Posted on 8th September 2021 in the categories: Sub-Contract Manufacturing, Assembly Techniques

Comprehensive Design Services & Specialised Assembly Techniques

Comprehensive Design Services & Specialised Assembly Techniques from Goudsmit UK

Often client’s approach us with a pre-designed assembly for some design assistance. Goudsmit UK’s focus is engineering and design, so we are easily able to facilitate their requirements. Most often we are engaged to achieve one of the following goals:

  • Cost reduction
  • Enhanced performance
  • Material reduction or change
  • Miniaturisation

Design capabilities

With substantial knowledge in the area, we offer a wide range of design capabilities, summarised below.

Mechanical design

This is often an underappreciated discipline and one which is poorly practised on a wide scale. Good mechanical design, combined with knowledge of manufacturing techniques and costs, is invaluable when it comes to assisting clients with the design of their assemblies. Knowing how to tolerance mating parts and how various assembly techniques are applied is key and translating these into accurate 3D models and drawings is necessary to communicate the design to the manufacturing arena. Finally knowing how the materials behave mechanically and within their environment will lead to better design, a better finished and more durable product in the field.

Mechanical analysis

Often the magnetic performance of an assembly is just one of the functions. There are other parameters we often need to investigate during the design, the most common being mechanical behaviour under load. Using FEA analysis, Goudsmit UK can load and fix a component in a multitude of different ways to look at how that component will perform or deform under that load. For example, we design high speed rotating machines however, often how the machine behaves mechanically is more difficult to predict than magnetically. A good understanding of materials and manufacturing techniques is necessary, with our expertise in component supply we can also match up the design and production disciplines.

Thermal analysis

As with mechanical analysis we need to ensure that any design works thermally, whether that be in a high temperature environment or generating thermal energy which needs to be dissipated. Radiation and convection patterns need to be understood to allow the design to be optimised to provide the heating or cooling function required.

2D magnetic design

For products which can be analysed in a single plane or which are rotationally symmetric we can use 2D software and of course our design experience. We can look at characteristics such as field strength, flux density, saturation, force between objects etc. to allow us to ascertain the optimal design for an assembly. Parametric analysis can be used to look at the effect of changes in key dimensions or materials.

3D magnetic design

For more complicated products which need to be modelled in three dimensions we use a 3D software package. This is a slower process as it is data heavy and large matrices are required to find the numerical solution. Coupled with our design know-how we have the ability to characterise and simulate an application without ever having to build a prototype. Again, we can look at characteristics such as field strength, flux density, saturation, force between objects to fine tune the design.

Assembly techniques

As specialists in manufacturing assembly, Goudsmit UK have developed substantial knowledge and expertise related to several assembly techniques. A brief outline of these is listed below.

Mechanical assembly

Press fits, interference fits, fasteners, threads and clips are some of the lowest risk methods of assembling components available, with also having the ability to test and validate. Goudsmit UK will often look at mechanical assembly as a first-choice solution.

Insert moulding

Commonly used to combine metals and plastics without gluing, this is a technically advanced solution which requires well designed moulds and precision components.

Over moulding

When looking to combine two polymer parts Goudsmit UK often look to over moulding. Although requiring an extra mould tool it is an excellent way to ensure parts remain firmly assembled. Often the polymers are quite different with a rigid polymer being combined with an elastomer.

Gluing

This needs to be a well thought out and well tested solution. Gluing must be well controlled with proper dosing equipment, refrigerated storage, thorough application and curing instructions respected and complied to. Environment and fatigue testing of samples is essential to ensure the correct functioning of the product over time. We frequently use glue in our assembly products however, we do so with some caution and considerable testing cycles.

Heat staking

This is when a polymer is heated to a temperature where it exhibits plastic behaviour and then is deformed to form a fastener. This powerful and repeatable technique is one we use with greater frequency at Goudsmit UK.

Ultrasonic welding

Soundwaves are used to weld two polymers together. Another specialised technique that requires tooling to hold the parts and direct the sound waves to the required area. Once perfected repeatability is exceptional, and it can be easily tested by sectioning the welds.

Welding

When two metal parts cannot be joined using a fastener, Goudsmit UK use metal welding. A manual skill that relies on the operator and testing is quite lengthy. However, it can be difficult to provide a good cosmetic finish.

Brazing

Like welding, two parts can be brazed using a copper-based alloy which melts and fills the gap between the two tightly fitting parts using capillary action. There are several different techniques, fillers and inert atmospheres used.

Goudsmit UK

At Goudsmit UK, we maintain the highest standards at every stage of product development. With ISO 9001 and AS 9120 certifications, customers can be assured of our product and service quality. Take advantage of bespoke design and assembly solutions to meet your unique application requirements. All our products are fully tested and packaged according to customer specifications and can be shipped to you or directly to your customer.

For more information visit our webpage or download or brochure.

Contact our team on 02890 271 001 or at info@goudsmit.co.uk

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