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Metal tubing continues to play a critical role in medical device manufacturing, but with the array of available plastic materials it can be hard to determine which material is the right one.

With its unique properties, tungsten wire is used in a wide range of industry applications, from tungsten filament wire bulbs to tungsten thermocouples.

While laser cutting can produce a small kerf and tight tolerances, other precision cutting methods may be preferable for 2-axis cutoff of small metal parts.

In addition, the tighter the tolerances, the more difficult the component parts can be to assemble. That means downstream, tight tolerances can also increase the cost of assembly due to increased labor and higher scrap rates.

When choosing a resistance welding electrode for any application, a thorough understanding of material properties helps to avoid production line issues.

Calibration standards for devices and equipment used in measuring, inspecting, and manufacturing of precision metal parts can pose some unique challenges.

To avoid the challenges of verifying OD/ID concentricity, try to use other applicable GD&T symbols in place of concentricity in tubing drawings and designs.

Learn how the right electrode material, design, and construction can help to prevent bonding problems in resistance spot welding electrodes.

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This is an indication that, unless a special tolerance value is given, the default tolerance should be used — varying by the other convention of how many values are presented to the right of the decimal point, even if those values are zero.

Learn how precision cut off and stamping compare in achieving distortion-free flatness, a sharp edge, and the precise exterior diameter needed for a spacing ring.

For example, one Metal Cutting customer said they needed “a simple part”: a solid with a length and a diameter specified at a four-decimal tight tolerance (±0.000X). However, in probing for details, we discovered that the part needed a big corner radius, with no sharp edges — an interaction that would put the tight tolerance diameter at risk

Electrochemical cutting (ECC) combines electrochemical erosion and grinding to produce a burr-free, shiny surface to a tight tolerance of ±0.005” (0.127 mm).

GD&T cylindricity is a three-dimensional tolerance feature used to indicate both roundness and straightness along the entire axial length of a cylindrical part.

Dec 26, 2010 — Look for upsharp edge chipbreakers, because you want to minimize cutting force. Use grades that are tougher rather than long-wearing.

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With these RFQ tips, you can not only speed up the quote process, but also ensure you get the part you want and a cost estimate that is as accurate as possible.

Learn the advantages of copper tungsten electrodes for resistance spot welding of wire harnesses in battery electric vehicles (BEVs).

Learn how to prevent and detect surface flaws in the glass to metal seals used in the manufacture of a wide range of electronic products.

Unfortunately, consistent results aren’t always guaranteed. Learn what you can do to ensure calibrated measuring yields accurate results.

Eddy current testing is an important method of nondestructive testing that is often used to inspect for flaws in the surface or sub-surface of metal materials.

For measuring and inspecting the ID of small parts tubing, pin gages or optical measurement systems help ensure that small tubing will meet specifications.

High precision internal grinding methods such as ID grinding and honing are used to achieve smooth finishes and tight tolerances on bore, hole, and tube IDs.

Learn more about Metal Cutting’s certification in the ISO 9001:2015 standards and commitment to quality management practices.

It may be tempting to assume that a very tight tolerance should be your default choice. But, when they aren’t essential, it could increase your costs needlessly.

So, what is an appropriate tolerance for machined parts or cut-off parts? Before you commit to tight tolerance machining or cutting, consider:

Any surface will have flaws under the right magnification. In this video we explain the inherent challenges with blanket requests and how to overcome them.

Learn about the variables to consider when choosing the best resistance welding electrode material for specific resistance spot welding applications.

While CNC machining can produce an array of complex, precision metal components, there are some challenges to the process you need to be aware of.

Learn why the characteristics of titanium tube make it a good choice for medical devices and other applications that require strength, light weight, and corrosion resistance.

The properties of tungsten wire are valued in the medical device industry, for use in electrocautery, electrosurgery, neural probes, and other applications.

The reality is, the tighter the tolerance, the more likely it is you will have to add the cost of the following into your part:

Fortunately, having uncovered these critical details, we were able to work with the customer and adjust the specifications to make a part that works for its intended use.

Small gages such as pin gages or pin plug gages are useful tools for inspecting IDs and making sure small diameter metal tubing meets specified tolerances.

Celebrating 50 Years of Precision Manufacturing: Metal Cutting Corporation is genuinely thrilled to say we have just passed a significant milestone in our company history.

How does laser cutting compare with other precision metal cutting methods? Watch this video to learn some of the pros and cons of this metal cutting method.

When doing a request for a quote, it may be tempting to assume that a very tight tolerance — perhaps the tightest tolerance possible — should be your default choice. Instead, it’s important to strike a balance between excessively cutting costs and implementing unnecessary requirements.

Learn how tungsten as an alternative to precious metals can help you achieve uncompromising quality and still keep your budget on track.

Learn 7 simple rules to help ensure that calibrated measuring yields accurate and consistent results for your small parts manufacturing.

Waterjet cutting is typically used to cut complex shapes from large, flat sheets of metal but may not be the best choice for 2-axis cutoff of small parts.

In material sourcing for the production of precision parts, avoiding non-standard material sizes can help to control costs and optimize for manufacturability.

Copper tungsten electrodes combine the thermal resistivity of tungsten with copper’s resistance to DC arcing, making them a smart choice for EDM of carbides.

Cold sawing can do high-speed, burr-free cutoff of rods, tubes, and extrusions, but it is not ideal for very short lengths, smalls ODs/IDs, or hard metals.

Follow these tips on how to choose a vendor for cut off metal parts and get the results you want for your precision manufacturing needs.

Learn why manufacturers, designers, and engineers need to keep metal expansion from heat in mind when they create part specifications and decide how precise the part’s dimensions need to be.

Pull rings for medical devices can be cut from 304 grade stainless steel tube or Swiss machined to provide specialty features and use other materials.

Besides having an impact on the cost of parts and assemblies, specifying a tight tolerance affects what tools and machines need to be used and the cutting technique that will be employed — which in turn also affect costs.

Learn more about the principles of centerless grinding and how it can be used to achieve tight tolerance surface finishes on small cylindrical metal parts.

Learn about the advantages of precision CNC machining in the manufacture of small, complex parts requiring tight tolerances, smooth finishes, and repeatability.

For more tips on how to improve your quote request to optimize for manufacturability and produce the results you’re looking for, download our white paper How to Fine-Tune Your Quote Request to Your Maximum Advantage: Frequently Asked Questions in Small Parts Sourcing.

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When a single part has multiple tolerances that conflict, the tighter, more challenging tolerance must guide production and ultimately drives the part’s cost.

Learn why a small diameter metal probe requires choosing a material that is strong enough to maintain the probe’s shape, straightness, and direction.

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However, if a tolerance is tighter than you really need, you’ll end up paying for it. But by carefully considering the end use, where the part is going, and what the part needs to do, you can:

While graphite is often used, the properties of copper tungsten make it an ideal material for EDM electrodes for certain applications.

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For intricate geometries, sharp corners, unparalleled wear resistance, excellent cutting speeds and machinability, copper tungsten is the material of choice.

Learn how to optimize for manufacturability through a unified approach to product design and the creation of a thorough and detailed request for quote (RFQ).

Industry Trend No. 1: Increased exporting and global trade has a positive impact on revenue, growth, and competitiveness, while expanding a manufacturer’s customer base.

While automation plays a growing role in precision machining, lights out operation is still more a fantasy than a reality for most small part manufacturing.

It’s critical to choose a supplier you can envision working with for the long haul. Review these practical guidelines to make the right decision.

Our name might not give it away, but precision cut off of tight tolerance, small metal parts is at the core of our business.

Metal Cutting utilizes lapping and machining as well as other techniques to achieve flatness vs. parallelism for metal cut to length.

When designing a part, remember that different tolerances may require different processes, and not all processes can produce results to the same tolerance.

Double disk grinding provides dimensional accuracy for metal part applications that require tight tolerances, parallelism, flatness, and thickness control.

Designers sometimes automatically program their software to a certain tolerance, resulting in all dimensions being specified to the same tolerance, whether or not they need to be. This can result in unnecessarily tight tolerances and unnecessary costs .

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As important as inspections are, 100% inspection requires time and cost without a guarantee of 100% compliance. See what a sampling plan is and how it solves this challenge.

The characteristics of the precision tubing used in liquid dispensing systems can significantly affect the fluid dispensing process and testing accuracy.

The creation of new specialty metals offers alternatives to stainless steel for components used in medical device applications.

Learn how the guide bushing and other features of modern CNC Swiss screw machines eliminate deflection to improve efficiency, consistency, and accuracy.

Over time, we’ve developed a special appreciation for tungsten and what it can do. Learn some interesting facts you may not have known.

Precision CNC Swiss machining is often used to produce bone screws and anchors with the features needed for a wide range of orthopedic and dental applications.

In circular runout vs. total runout, the first controls variation in circular features of a part while the other controls variation in the entire part surface. Learn the difference and how to measure them here.

The process of creating a vacuum atmosphere, either repeatedly or in one-time production, is an important part of electronic component manufacturing.

Accepting the default tolerances without understanding whether they’re truly necessary, or simply not noticing them at all, can needlessly drive up costs. Here are just a few common examples:

Eddy current testing is an important method of nondestructive testing. See what you may not have known about the process.

There are 5 key areas that should never be left blank when filling out your request for cutting quote. Do you know what they are?

Laser printing of metal is popular for a number of applications, but can you‭ ‬use it for printing of metal for‭ ‬such large quantities of such small parts?

Tolerances affect product design, manufacturing, and quality control, making them critical to the successful performance of an end product. Therefore, determining tolerances and the amount of acceptable variation in machined or cut parts is a critical component of the cost of quality.

Learn why resistance welding electrodes require a material with the right combination of thermal conduction, electrical resistivity, and reactivity.

The fundamentals of small parts sourcing — dimensions, tolerances, and materials — have a lot to do with whether a part is optimized for manufacturability.

For EDM electrodes, copper tungsten offers excellent electrical conductivity, DC arcing resistance, thermal conductivity, and wear resistance.

Utilizing a controlled environment helps to minimize the effects of heat expansion and other temperature issues on the measurement of metal parts.

Thin-wheel abrasive cutting is an ideal method for high-volume 2-axis metal cutoff that requires precision, tight tolerances, no burrs, and a smooth end finish.

Learn some common myths about plastic and reasons why it may not be a better choice than metal tubing for medical device applications.

Where feasible unless a tight tolerance is required for proper fit or function of the final part or assembly, opting in the design phase for a loose tolerance can help to keep development and production costs down.

Learn about the role that tight tolerance plays in optimizing for manufacturability, and how to specify tolerances to ensure part quality and control costs.

When polishing metal parts for 3D printed medical devices, the goal is to achieve the proper surface finishes while maintaining the device’s complex design details.

Tungsten, also known as wolfram or volfram, has a high melting point and other interesting properties that are useful in many industries and products.

Precision flat lapping and other lapping techniques can be used for small parts requiring tight control of surface finish, flatness, thickness, and parallelism.

With a metric tolerance chart, you need to account for the upper and lower tolerance spec limits when converting between standard and metric measurements.

Learn how the properties of copper tungsten reduce or eliminate the challenges posed by those materials when they are used in their pure forms.

A metal surface finish chart is a handy guide to standard surface finishes and characteristics such as measurement units, conversions, and typical Ra values.

Learn how best practices as well as material and design considerations have an impact on the life and effectiveness of resistance spot welding electrodes.

Learn why infiltration, density, and other properties of an alloy such as copper tungsten are important to  the quality of spot welding electrodes.

You need to ask yourself: Does the economical method utilize machines with the necessary nominal tolerance capabilities? If not, a tight tolerance could result in a very expensive production method.

The Swiss machine has evolved and improved since the original Swiss lathe was invented, making the modern method an important part of precision CNC machining.

Learn the vital components of an effective quality control program and its role in ensuring that metal parts meet their requirements for design and function.

Thousands of resin compounds have been developed to expand the design options for tubing in medical devices. Yet, there are number of myths. Learn why plastic may not be a better choice to metal tubing in medical applications.

In addition, the part needed a smooth surface finish that would require mechanical polishing, which in turn would remove material and affect the specified tight tolerance.

Customers sometimes ask why a part is so expensive, not realizing that extending tolerances out just one more decimal point can increase the cost by a factor of two or three. That’s because a tighter tolerance requires greater care in fabrication and inspection to ensure accuracy.

Metal Cutting Corporation uses visual and mechanical methods of metal inspection to help ensure that small parts meet customers’ manufacturing requirements.

In these scenarios, small variations in each part’s dimensions can multiply, especially with complex assemblies, resulting in tolerance buildup and unacceptable variations in the intended design.

GD&T tolerances provide manufacturing guidance that must balance the need to make a part functional with the need to produce the part cost-effectively.

For some medical device applications requiring biomaterials, tungsten and gold-plated tungsten wire may be suitable alternatives to precious metals such as gold.

Circularity tolerance based on diameter helps to control roundness and ensure that small precision metal parts fit properly, move smoothly, and wear evenly.

Jan 24, 2019 — The combo tool is attractive because it seems that for a lower price I get a machine that will do what I need for my hobby. I am making ...

Adherence to ISO 9000 standards by an organization tells customers that it is committed to implementing structured quality management practices.

OD grinding is used to shape the external surface of objects between the centers and excels at removing circular defects and restoring or creating roundness.

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Learn how potting can be used to create a tightly sealed package for electronic switching devices, such as the flat ribbon in semiconductors.

Tungsten wire continues to be a product that has a large number of diverse applications, for many of which there is no known substitute. Find out why tungsten remains widely used.

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Learn how additive manufacturing (AM) — one of today’s fastest growing technological innovations — is changing the face of contract manufacturing everywhere.

Get an expert machinist’s perspective on how CNC metal cutting has evolved in the age of tight tolerance, micro-machining of small parts.

While an automatic lathe can do simple 2-axis cutoff of metal rods and tubes, it is designed for more complex, multi-step machining operations.

Custom bushings that are Swiss machined for use in catheters and other medical devices allow the devices to function at a high RPM while resisting wear.

For deburring of small metal parts, mass production requires the action of hand tools to be re-created by mechanical devices suited to high-volume applications.

People often ask Metal Cutting Corporation if we do “metal fabrication” — and the truth is, the answer depends on how you define the term.

Learn the key parameters for choosing a method of 2-axis precision cut off of metal parts based on part type, material type, and part dimensions.

And of course, it’s vital to keep in mind the role that the complexity and dimensions of a design, as well as its tolerances, will ultimately play in part manufacturing costs.

Get answers to common questions about dissimilar metals regarding high and low conductivity electrodes and friction stir in the construction of an electrode.

The centerless grinding process is ideal for finishing small cylindrical metal parts that require a tight tolerance and high-volume production. Learn some of the fundamentals of this process.

Learn how better materials for resistance welding electrodes speed up your welding operation. This white paper is designed to help you make a successful electrode materials choice.

Consider the methods used for heat treating metals, as well as the effects, when specifying your requirements for the cut-off of small metal parts.

A statistically valid sampling plan in quality control provides a high level of confidence that if the sample is acceptable, the entire lot is acceptable.

The key to calibration tolerance is understanding both what a device is capable of doing and the tolerance to which the device has been calibrated.

With profile of a line vs. profile of a surface, the former controls variation at specified cross sections while the latter controls the entire feature surface.

There are standards in place for different industries, with tolerances recommended based on factors such as function, material, machine, and process. There are also handbooks, technical guides, and fact sheets that provide default tolerances for a variety of products and processes.

Proper electrode design and construction is essential to ensuring consistent weld quality, minimum electrode sticking, and maximum electrode life. Learn how electrode design can impact your prod line.

Making an informed decision about how tight a tolerance really needs to be can help you ensure product quality, optimize manufacturability, and speed time to market.

Dopants raise the recrystallization temperature of tungsten wire and other wires, giving non-sag properties to tungsten light bulb filaments and other products.

Learn the vital components of an effective quality control program and its role in ensuring metal parts meet their requirements for design and function.

Learn why precision CNC Swiss machining is used in the production of medical electrodes made from MP35N® for electrical signal delivery devices.

In comparing common tungsten uses in 2007 and today, it is clear that tungsten remains one of the most widely used and beneficial of the refractory metals.

202443 — A lathe is a machine that shapes materials by spinning them against cutting tools. Lathes have gained popularity among professionals for their ability to do ...

Metal Cutting’s methods for cutting metal tubing, such as thin wall steel tubing for medical devices, are unique compared with machining and laser metal cutting.

For example, depending on the end use of a product, you may indeed be able to opt for a standard default tolerance if the risk of failure in the product is low or would not have severe consequences.

Precision metal grinding is often the best way to remove small amounts of material and achieve the right finish or tight tolerance dimensions on part surfaces.

While honing and lapping are both used to fine-tune the finish and dimensions of metal parts, the two processes differ in where and how they achieve results.

Surface finish requirements are among the details that are critical to creating a complete RFQ that will help to optimize for manufacturability.

Different precision metal cutting options vary in characteristics and appropriate applications, making the choice not quite so easy. This guide will help.

Learn the key parameters for choosing a method of 2-axis precision cut off of metal parts based on part type, material type, and part dimensions.

Incandescent bulbs made with tungsten wire filaments continue to be used in automobile turn signals despite the parallel adoption of newer LED technology.

How do you qualify a new sourcing partner and ensure an efficient and problem free experience? Considering these points will help you make a decision you can feel confident about.

With the eddy current testing ‬procedure, there are a number of variables that ‬have an effect on ECT, what it can find,‭ ‬and ‬what it cannot find.

Specifying the magnification level and details of how a material surface must be examined helps to ensure that parts will pass inspection and meet your needs.

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If you don’t know or are unsure about what tolerances are right for your application, don’t worry. You and your manufacturing partner can walk through the decision points together, to help you identify the mission-critical tolerances for your parts. Just ask!

When measuring the perpendicularity of small metal parts, consider the effects of a part’s diameter, length, straightness, and manufacturing method.

Surface flatness is an indicator of all points along a surface lying in the same plane, with the highest and lowest points within the flatness tolerance range.

Gold-plated tungsten wire is useful in filtration, printing, copying, and other applications, and as an alternative to precious metals in some medical devices.

Finding a supplier who can deliver quality and on-time service can be tough, especially when it comes to the medical device and other heavily regulated industries. This guide makes it simple.

A fully complete RFQ tells a story about the buyer, the company, and the end product and its use — information we can use to provide the right quote (and the right price).

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Precision tubing plays a vital role in helping to ensure the accuracy of liquid dispensing systems used in many biotechnology and laboratory environments.

Nickel-based alloys are also referred to as ni-based superalloys due to their outstanding strength, heat resistance and corrosion resistance. The face-centered ...

Choosing the right resistance spot welding electrode for an application depends on understanding critical properties of the different electrode materials.

The electrochemical grinding process is a highly specialized method that combines surface grinding, chemistry, and fixturing, and has limited applications.

But undoubtedly there are times when a very tight tolerance is absolutely mandatory — when the difference between a product that works and one that fails means using dimensional tolerances expressed in decimal places that go much further than you initially expected.

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The straightness properties of tungsten wire make it valuable for small diameter tungsten probes used in semiconductor wafer testing and neural activity testing.

Learn about the five major challenges to consider when choosing CNC machining services and a partner for the manufacture of complex and precise small parts.

Explore the advantages of pure tungsten and pure molybdenum as alternative materials for use in spot welding electrodes.

While the idea of zero tolerance machining or cutting might sound appealing, it’s important to acknowledge there really is no such thing as “zero tolerance.”

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Trochoidal/Peel Milling or Dynamic milling feeds and speeds. RPM ... High Feed End Mill - Indexed end mill with an extremely low lead angle that ...

Industry Trend No. 2: Manufacturing globalization and regionalization provide opportunities for partnership, innovation, competitive advantage, and growth.

Wire EDM cutting advantages and disadvantages for 2-axis cutoff depend on factors including the material used, part parameters, and surface finish requirements.

Surface grinding services utilize precision surface grinding methods to make cubic metal parts square and parallel or the ends of metal rods perpendicular.

What is lapping? In the right hands, this little-known process can produce parts with highly polished ends, tight length tolerances, and extraordinary flatness.

Industry Trend No. 3: Rising labor costs overseas are one factor in the move away from outsourcing and toward reshoring of some businesses and factories.

Surface finish requirements are just some of the details critical to completing an RFQ that will help you optimize for manufacturability.

While the most familiar use of tungsten (incandescent light bulbs) continues to fade, the unique range of properties continue to make tungsten wire irreplaceable for a number of products and applications.

Feb 2, 2024 — The Caboose cutter in Barbados is reason enough to go back.

The metal shearing process can be quick and inexpensive for cutting some simply shaped parts, but it has disadvantages including burrs and end deformation.

Learn about the important role of machining and tooling in the manufacture of metal parts for today’s fuel injection systems.