A San Diego start-up company needed to protect a suspension area on their newly developed bikes. Eminent Cycles www.eminentcycles.com are selling a bike that can be custom designed and has the highest possible quality parts. They needed a supply partner with a go-get attitude so they decided to ask Alpha Custom Solutions to source the material and manufacture a product that would meet their exacting specifications.
The final product is made from HDPE (High Density Polyethylene) at 0.035" thickness. This type of plastic has few branches so it provides a high-strength-to-density ratio which is ideal for a bike application. HDPE material is rigid but provides strength and flexibility but also important for outside use as it is UV and moisture resistant.
If you have a need for a custom product please contact: www.alphacustomsolutions.com
We were given two major challenges - to die cut parts out of a hard brittle carbon fiber material which was 0.030" thick and to maximize the number of parts we could make from the raw material sheets which were supplied by the customer.
After experimenting with various die cutting variations we were able to die cut the carbon fiber with our 100 tonne clam shell press and which produced a very good clean cut. Also as per our standard practice we always try and find the best solution to make the most parts from a raw material sheet or roll. This may involve us taking a little longer to calculate but its in the best interests of our customers especially as some raw material can be up to 75-80% of the total manufacturing cost. With the part design for this project we were able to nest 2 parts together.
If you need a gasket using Neoprene rubber or foam let us know. This particular gasket is 0.062" thick Neoprene rubber, 60 duro hardness with PSA on 1 side. This gasket is 3" square and required bolt holes very near to the edge of the part.
Poron - we can die cut various thicknesses
One of the most common used materials we die cut is Poron. We manufacture hundreds of gaskets using Poron every week. The gasket shown in the photo is Poron at 0.031" thick with small diameter holes and the center cut out. If you have a gasket project that requires Poron material please get in contact us.
We had a tough challenge to cut very thin 0.010" Lexan material and make a 1.60" dia OD with a 1.57" ID. We utilized our die cutting experience by producing a steel rule die with an outside beveled edge and were able to manufacture quality custom gaskets. If you have a difficult project which requires Lexan material please contact us: www.alphacustomsolutions.com
About the Author
With over 25 years of experience in the manufacturing industry, Martin Chell brings a wealth of knowledge to his client projects. He has worked with large companies including Qualcomm and completed projects in a variety of aerospace, biotech and other applications.
“The die cut samples look great.” ~ Aquapail
“Thanks so much for the great service.” ~ Robert, Hat Fitness
“The gaskets worked out just fine. Thanks for your help.” ~ Chong, Redpoint Engineering