measurements using CMM, generating a 2D Cad drawing of the new model for manufacturing.

After a print of the new model was fully drawn up, we then built a prototype of this new unit to ensure the device met customer dimensional specifications. Once the prototype was approved by our client, we employed our 4-axis CNC vertical milling machinery to manufacture the part complete.

Meeting precision tolerances as low as +/-.001 of an inch and ISO 900 standards, we built the planer head to measure precisely 3.850 inches in outer diameter and 4 inches in length. The part also weighed 4 pounds and featured insert pockets. Using our advanced design and machining capabilities, we were able to successfully reverse engineer an aluminum planer head for the furniture industry to better meet our client's specific product requirements.