March, 2020


www.us-tech.com


Page 21


Applications for Precision Sheet Metal in Electronics Manufacturing


By James Belosic, President of Application Engineering, SendCutSend T


oday’s consumers demand cus- tomization. One industry study commissioned by Protolabs de-


termined that 86 percent of Ameri- cans found customization appealing when it comes to electronic devices. This is a trend that is steadily on the


ing, or water jetting. These methods of cutting require more set up than laser cutting, which means they are prohibitively expensive for low unit runs. The cost savings provided by laser cutting enables companies to invest in innovation and production efficiency, without jeopardizing their financial bottom line. Tight tolerances, usually ±0.003


in. (0.08 mm) or less, make precision sheet metal valuable for prototyping components that require accurate fit- up and geometry for assembly. Many types of metals can be


used for laser cutting, making it a flexible option for electronic products that are made up of complex parts — some requiring durability and others requiring malleability. Modern fiber


optic lasers can cut a wide variety of metals, such as bronze, stainless steel, copper, titanium, Nitinol, In- conel, and other exotic or difficult-to- process metals.


Speed and Customization When exploring product oppor-


tunities with customers, creators Continued on page 23


HJ4000 SMD Rework Fixture


 


 Custom copper busbars.


rise, with MicKinsey and other top- tier management thinkers tackling the technological challenge of mass customization. What is more intriguing about


this trend, as identified by a Deloitte study, is that of the consumers who are craving customization, one in five are willing to pay a 20 percent premi- um for the privilege. Basically, elec- tronics manufacturers could increase their profit margins significantly if they have the means to deliver cus- tomized products at scale. This presents both an exciting


commercial opportunity, as well as a confronting question about capability. To survive in this new world of con- sumer customization, electronics man- ufacturers need to build capabilities and processes that allow for one-off custom designs at a manageable cost.


Laser-Cut Sheet Metal There are several uses for preci-


sion sheet metal in electronics, in- cluding prototyping and customizing machine parts and enclosures, laser- cut copper busbars, or developing custom control panels. Laser cutting has an emphasis


on rapid turnaround times and no minimum order quantity. This helps manufacturers to reduce inventory and allow for quick design iterations or individual personalization — per- fect for prototyping parts or one-off projects. This process is also inexpen- sive, when compared with machining and milling, creating a distinct com- petitive advantage for manufactur- ers looking to meet the demands of consumer customization. On top of building capability for


customization, electronics manufac- turers are trying to reduce their ex- penses and stay competitive. Metals are increasing in price and tariffs are making it difficult to manufacture electronics at a profit. The process of laser cutting is


more affordable than other methods of production, such as CNC machin- ing, stamping, punching, 3D print-


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 


  


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FEATURES •  •  • •   •  •  •  


 


 •  


 


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    •


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