After 40 years in the metal fabrication industry, this business strives to innovate metal fatigue and failure mitigation techniques that are used in the aerospace, automotive, biomedical, chemical, defense, energy, and fitness industries as well as the nuclear and oil & gas, as well as the rail industry.
While the business did engage in product design on occasion, the majority of its research and development was focused on the creation of production methods. It was determined that the company's research activities fell into three separate categories: stamping, molding, and tooling.
Process design necessitated substantial research and development, which began with an analysis of the component specifications and progressed to an evaluation of the different metal production technologies available. There were engineers on the team as well as technicians, prototype assemblers, testers, and quality assurance personnel. They addressed difficulties relating to shape, fit, material, and performance. Calculations, as well as computer models, were assessed and adjusted as a result of this process. Concerns were raised about issues like configuration, material composition, and manufacturability, among others. Typically, the business created four to five distinct prototypes for testing and evaluation. From the information gathered in the prototype building phase, adjustments would be made to the tooling, fabrication process, or even the product design. For example, prototypes may be created to assess alternative component configurations as well as their resilience to external conditions such as vibration or high temperatures. Several prototypes or samples were frequently built and tested to examine different designs and process applications.
Engineering and prototype assembly teams worked together to create the prototypes that were ultimately used in the production of the final product. Design criteria were sent to prototype assemblers, who were then in charge of producing and constructing prototypes according to those needs. Materials that are primarily utilized in the process of building a prototype include various metals, circuit boards, PC boards, transistors, circuits, wires, and plastic. Secondary materials include other types of polymers. The cost of these supplies was frequently deducted as qualified research and development expenses.
Following that, the prototype designs were put through their paces and validated against the product requirements that were anticipated. Design testing was frequently unsuccessful, necessitating the need for the design to be revised at the component or prototype level, as needed. Testing criteria were addressed by design and process changes during the course of this procedure, which was a continuous cycle between design and assessment. Prototypes may be submitted to environmental testing, which will typically involve vibration and temperature tests. Additionally, acceptability testing was carried out once all other tests had been completed successfully.
Custom fixtures die castings, and tooling was created by the team to bring the product into full production. Also required for the production of prototypes and samples was a set of these. It would also be necessary to establish a repeatable testing and quality control procedure that could grow in response to changes in production volumes. The production component approval procedure (PPAP) was the final stage to complete before the commencement of manufacturing.
One firm is receiving more than $130,000 in yearly R&D tax credit advantages from the federal and state governments.