Our customer came to Ajax because they had problems holding tolerances on an aluminum bracket with a square notch. It is a safety component on a consumer small appliance, so it has to be right.We designed a strengthening gusset that lets the part work-harden, while maintaining dimensional integrity within .5°.

When the customer moved manufacturing to China, they retooled everything except our part. The offshore operation couldn’t meet the functional requirements. As a result, we didn’t lose a client—we gained a market. Our volume has increased from 50,000 parts a year for the U.S. market to nearly a million parts a year globally.

Product DescriptionProgressive stamped aluminum bracket with square notch
Capabilities Applied/ProcessesProgressive metal stamping
Tightest Tolerance.005 inch and .5° +/-
Material Thickness.125 inch
Material Used5052 H34 aluminum
Material FinishN/A
Industry for UseConsumer appliance
Volume1 million annualy
Delivery TimeKanban
Delivery LocationChina
Standards MetU/L
Product NamePressure safety lock
Project ScopeProduct re-design; material selection; rapid prototyping; production tooling
Design WorkRapid prototyping; production tooling