Research & Development
Research and Development
From design to production – a partner you can trust
Improving an existing product, getting a new product to market, or testing a concept requires a research and development partner you can trust.
Our time-tested research and development process enables established manufacturers to test the design and functionality of metal stamped parts before investing resources in full production.
STEP ONE: DESIGN REVIEW
The first step of our process is a review of your design and/or prints. Whether you begin with a CAD file, or a simple sketch, we will undertake a detailed material and manufacturing analysis to determine how to cost-effectively produce the part. In some cases, we may suggest design or material changes to ensure that we can transfer smoothly to full production.
Perhaps you have a part, but no design or print? We can also replicate (reverse engineer) an existing part.
STEP TWO: PROTOTYPING
Prototypes are an essential part of the research and development process. Any part, no matter how thoughtfully designed, requires testing and refinement. Prototypes allow the design team to thoroughly evaluate and test the part, the dies, and the manufacturing process before production begins.
In order to assure the highest quality stamping, more than one prototype may be necessary. We partner with you throughout the process, working to produce the part you need at the price you require.
STEP THREE: PRODUCTION
Once your part is approved, we are ready for full, sustainable production. In addition to precision stamping, we are equipped to coordinate outside services with our suppliers/strategic partners to produce the finished product to your exact specifications.
Why Choose Integrity MFG?
Integrity MFG works with our clients from conception to completion providing professional solutions and guaranteeing exceptional products. When you work with Integrity MFG you can always expect:
- Open communication and collaboration with our management team
- Innovative and cost-effective solutions designed to increase productivity, save time, and money
- Dedication to giving the customer exactly what they want
- Streamlined processes designed to provide short lead times
The Integrity Advantage
As a woman-owned, American-made business we are a leader in the manufacturing of precision stamped parts and assemblies for a wide variety of industries. Our capabilities include producing complex custom components requiring tight tolerances and runs of 1,000 – over 3M parts. As a centrally located supplier to industries around the globe, we can meet tight lead times and ship to any destination.
Specifications
Part Thickness: .004″ – .500″
Press sizes: 45 ton – 1100 ton
Three 3 ton cranes, four 5 ton cranes, and a 10 ton crane
Materials
Low Carbon Steel, High Carbon Steel, Brass, Copper, Aluminum, Phosphorus Bronze, Stainless Steel.
FAQs
Stamping is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape.
Plate-Forming is a method of creating steel parts and pieces through mechanical deformation. Forming allows for the reshaping of a work piece without removing any material and changing the mass.
Steel fabrication is a process involving the shaping of raw steel into a product or item that can be used in assembly or construction. The process often involves cutting, bending, and assembling.
Passivation, in physical chemistry and engineering, refers to coating a material so it becomes "passive," that is, less readily affected or corroded by the environment.
Laser cutting is a technology used in industrial manufacturing that uses a laser to vaporize materials, resulting in a cut edge.
Welding is the process of joining two pieces of material together with similar melting points and composites using fusion.
The joining and attachment of parts, subassemblies, and components in a sequence to produce a finished result.
Deburring is a material modification method that takes sharp edges, or burrs from a material and leaves the material with smooth edges.
Reverse engineering is a process in which machines, aircraft, parts, and other products are deconstructed to obtain design information. Reverse engineering also entails the deconstruction of individual components of larger products. The process allows you to establish how a part was designed so that you can recreate it.
3 axis machining involves a workpiece in a fixed position while the cutting tool operates along the X, Y, Z plane to cut away material. 3-axis machining is most suitable for parts that do require a lot of depth and detailing.
4-axis machining adds movement of the cutting tool and allowing rotation around the X axis. As a result, there are 4 axes X, Y, Z and A rotating around the X axis. The majority of 4 axis CNC machine tools allow the workpiece to rotate, which is called b-axis, so the machine can act as both milling machine and lathe.
5-Axis machining is a process where you take a large block and remove the excess. On a 5-axis machining-center, the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from any direction.
CNC milling (Computer Numerical Control Milling) is a machining process which utilizes computerized controls and rotating cutting tools to remove material from the workpiece to produce a specific product or part. The process is suitable for machining materials like metal, plastic, glass, and wood, and producing a variety of custom-designed parts and products.
Prototype machining is a process in which a small number of part(s) are produced before a larger number of parts are needed. Shops may do prototype machining for many reasons such as knowing what a part will look like when it is produced and testing the part to see if it functions as intended.
815-680-8401Monday - Thursday, 6am - 4pm
admin@integritymfginc.com
Frankfort, IL 60423