Summary
Toolcraft successfully reverse-engineered a critical component board pin installation jig for a telecommunication and avionics manufacturer based in Mason City, Iowa. This project highlights Toolcraft’s ability to work with limited information and deliver a customized solution crucial for the client’s ongoing production.
Project Overview
- Product: Component Board Pin Installation Jig
- Industries: Telecommunication, Avionics, Military
The client, a major player in the avionics, industrial, telecommunication, internet, commercial, and military industries, required a reverse-engineered solution for a component board pin installation jig. They needed to modify the jig’s functionality without interrupting their production schedule by sending the original jig.
Overall Specifications
- Original Jig: Held two rows of pin slots, each containing 18 slots.
- Modified Jig: Required the same functionality but with a reduced slot count – 12 slots per row.
Uses and Applications
The modified jig would be used to efficiently press pins into a specific component board during the client’s production process.
The project aimed to maintain the original jig’s functionality and productivity while offering a modified slot configuration.
Quality Control
- Dimensional Verification: Throughout the manufacturing process, Toolcraft employed rigorous measurements to ensure the jig’s components met the specified tolerances.
- Functional Testing: Upon completion, the jig was used to assemble pins into a test board, verifying its ability to perform the intended function.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Design and Prototyping
Toolcraft engineers developed a detailed 3D model of the jig using CAD software. This model was then used to create a 3D printed prototype using ABS plastic. The prototype allowed for thorough testing and validation of the jig’s design and functionality.
Tooling Development
Based on the successful prototype testing, Toolcraft developed and manufactured the necessary tooling for mass production of the final jigs. This included custom jigs and fixtures to ensure precise and consistent machining of the components.
Material Selection
Toolcraft selected 4140 pre-hardened steel as the material for the final jigs. This material offers a combination of high strength, wear resistance, and machinability, making it suitable for the demanding application.
Machining
The jig components were machined using CNC milling machines to achieve the precise dimensions and tolerances specified in the design. The machining process included operations such as drilling, reaming, and milling to create the various features of the jig.
Assembly
The machined components were then assembled into the final jig using precision fasteners and assembly techniques. The assembly process included aligning and securing the various plates and pins to ensure proper functionality.
Inspection and Testing
Each completed jig underwent a rigorous inspection process to verify that it met all the specified dimensions and tolerances. Functional testing was also performed to ensure that the jig could accurately and reliably press pins into the PCB.
Conclusion
This project demonstrates Toolcraft’s comprehensive capabilities in reverse engineering and precision manufacturing. By utilizing 3D printing for prototyping, advanced machining techniques, and a meticulous inspection process, Toolcraft delivered a high-quality, custom-engineered solution that met the client’s critical needs. This project highlights Toolcraft’s commitment to delivering innovative and reliable solutions for its customers.
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