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The client is a manufacturer of high precision magnetic positioning stages. One of the components was originally manufactured by using a CNC milling machine, followed by the assembly of dozens of positioning pins. Due to the relatively large size of the component, the precision during the machining and assembly process could not be controlled, increasing the likelihood of rework in the later processes. The rework process was cumbersome and time-consuming, making it difficult to maintain costs. The functionality of the positioning stage relies on accurate positioning, which is determined by the pitch of the milling holes, the tolerance of the holes and pins, and error when riveting the pins . As the stages lengthen, the cumulative tolerances also increased, leading the cost of machining to rise exponentially, making it challenging to effectively control the accuracy of the product. After understanding the client’s issues and challenges, we completely eliminated the hole milling and the pin riveting processes. We modularized the length of the stage, integrating the positioning function directly into the mold. By creating the positioning intervals on the surface of the mold, the accuracy became entirely mold dependent. This not only saved the costs of machining holes and riveting pins but also eliminated the issue of cumulative tolerances. This approach improved the stability of the component’s tolerances and completely avoided rework in the later processes, allowing the client to effectively control costs and lead times. Subsequent feedback from the client indicated that all products met the required standards. We replaced six different types of the stage for the client, proving the success of this case. The expertise of Ace Powder metallurgy in mechanical components made the solution straightforward

The client is a vendor of hand tool socket wrench sets. One of their products, a BIT to socket quick-release, consisting of a socket and a turning knob, the turning knob was made from machining, resulting in high costs, long lead times, and had an ordinary appearance, which led to poor sales. The client clearly stated that cost and lead time were his biggest concerns. Reducing costs and accelerating lead time were the primary goals. Additionally, the client is an aesthetical and practical person. To meet his needs, constant communication and the creation of 3D renderings were essential. After countless discussions and revisions, we successfully developed a low-cost, short lead time, practical product that also incorporated auspicious Feng Shui numbers in its design. After completion of the T1 sample, the client was pleased with the resulting sample and received orders shortly after. His client was so satisfied with the appearance and practicality that they didn’t even negotiate the price; they only requested a small batch for trial production within two weeks. Fortunately, the design had eliminated machining processes, and with Ace Powder Metallurgy’s efficient production process, we successfully completed the order on time and passed the assembly inspection. This successful case not only resolved the client’s long lead time issue but also increased the product value due to the customized appearance. Moreover, the elimination of machining in the design saved costs, indirectly accelerated delivery time, and further shortened the time to market. Ace Powder Meallurgy’s customized services always think ahead of the client’s needs. When designing products, we intentionally crafted the number of component features to represent auspicious feng shui numbers, enhancing the client’s confidence in the product and providing intangible value.

The client specializes in manufacturing adjustable fixation brackets for medical use. One of the components, the joint adjustment gear, has specific torque requirements. The existing supplier could only meet 100% to 125% of the required torque. Since this is a medical product, the client wanted to reliably increase the safety factor to over 150%. After understanding the client’s needs and analyzing the components from the current supplier, we found that the product’s density was only 6.65 to 6.8 g/cm³. Further investigation revealed that both the raw materials and mold design were not suitable for high-density production. We modified the raw materials, redesigned the molds, and improved the manufacturing process, successfully increasing the density to 7.2 g/cm³ and stabilizing the safety factor to between 235% and 280%. This successful case not only alleviated the client’s concerns about insufficient product performance but also gained recognition from the end assembly plant, allowing the client to become the primary supplier. Since then, we have also successfully developed a second type of the joint adjustment gear. And the order batch has increased substantially. The powder metallurgy industry has its own specializations, and without finding the appropriate manufacturer, it is impossible to solve such problems. High-density applications require special raw materials, mold design, and processes to achieve the goals. Ace Powder Metallurgy’s decades of accumulated expertise and experience in high density have become the benchmark in the industry.