The request was to make just one jig for a single-use application.
We received an inquiry from someone looking for a manufacturer to create a jig for a certain experiment.
A jig used in experiments with demanding conditions, such as combustion tests.
They wanted to make just one to test it out first.
However, it was difficult to find a company willing to take on a one-off, small-scale production project.
The discussion then turned to whether the design itself could be revised.
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, which involved machining from a solid block of metal, tended to increase both the number of parts and the weight.
Machining itself isn't inherently bad.
However, if you request a quote for a one-off, small-lot order using this drawing, the cost is likely to be high.
The number of places 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 removing it is directly added to the processing cost.
In mass production, the setup cost per unit is reduced by dividing it by the number of units produced.
For one-off or small-volume orders, setup costs tend to be a significant factor, adding up to the price per unit.
If you narrow down the manufacturing method to just one during the design phase, this tendency will remain.
While some parts can be done easily and cheaply using sheet metal processing or other methods,
Often, the shape is left as it was after machining.
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 confirm what the jig actually does.
For example, there are parts that determine the position, parts that require strength, and parts that are for appearance and mounting.
We will divide the roles according to each function.
Then, we compare multiple processing methods, such as sheet metal fabrication and cutting.
Each processing method has its own strengths in terms of shape, strength, and cost.
Even with the same functionality, the final result can vary depending on how it's made.
- 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 processing methods according to function.
From the rough sketch, identify the parts that can be replaced with sheet metal.
Specifically, first draw a rough sketch of the entire jig,
I have listed the required strength and precision for each component.
Next, we mark the parts that seem like they could be done without cutting.
For parts where strength is not particularly important, or where a flat shape suffices,
We considered whether it could be replaced with sheet metal processing.
When using sheet metal, the strength is determined by the thickness of the sheet metal, so we also need to confirm the required sheet metal thickness.
When the component configuration is rearranged in this way, only the parts that can only be made by machining remain.
This alternative design reduces both the number of parts and the weight.
This will make it easier to get quotes even 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 they are, but rather re-selecting the processing method to suit the usage conditions,
This perspective is applicable not only to jigs but to prototyping in general.
If you simply continue using old drawings and past production records,
Sometimes, the processing environment and conditions from that time remain as the underlying assumptions.
If we review it under the current conditions, we may find parts that can be made lighter and cheaper.
When looking for a company that can manufacture jigs even for a single unit, instead of searching with a fixed drawing,
Finding someone who can help you rethink the design from the ground up will broaden your options.
From design revisions to selecting the manufacturing site
MACHICOCO is a company based in Higashi-Osaka, and works in collaboration with engineers from local factories.
We are currently working on a product development project.
They do not own large facilities in-house, and are involved not only in development and manufacturing,
We work together with you all the way through to the point of sale.
For consultations regarding jigs and testing equipment,
You can be involved from the design stage, including reviewing existing drawings and revising manufacturing methods.
Because we have connections with engineers who can handle both sheet metal processing and cutting processes,
The process can be carried out by selecting the most suitable processing location for each part.
Selecting a manufacturer for one-off or small-batch production,
We also provide consultation services 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
Drawings are not required.
Even before the processing method is decided, we can consider the manufacturing method while looking at drawings and actual samples.
First, I'd like to see what you have.
