The request was to make just one jig for a single-use application.
We received an inquiry from someone looking for a manufacturer for a jig for a certain experiment. The jig is to be used in experiments with demanding conditions, such as combustion tests, and they wanted to have just one made to test it first.
However, we had difficulty finding a company willing to take on a one-off, small-batch production, so we started discussing whether we could revise the design itself.
If we stick with the old drawings, the number of parts and the weight will increase.
The drawings I was consulted about were drawn with machining in mind. The design involved cutting from a solid block of metal, which tended to increase both the number of parts and the weight.
There's nothing inherently wrong with machining itself. However, if you request a quote for a one-off, small-batch order based on this drawing, the cost is likely to be high, and the number of companies willing to take on the job will be limited.
Machining processes result in the loss of both material and time as material is removed.
Machining is a processing method that involves removing unwanted parts from a block of material to create a specific shape. The material that is removed is essentially unusable, and the time spent on the cutting process is directly reflected in the processing cost.
In mass production, the setup cost per unit is reduced by dividing it by the number of units. In the case of one-off or small-batch production, the proportion of setup costs tends to increase, and this becomes a significant factor in the price per unit.
If you narrow down the manufacturing method to just one during the design phase, this tendency will remain. Even parts that could be easily and cheaply processed using sheet metal or other methods are often left in their original, machined form.
First, identify the functions required for the jig, and then re-select the machining method.
When reviewing the design, the first thing we did was to confirm what each jig actually does. We divided its role according to its function, such as the part that determines the position, the part that requires strength, and the part that is for appearance and mounting.
Furthermore, we compare multiple processing methods, such as sheet metal fabrication and machining. Each processing method has its own strengths in terms of shapes, strength, and cost, and even for the same function, the finished product will differ depending on the manufacturing method.
- Sheet metal fabrication is a method that allows for the relatively inexpensive production of thin, lightweight parts by bending and cutting sheet-like materials.
- Machining is suitable for complex shapes and parts requiring high precision, but it is a machining method that is prone to material and time loss.
- Even with the same part, the range of processing methods you can choose from will vary depending on the required level of strength.
Instead of making everything by machining, we rethought the design from the perspective of combining machining methods according to function.
From the rough sketch, identify the parts that can be replaced with sheet metal.
Specifically, I first drew a rough sketch of the entire jig and wrote down the required strength and precision for each part. Then, I marked the parts that could be made without machining.
We considered whether parts that didn't require high strength or could be flat in shape could be replaced with sheet metal fabrication. If we replaced them with sheet metal, the strength would be created by the thickness of the sheet metal, so we also confirmed the required sheet metal thickness.
By rearranging the component configuration in this way, only the parts that can only be manufactured by machining remain, resulting in an alternative design that reduces both the number of parts and weight. This also makes it easier to obtain quotes for one-off or small-lot orders.
Design can begin with questioning drawings and manufacturing methods.
The idea of not simply accepting existing drawings as the basis, but rather re-selecting the manufacturing method to suit the usage conditions, is a perspective that can be applied not only to jigs but to prototyping in general.
If you simply carry over old drawings and past production records, the manufacturing environment and conditions of that time may remain as assumptions. By reviewing them under current conditions, you may find parts that can be made lighter and cheaper.
When looking for a company that can manufacture jigs, even for a single unit, it's better to look for someone who can collaborate with you on the design from the beginning, rather than just searching with a fixed set of drawings. This will broaden your options.
From design revisions to selecting the manufacturing site
MACHICOCO is a company based in Higashi-Osaka that works in collaboration with engineers from local factories to develop and sell products. They don't own large-scale facilities and are involved in every stage, from development and manufacturing to sales.
When consulting on jigs and testing equipment, we can be involved from the design stage, including reviewing existing drawings and revising processing methods. Because we have connections with engineers who can handle both sheet metal processing and machining, we can select the most suitable processing location for each part.
We also provide support for selecting manufacturers for one-off and small-batch projects, as well as consultations regarding manufacturing and mass production beyond the prototyping stage.
You can start a conversation with hand-drawn pictures and photographs.
When you contact us for advice, please send us the following information to help us proceed with your inquiry.
- Hand-drawn rough sketches and drawings
- Photos of actual products or prototypes
- Approximate dimensions
- How to use the jig and its operating conditions
- Desired quantity
You don't need drawings. Even if the processing method hasn't been decided yet, we can consider the manufacturing method while looking at drawings or actual samples, so please show us what you have first.
