Alloy Fabricators can certainly provide prototype machining services for clients within a confirmed order. For example, a company might want to order 50 or 100 machined parts and requests that a sample be made first to confirm their project specifications are correct before they proceed.
In those cases, when a sample acts as a prototype within a confirmed order, we are able to give the customer a machined prototype for the same cost of the rest of the per piece price for the run, depending upon its complexity.
The types of slight alterations that typically come back when we do a prototype within a product run generally are either color or locations; the client might change the selected powder coating color or move a hole location over say an 1/8 of an inch—minor yet critical changes that can determine the success or failure of a project.
We do offer on-site engineering and design support for our clients’ metal fabrication needs, and that can at times help them realize some cost savings. For example, a customer might have designed a project to include a weld and our team discovers that instead of welding two parts together we have the capability to create a single formed piece. This helps them realize cost savings because it reduces the number of applied processes for the project. Other times it might be possible to insert fasteners instead of tapping holes, switching from a process that requires a skilled operator to a simpler, less expensive method of achieving the end result.
Overall the types of materials we work with most often include carbon steel, stainless steel, aluminum, brass and sometimes copper. On a daily basis we work mostly with carbon steel, aluminum and stainless steel. Material selection depends heavily on where and what the part is destined to do or perform. We stock our own raw materials. This aids with quality control purposes and allows for a quicker turnaround times.
In order to provide a proper estimate or quotation the customers should supply us with a drawing and an order quantity. An estimated annual usage works as well, then we can provide them with a blanket order quotation.
We prefer the Kanban system because of the advantages it offers the customer. In a Kanban system the parts ship instantly, with zero wait time, while a blanket order has a minimum lead time of three weeks. Kanban means that we keep stock for customers who choose that option. The client specifies the number of parts they anticipate needing throughout the year (or a few years to come) and the number of parts they might draw on that order at any given time. For example, if the order specifies 100 pieces per year with 10 parts available to ship at any given time, we can ship 10-part quantities at intervals while the customer receives the 100-piece price for the order. Kanban gives them this price advantage without the commitment of a blanket order and ships same day.
We offer any number of services related to precision metal fabrication. They include a powder coating line, assembly in house, zinc plating, heat treating, anodizing and of course drop shipping direct to third parties.
A stamping press presses or stamps out parts in one pass. Other than finishing, once the part is through the press it is considered done.
Custom metal fabrication is a more involved process that takes multiple parts or uses multiple processes to complete the finished piece. The typical precision metal fabrication job that comes through our door sees four to five different processes or treatments before it is done. It could utilize up to seven or eight, but four to five is more common. Types of treatment include shearing, punching, welding or powder coating. A part could be laser cut, tapped, formed, welded or machined. Grinding will smooth out edges. The services required depend on the end result the customer needs.
Custom tooling for metal alloy fabrication can take a week for a simple part and up to three or four weeks for a more complex piece.
The three major concerns customers express to us include price, quality and delivery. Our lead times average anywhere from two to four weeks.
We offer intense quality inspection and just added a counter-measure machine (CMM) last year to improve our inspection process and precision.
In terms of pricing, we offer tiered pricing, so customers can select the price/volume that works best for their operations. And don’t forget we can operate on the Kanban system, which offers advantages over blanket ordering. Although the higher the quantity the greater the discount, we cater to the small business owner. The average order size we received is close to 100 pieces and can go up to 1,000. We do take orders for fewer than 100 pieces as a business-to-business service for special parts.