- Home
- Browse Catalog and Order Now
- Ready to Ship Blanks
- Made to Order Blanks
- Aluminum & Steel Custom Vice Jaws
- Metal Services
- Materials
- Company
- News
- Contact Us
Aluminum plates are widely used in various industries, from aerospace to automotive and even construction. These versatile and lightweight materials offer numerous benefits, from corrosion resistance to durability. Read on to find out what you should know about how aluminum plates are produced.
Aluminum production starts with bauxite, an ore containing aluminum oxide. In bauxite mining, the ore is extracted from the earth’s surface with an open-pit technique. Once mined, bauxite is processed through a series of steps, such as crushing, grinding, and washing, to remove impurities and recover the valuable aluminum oxide.
After bauxite extraction, the aluminum oxide is further refined using the Bayer process. Bauxite is mixed with sodium hydroxide to form a slurry. This bauxite-sodium hydroxide mixture is heated under pressure, dissolving aluminum oxide and leaving behind impurities. The dissolved aluminum oxide is then separated from the remaining solids and subjected to precipitation, which yields a pure form of aluminum hydroxide.
The next step involves converting aluminum hydroxide into aluminum. This transformation takes place in the Hall-Héroult process, which involves dissolving the aluminum hydroxide in molten cryolite. An electric current is then passed through the solution, initiating an electrolytic reaction that separates aluminum from oxygen. The pure aluminum is then collected at the bottom of the electrolytic cell and siphoned off for further processing.
Finally, the aluminum is shaped into plates. The process begins with large aluminum ingots, which are preheated and passed through a series of rolling mills to achieve the desired thickness. The plates may undergo extra treatments to enhance their properties, such as heat treatment to increase strength or surface treatment for better corrosion resistance. Once the aluminum plates meet the required specifications, they are cut to size.
Now that you understand what you should know about how aluminum plates are produced, be sure to select the right material for your applications from a professional aluminum plate distributor like TCI Precision Metals.
The automotive industry relies heavily on steel blanks for various applications due to their durability, cost-effectiveness, and adaptability. Continue reading to learn more about how steel blanks are used in the automotive industry.
One of the main uses of steel blanks in the automotive industry is for the production of body panels and structural components. These parts provide the framework for a vehicle and play a crucial role in its overall safety, performance, and aesthetics. Steel blanks offer the strength and rigidity needed for these components while remaining lightweight and cost-effective.
Fuel tanks are another essential component in vehicles that often rely on steel blanks. These blanks are shaped into the required size and design to fit each vehicle’s specifications. Steel is a corrosion-resistant and durable material, ensuring the fuel tank can withstand harsh environmental conditions and protect against potential leaks.
The exhaust system is responsible for channeling harmful gases away from a vehicle’s engine and cabin. Steel blanks are widely used in the manufacturing of exhaust systems due to their heat resistance and durability. High-quality ready-to-ship stainless steel blanks help maintain the integrity of the exhaust system, ensuring it functions effectively and lasts for a long time.
The suspension and chassis of a vehicle play a vital role in ensuring a smooth, comfortable ride and optimal handling. Steel blanks are commonly used to create suspension and chassis components, such as control arms, cross-members, and subframes. The strength and resilience of steel make it an ideal material for these critical parts.
Now that you know how steel blanks are used in the automotive industry, never count out steel for your projects. The properties of steel—durability, heat resistance, and cost-effectiveness—make it the go-to material for various applications in the automotive industry and throughout other areas of manufacturing.
The CNC machining industry continues to evolve, driven by advancements in technology, growing demand, and a focus on sustainability. Manufacturers are constantly seeking new ways to increase efficiency, reduce costs, and remain competitive in the global market.
To help you stay informed and ahead of the curve, we’ve compiled a list of the top 12 CNC machining trends to watch out for in 2023. From automation and IoT to eco-friendly processes and advanced materials, these trends are shaping the future of CNC machining.
Automation and robotics continue to be a significant trend in CNC machining as companies strive for increased efficiency and reduced labor costs. The integration of robots and automated systems in the manufacturing process allows for consistent production quality, faster cycle times, and reduced human error. As robotics technology advances, you can expect to see further improvements in CNC machining processes, including streamlined material handling and better machine-to-machine communication. As automation continues to grow, the need for consistent materials also grows. Material that is consistent in all-around dimensions, part-to-part, streamlines part placement, and loading and unloading by robots or cobots.
Artificial intelligence (AI) is playing a growing role in CNC machining as manufacturers seek to optimize production processes and improve decision-making. AI-driven algorithms can analyze vast amounts of data, identify patterns, and make informed predictions to enhance machining efficiency. This technology can also help monitor tool wear, predict machine maintenance needs, and optimize cutting parameters, resulting in reduced downtime and increased productivity.
3D printing is no longer a novelty in the world of manufacturing. This technology has evolved to complement CNC machining in various applications, such as rapid prototyping and production of complex parts. The combination of CNC machining and 3D printing allows manufacturers to create intricate components with tight tolerances, reduce material waste, and shorten lead times. As 3D printing technology advances, you should expect greater adoption and integration with traditional CNC machining processes.
Hybrid manufacturing combines additive and subtractive manufacturing methods to create a seamless, efficient production process. This trend enables manufacturers to produce parts that were previously impossible or extremely difficult to create using traditional methods alone. By integrating CNC machining with technologies like 3D printing and laser cladding, manufacturers can reduce material waste, increase production speed, and create complex geometries with high precision.
Multi-axis machining has been gaining traction in recent years due to its ability to produce complex parts with high precision and reduced setup times. As the technology continues to advance, manufacturers can now utilize 5-axis and even 6-axis machines to create intricate components faster and more efficiently. This trend is expected to continue in 2023, as more industries recognize the benefits of multi-axis machining and invest in the necessary equipment.
High-speed machining (HSM) is becoming increasingly popular in CNC manufacturing since it contributes to reduced cycle times and improved surface finish quality. HSM techniques utilize faster spindle speeds and feed rates, allowing manufacturers to produce parts more efficiently while maintaining tight tolerances. In the future, you can expect to see further advancements in high-speed machining technology, including improved precision metal cutting tools and more efficient cooling systems.
The Internet of Things (IoT) and Industry 4.0 are driving a new era of connectivity and data-driven decision-making in CNC machining. By integrating sensors, smart devices, and advanced software, manufacturers can monitor machine performance, track production data, and optimize processes in real-time. This trend shows no signs of stopping, as companies invest in IoT and Industry 4.0 technologies to stay competitive and improve overall manufacturing efficiency.
As industries demand higher performance and more durable components, there is a growing need for advanced materials in CNC machining. These materials, such as advanced ceramics, composites, and high-performance alloys, offer improved strength, durability, and wear resistance compared to traditional materials.
As time goes on, you can expect more research and development focused on creating advanced materials that can withstand extreme conditions and improve the performance of CNC-machined parts.
Machine tool monitoring is becoming increasingly important for CNC machining, as it helps manufacturers identify issues, optimize processes, and reduce downtime. Advanced monitoring systems can track various machine parameters, such as spindle load, vibration, and temperature, to identify potential problems before they escalate.
In the future, you’ll likely see more sophisticated monitoring systems that can predict maintenance needs, improve machining accuracy, and increase overall productivity.
Sustainability is becoming a top priority for many industries, and CNC machining is no exception. In 2023, expect an increased focus on eco-friendly manufacturing processes that minimize waste, reduce energy consumption, and utilize environmentally friendly materials. Manufacturers may adopt technologies such as dry machining, which eliminates the need for coolant, or invest in energy-efficient equipment to reduce their carbon footprint and contribute to a more sustainable future.
Virtual Reality (VR) and Augmented Reality (AR) technologies are starting to make their mark on CNC machining, offering new ways to improve training, design, and collaboration. VR can create immersive environments for training operators, allowing them to practice their skills in a safe and controlled setting.
AR can overlay digital information onto the physical world, helping operators visualize complex data and make better-informed decisions during the machining process. We predict that these technologies will become more prevalent in the CNC machining industry, enhancing productivity and efficiency.
In 2023, data-driven decision-making is expected to become even more critical in the CNC machining industry. The increasing availability of data from connected machines and sensors, combined with advanced analytics and AI, enables manufacturers to make better-informed decisions about their processes.
By harnessing this data, manufacturers can optimize their machining processes, predict maintenance needs, and improve overall efficiency. This trend will continue to grow as more companies recognize the value of data-driven insights and invest in the necessary technology to collect, analyze, and act on this information.
Now that you know the top CNC machining trends to watch out for in 2023, you’re well-equipped to stay ahead of the competition and make the most of emerging opportunities in the industry. By embracing automation, IoT, data-driven decision-making, and eco-friendly processes, you can increase efficiency, reduce costs, and maintain a competitive edge in a constantly evolving market.
The metal manufacturing industry is crucial to other sectors, from automotive to aerospace and beyond. Despite its importance, misconceptions about the industry persist. Read about these four common metal manufacturing myths.
Contrary to popular belief, metal manufacturing is a highly advanced industry that continuously incorporates cutting-edge technology (sometimes literally). Modern metal manufacturing facilities employ state-of-the-art machinery, such as CNC (computer numerical control) machines, for their high precision and repeatability.
While metal manufacturing was once harmful to the environment, the industry has made significant strides in reducing its environmental impact. Today, metal manufacturers are increasingly adopting sustainable practices, such as recycling scrap materials, using energy-efficient equipment, and minimizing waste. Moreover, many companies are investing in renewable energy sources and exploring new, eco-friendly materials to reduce their environmental footprint.
It's a common misconception that all metals are the same or have similar properties. In reality, metals are unique and have distinctive characteristics and applications. For instance, aluminum is lightweight and corrosion-resistant, making it ideal for aerospace and automotive applications.
Stainless steel, on the other hand, is known for its strength and durability. It is a popular choice for construction and medical equipment. Understanding the specific properties of each metal is crucial for selecting the right material for a project.
We can debunk the misconception that grinding is a slow and inefficient metalworking process. While grinding may be slower than other machining methods, such as milling or turning, it offers unparalleled precision and surface finish quality. Metal finishing services include surface grinding, cylindrical grinding, and centerless grinding. They can achieve extremely tight tolerances and smooth finishes, which are often unattainable with other machining techniques.
Now that we’ve debunked these four common metal manufacturing myths, we hope you better understand how metal manufacturing shapes the world around us and meets the demands of various industries.
In the world of metallurgy, it's crucial to grasp the concept of ferrous metals. They are a subcategory of metallic alloys, like steel and cast iron, and are renowned for their strength and durability. Read on to find out what you need to know about ferrous metals.
Ferrous metals are a class of metals and alloys that contain iron (Fe). The iron content grants these metals specific characteristics, like magnetic properties and an enhanced ability to resist wear and tear. Some common examples of ferrous metals include stainless steel, carbon steel, cast iron, and wrought iron.
The applications of ferrous metals are vast, spanning numerous industries. Their strength and durability make them ideal for construction materials, vehicle manufacturing, and heavy industrial equipment. These metals are common in household appliances, and their magnetic properties make them essential for motor and electrical applications.
A critical process in working with ferrous metals is precision metal grinding. This method uses abrasive technology to achieve tight dimensional tolerances, smooth surface finishes, or specific mechanical properties. Precision metal grinding is especially crucial when dealing with ferrous metals in high-stress environments, such as aerospace and automotive applications.
While ferrous metals have many benefits, they also have a few challenges. The iron content of ferrous metals makes them susceptible to rust. Fortunately, you can mitigate this problem with special coatings, stainless steel alloys, or other forms of corrosion prevention.
Now that you understand what you need to know about ferrous metals, we hope you have a greater sense of their various applications. Whether you need to develop construction materials or electronics, you’ll surely use ferrous metals from a reliable metals distributor. Remember to consider the drawbacks, like susceptibility to rust, when choosing the appropriate materials for your needs.
In the ever-evolving world of manufacturing and construction, efficiency and precision are central to successful operations. This is where professional metal services come in; they offer invaluable benefits that enhance productivity and drive competitive advantage. Read these four benefits of professional metal services.
Professional metal servicers stand out for their commitment to quality and precision. These experts have the necessary skills and technology to meet your specifications, ensuring every product is high quality. This precision extends to even the smallest details, which can make a big difference in the final product.
Turning to professionals for metal services can bring significant time and cost savings. With their experience and state-of-the-art equipment, these professionals can expedite production, saving you time. In addition, their expertise in material utilization can minimize waste, reduce costs, and promote sustainability.
Professional metal services encompass a wide range of capabilities, from forming, bending, and cutting, to welding and finishing. Precision metal cutting services enable the creation of custom shapes and sizes with remarkable accuracy. Precision metal cutting can meet a wide array of design requirements whether they’re creating complex geometric shapes or cutting through tough materials. These experts offer flexibility and creativity in manufacturing and construction projects.
Another major benefit of professional metal servicers is the increased level of safety they provide. Metalworking can be hazardous if not handled correctly, particularly with intricate cutting and shaping processes. Professional metal service providers have the expertise and knowledge to handle these tasks safely. They utilize state-of-the-art equipment and follow strict safety regulations to mitigate potential risks.
Now that you know these four benefits of professional metal services, it's time to consider how they can impact your projects. Whether you're in the construction or manufacturing industry, employing professional metal services can significantly enhance your operations while ensuring precision and high quality.
TCI Precision Metals Achieves ITAR Registration
Commitment and Compliance with National Security
TCI Precision Metals proudly announces its successful attainment of ITAR registration. The International Traffic in Arms Regulations (ITAR) registration signifies TCI Precision Metals' dedication to national security and adherence to rigorous compliance standards.
ITAR regulates the export and import of defense-related articles, services, and technical data to safeguard national security interests. By meeting the stringent requirements set forth by the United States Department of State, TCI Precision Metals has demonstrated its commitment to responsible business practices and the protection of sensitive information and technologies.
Achieving ITAR registration required TCI Precision Metals to undergo a comprehensive evaluation of its operations, policies, and procedures. The company successfully met all the requirements, including implementing a robust compliance program, obtaining appropriate licenses and authorizations for controlled exports, and establishing strict access controls and screening processes.
With its newly acquired ITAR registration, combined with its existing AS9100 Rev D, and ISO 9001:2015 Certifications, TCI Precision Metals is well-positioned to expand its reach and collaborate on defense-related projects and contract opportunities. The registration opens doors to partnerships with the U.S. government, defense contractors, and other entities in the defense industry, facilitating the controlled exchange of sensitive information, technology, and services.
"We are proud to have achieved ITAR registration," said Ben Belzer, President, and CEO of TCI Precision Metals. "This accomplishment demonstrates our unwavering commitment to national security, compliance, and responsible business practices. It also positions us to better serve our customers in the defense industry and expand our capabilities to support critical defense projects."
TCI Precision Metals recognizes that ITAR compliance is an ongoing process and will continue to invest in maintaining and improving its compliance program. The company will conduct regular internal audits, implement robust training programs, and stay abreast of any regulatory updates to ensure its operations remain aligned with the latest requirements.
Founded in 1956, TCI Precision Metals is a family-owned manufacturer producing precision Machine-Ready Blanks from aluminum, stainless steel, and other alloys. Precision Machine-Ready Blanks eliminate the need for in-house sawing, grinding, flattening, squaring operations, and outside processing. Blanks are consistent, part-to-part, which reduces setup time, and in the case of flat blanks, the production process alleviates residual stress in the material which results in reduced part movement during finish machining. Each blank is deburred, cleaned, and individually packaged to avoid damage during shipping. Ready-to-Ship Blanks arrive square, flat, and parallel within ± .002” of specified dimensions. The company also provides Sawing, Grinding, Milling, and Finishing operations on customer-supplied materials.
Here at TCI, we tell ourselves this on a regular basis in an effort to stay in touch and keep current. What are customers looking for? What best practices are out there that we have not discovered yet? We are driven by constant improvement and if you are not, you should be. There are always better, more efficient ways to do things; sometimes we come up with them ourselves, but more often we learn from someone else.
Taking our own advice, we recently completed an International Tech Tour sponsored by the NTMA. Over the course of one week, we visited four outstanding manufacturing companies in Germany and Switzerland to see how they get things done. Why so far you might ask? Because according to Forbes, the label ‘Made in Germany’ evokes perceptions of quality, efficiency, and trust, more than any other country in the world. Based on surveys, consumers across many nations have more respect for Germany’s prowess at building and producing products than they do most others. The term ‘Swiss Made’ invokes the same feeling.
Our gracious hosts were: Heidenhain, Mori/DMG, Huele and BIG Kaiser.
The time and travel were well worth the effort, and we came away with a fresh perspective in several areas:
Lean Manufacturing – It was immediately apparent as we walked the shop floors that lean was a top priority. Everything was moving, people, machines, and parts; there were lots of green lights on. The floors were clean and organized with everything highly visible. There were no long fetches from one machine or process to the next, and if something was not relevant to the production at hand, it wasn’t there.
Robots – Where feasible, robots were actively loading and unloading parts from machines. In most cases, the materials being handled by humans and robots/cobots were pre-machined for uniformity and precision placement into fixtures. Headcounts seemed noticeably light compared to the number of machines being run.
Apprenticeship – All facilities took part in apprenticeship programs. Students from local high schools spend 2-3 days each week working and honing their craft. This leads to long-term employment, low turnover, and engaged and skilled workers. Apprentice programs play a crucial role in German and Swiss manufacturing and are widely regarded as a key component of the country's vocational education and training (VET) system. These programs, known as "Ausbildung," have a long-standing tradition in Germany and are highly valued for their contributions to workforce development and the economy.
More Digital, Less Paper – In general, German, and Swiss manufacturing companies have been actively embracing digitalization and striving to eliminate paper-based processes to improve efficiency, reduce costs, and enhance sustainability. This was evident in the shops we toured, the use of paper was scarce or non-existent on the shop floor. I consider the following as strong contributors to the paperless shop:
Shop Layouts – I was impressed with the general state of the shops we visited. They were meticulously laid out to improve workflow, present a good working environment, and projected a sense of quality that is associated with Made in Germany or Swiss Made. I came away with the perception of clean, polished, high precision manufacturing, not a bad message.
Our goal is to use what we have learned for continued improvement in our own shop because, at the end of the day, the promise of increased efficiency and throughput is why our customers buy from us.
Thanks for reading –
Ben
New Amada THV460 Precision Duplex Mill Supports Continuing Customer Demand for Machine-Ready Blanks™
TCI Precision Metals today announced the installation of a new Amada THV460, its latest addition to a growing line of precision duplex milling machines. The new THV460 joins an existing THV430 and THV800 used by TCI Precision Metals in the production of Machine-Ready Blanks. The ongoing addition of Amada mills to TCI’s shop floor improves efficiency and shortens customer lead time as demand for Custom Made-to-Order and Ready-to-Ship Machine-Ready Blanks continues to rise.
TCI Machine-Ready Blanks are milled in width and length, using Amada’s specially designed twin spindle, in one set up instead of two. This reduces setup time and increases efficiency. One or more Machine-Ready Blanks can be produced together, up to the machines' overall dimensional capacity, which in the case of the THV460 is 18.4″W x 18.4″L x 5.9″H. The value is passed to TCI customers through shorter lead times and competitive pricing.
“We are committed to providing our customers with value in the form of precision high-quality blanks, delivered on time and at a price that is less than they can produce the same materials in their shop,” said Ben Belzer, President, and CEO of TCI Precision Metals.
Precision Machine-Ready blanks eliminate the need for in-house sawing, grinding, flattening, squaring operations, and outside processing. Each blank arrives deburred, clean, and individually packaged to avoid damage during shipping. Blanks are available in two ways: Ready-to-Ship blanks can be ordered online for same-day or next-day shipping, and arrive square, flat, and parallel within ± .002” of specified dimensions all around; custom Made-to-Order blanks are made to customer specifications and are guaranteed as close as +/- .0005” dimensionally and as close as .002” flatness, squareness, and parallelism.
TCI Precision Metals has installed a 42-inch CNC double-disc grinding center at its Gardena, Calif., facility. Technology advancements built into the new machine improve overall efficiency by more than 50 percent compared to traditional double-disc grinders, which will help TCI Precision Metals shorten customer lead times while maintaining close dimensional and flatness tolerances customers have come to expect from the company’s Machine-Ready Blanks.