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Fabrication & Assembly of a Mechanical Assembly for the Telecommunications Industry

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Mechanical Assembly for Network Server
Mechanical Assembly for Network Server
Working with our client in the telecommunications field, McAlpin fabricated and assembled this featured mechanical assembly for a network server application. We began by designing and building all the necessary fixtures and tooling needed for manufacturing, relying on wire EDM machining processes. Metal fabrication involved a combination of countersinking, press brake forming, laser cutting, shearing, thread tapping, and deburring, followed by TIG welding and PEM staking. We used two different PEM nut sizes: M3 x 5 x 1.02 mm and 6-32 x .060 in. All assembly was done manually, followed by riveting.

To ensure the quality of our work, we used a Trumpf laser cutter during manufacturing. The final assembly measured 15.200 in. long, and we held a close, .003 in. tolerance, as well as a .040 in. flatness tolerance. We finished the assembly with zinc plating. After ensuring all design and manufacturing standards had been met, as outlined in our client-supplied print, we delivered the mechanical assembly to our client.

Project Highlights

Product Description This Mechanical Assembly is used within a Network Server application
Capabilities Applied/Processes Custom Tooling Design & Build
  • Fabricate any Fixtures & Tooling needed to Manufacture Component
  • Wire EDM Machining
Metal Fabrication
  • Countersinking
  • Press Brake Forming
  • Laser Cutting
  • Shearing
  • Thread Tapping
  • Deburring
TIG Welding
PEM Staking
  • PEM Nut M3 x 5 x 1.02mm
  • PEM Nut 6-32 x .060”
  • Manual Assembly
  • Riveting
Equipment Used to Manufacture Part Trumpf Laser Cutter
Overall Part Dimensions Length: 15.200”
Tightest Tolerances ±.003”
Flatness of .040”
Finish Zinc Plating
Industry for Use Telecommunications
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Mechanical Assembly