Categories Production, Prototype

Our Metal Forming Capabilities

August 10, 2022

Manufacturing is a customized process and each program has its own set of requirements. We have over 60 years of experience working with unique sheet metal forming and fabrication programs. We tailor our solutions to your program’s specific needs. From cutting and bending to stamping and assembling, each program is unique. We manage your complete program in-house, vertically integrating all processes and technologies while maintaining a single point of contact.

Our manufacturing experts work with a wide array of metals, forming:

  • Aluminum, including bright or pre-painted
  • Stainless steel, including polished or bright grades
  • Carbon steels
  • Boron steel
  • Dual phase steel
  • Advanced high strength steels, including martensite and TRIP
  • Inconel®
  • Waspaloy®
  • Hastelloy®
  • Titanium
  • Magnesium
  • All ferrous metals

Stamping

automobiles stamping

We have stamping presses to metal form virtually any part you need. Our 33 presses range from 150 to 4,000 tons with bed sizes from 42” x 60” to 240” x 96”. Our equipment allows us to manufacture parts of various material specifications and thicknesses. This includes hand and coil fed transfer and tandem line presses. We also have 500 and 600 ton presses with roll-out bolsters that use multiple dies and minimize change outs over time. Combined, this series of presses gives us the ability to stamp the parts you need to get your product to market faster.

Hot Stamping

Hot stamping metal

Hot stamping is a different method than the traditional stamping we use for most of our programs. In a hot stamping application, we first heat the sheet metal to help form it. Hot stamping changes the chemical compound of the metal that has been stamped, making it stronger. This allows us to form higher strength materials without adding reinforcements, which add additional weight to the vehicle. It also allows us to use metals with higher yield and tensile properties.

This process is ideal for parts that are integral to the structure of the vehicle, such as B-pillar reinforcements. These parts protect passengers and take most of the vehicle load so it is important that they are very strong in case of an accident. Our hot stamping machines feature fully automatic robotic handling. This increases process repeatability and eliminates the occurrence of human error, increasing quality.

Our Capabilities

Our sheet metal business leverages old world techniques combined with the latest computer-controlled technology to bring your visions to reality. To provide complete services, our manufacturing capabilities include:

  • Process engineering
  • Kirksite foundry
  • Tool machining
  • Stamping
  • Hot stamping
  • Sheet metal fabrication
  • Laser cutting
  • Assembly

This range of services allow us to provide complete sheet metal forming and fabrication programs in-house, using our experience to provide you with a high quality product. Whether you need sheet metal fabrication for parts to assemble yourself or full BIW, we can design, build, and assemble your parts. 

We also develop custom assembly work cells based on your project’s specific needs to standardize processes and ensure consistent quality through the life of your project. These efficient processes allow for the rapid execution of product and process revisions, including managing master data files, incorporating working data files, and providing updates to all process documentation.

Read more about our full range of capabilities here.

Categories Prototype

Our Prototype BIW Capabilities

prototype manufacturing

July 28, 2022

How is our low volume/prototype BIW assembly process different from other metal forming companies? We take a strategic engineered approach and utilize robotics based on your requirements, our years of proven production experience, and automated technologies. This semi-automated process creates a leaner, more cost effective project. Your program can see greater repeatability, reduced piece price over the life of the project, and increased rate in flow.

Our prototype BIW capabilities include:

  • Process engineering
  • Foundry
  • Tool machining
  • Stamping
  • Hot stamping
  • Sheet metal fabrication
  • Bending
  • Laser
  • Assembly process
  • Production

From process engineering at the beginning of your project to hot stamping unique metals to final assembly of those parts, we house all of our capabilities under one roof. This allows us to have complete control of the quality of your project from start to finish.

We utilize our production manufacturing experience to develop robotics and flexible assembly cells that increase prototype repeatability. Our processes are fully integrated from design to assembly, which lets us ensure the quality you expect throughout the entire process. We can stamp, laser cut, join, and assemble large, complex geometries and assemblies, including full prototype BIW vehicles.

In-house Kirksite Foundry and Tool Design

Our in-house kirksite foundry allows for full control to support tooling and assembly for projects that require quick turnaround. It is EPA approved and has a pour capacity of over 750,000 lbs. a month. This uniquely positions us for prototype BIW projects. Our experienced craftsmen have decades of technical expertise designing tooling for prototype and short-run applications. Their years of knowledge in tool design process drives consistency, efficiency, and performance

Stamping

automobiles stamping

We have stamping presses to manufacture virtually any part you need. Our 33 presses range from 150 to 4,000 tons with bed sizes from 42” x 60” to 240” x 96”. Our equipment allows us to manufacture parts of various material specifications and thicknesses. This includes hand and coil fed transfer and tandem line presses. We also have 500 and 600 ton presses with roll-out bolsters that use multiple dies and minimize change outs over time. Combined, this series of presses gives us the ability to stamp the parts you need to get your product to market faster.

Hot Stamping

Hot stamping metal

Hot stamping is a different method than the traditional stamping we use for most of our programs. In a hot stamping application, we first heat the sheet metal to help form it. Hot stamping changes the chemical compound of the metal that has been stamped, making it stronger. This allows us to form higher strength materials without adding reinforcements, which add additional weight to the vehicle. It also allows us to use metals with higher yield and tensile properties.

This process is ideal for parts that are integral to the structure of the vehicle, such as B-pillar reinforcements. These parts protect passengers and take most of the vehicle load so it is important that they are very strong in case of an accident. Our hot stamping machines feature fully automatic robotic handling. This increases process repeatability and eliminates the occurrence of human error, increasing quality.

Complex Robotic Joining Methods

We employ a wide range of complex robotic joining methods based on your project’s specific needs and requirements, including resistance welding, hemming, adhesives for structure and bonding, and an onsite curing oven large enough for a completed BIW. Our three Centers of Excellence give us the capacity for large prototype joining projects as well as hybrid assembly and production programs.

Our joining technologies include:

  • AC manual weld guns (RSW)
  • DC manual and robotic weld guns with adaptive controls (RSW)
  • Press welder for fasteners (RSW)
  • Clinch press for clinch nuts or studs
  • Manual and robotic welders (MIG)
  • Fronius “cold metal transfer” manual and robotic welders (CMT)
  • Manual welding equipment (TIG)
  • Drawn arc stud welding
  • Self-piercing rivets (SPR) – (Henrob & Bollhoff)
  • Flow drill screws (FFS & FDS)
  • Bonding with onsite cure oven capacity for full vehicle BIW
  • Laser welding

This assortment of joining methods ensures we can meet the specifications and different joining arrangements your build needs.

On-Site Testing

We utilize world-class quality systems to ensure processes are delivering optimal results. Our metallographic laboratory is used for R&D, hot stamping material inspection, product validation, and weld failure analysis. This micro-structure analysis allows for very specific tensile strength and hardness testing. Our quality lab utilizes coordinate measuring machine (CMM) programming, portable laser scanning, and check fixtures to ensure tight tolerances are met. We have CMM equipment large enough to measure a full BIW, guaranteeing your final product meets your specifications. We also have the ability to test welds in real-time, which ensures speed-to-market and the quality our customers have come to expect.

Your Project’s Security

The security of your project is a top priority for us too. We have fully secured vehicle build areas to ensure the utmost confidentiality of your prototype project. Our buildings require key card access and all visitors must cover cell phone cameras while on-site. All visitors must also be accompanied by a QMC-EMI employee at all times to make sure they are only in approved areas of the building. We will implement whatever customized measures you require to protect the security of your prototype project as if it were our own.

To learn more about all of our prototype capabilities, visit www.qmc-emi.com/solutions/prototype/

#qmcemi #prototype #assembly #biw #metalforming

Categories Production, Prototype

Our Automotive Stamping Press Capabilities

June 15, 2022

With more than 60 years of experience, 33 presses, and the ability to work with a wide range of metals, we can provide the automotive stamping press servicesyou needs. We stamp everything from small brackets to closure panels, including full size body sides, floor panels, A-frames, hoods, and battery trays, among other parts. We are the only metal stamping company in the United States who has engineered a process that allows us to stamp complex parts in one piece, such as stainless steel lipskins for airplanes.

Our expertise goes beyond stamping a part and shipping it to you. We engineer the complete manufacturing process to ensure it is as efficient as possible. We utilize Autoform, formability software for the engineering, evolution, and improvement of the sheet metal forming process, including spring back analysis. As a full-service sheet metal solutions provider, we understand the key to being a successful partner is more than just delivering a high-quality product on-time and work to anticipate your program needs.

Our Automotive Stamping Press Capabilities

automobile metal stamping

We have automotive stamping presses to manufacture virtually any of the parts you need. Our 33 presses range from 150 to 4,000 tons with bed sizes from 42” x 60” to 240” x 96”. Our equipment allows us to manufacture parts of various material specifications and thicknesses. This includes hand and coil fed transfer and tandem line presses. We feature a 2,500 ton coil fed transfer press allowing for a faster, more automated process for large stampings and assemblies. Our brake press uses v-tool forming, reducing tool costs for straight, less complex bends. We also have 500 and 600 ton presses with roll-out bolsters that use multiple dies and minimize change outs over time. Combined, this gives us the ability to stamp the parts you need to get your product to market faster.

Kirksite Foundry Tools

Kirksite foundry tools

Each metal has its own set of unique specifications. We work with numerous advanced and exotic materials including:

  • Aluminum, including bright or pre-painted
  • Stainless steel, including polished or bright grades
  • Carbon steels
  • Boron steel
  • Dual phase steel
  • Advanced high strength steels, including martensite and TRIP
  • Inconel®
  • Waspaloy®
  • Hastelloy®
  • Titanium
  • Magnesium
  • All ferrous metals

Our experience with this wide range of metals and their distinctive properties is why we are one of the industry’s leaders in automotive stamping press services. We go above and beyond simple stamp and ship projects. We are your partner for all your metal stamping and forming needs.

To learn more about our metal stamping capabilities, visit https://www.qmc-emi.com/capabilities/stamping/

#qmcemi #automotivestampingpress #metalstamping #automotivemetalstamping

Categories Misc., Production, Prototype

Our Battery Enclosure Capabilities

June 1, 2022

Every program has its own set of unique requirements. For battery enclosure projects, we can help plan the entire process, from R&D to production. We specialize in a range of joining technologies, including SPR, RSW, MIG, TIG, laser welding, laser-hybrid welding, and adhesives, ensuring we have the expertise you need. Battery enclosures also require unique testing, such as leak testing, which is done to every battery box. We then complete a dimensional check using CMM or laser scanning.  This ensures every unit you receive meets your specifications. 

Learn more about our capabilities at https://www.qmc-emi.com/capabilities/

#qmcemi #batterybox #electricvehicles #metalcraft

Categories Production, Prototype

Our Production Capabilities: Sheet Metal Stamping

automobiles stamping

May 24, 2022

A program’s product design and volume determines the sheet metal stamping and production process. We carefully engineer the manufacturing process to ensure it is as efficient as possible. Our range of capabilities include process engineering, foundry, tool machining, cold stamping, hot stamping, sheet metal fabrication, bending, laser, and assembly process. By housing all of these capabilities under one roof we provide you with a high-quality, lean, competitive solution for your production requirements.

Our Capabilities:

  • Process Engineering – To improve accuracy and reduce trial and error, we utilize advanced engineering tools, such as stamping simulation, solid modeling, FEA simulation, and CNC machine coding.  Our expertise in each of these processes helps us meet challenging standards and deliver on-time, on budget programs you expect.
  • Foundry – Kirksite is a zinc-based alloy that is used to create short run production tooling. Kirksite tooling machines easily and the die surfaces can be polished to a smooth finish. Our in-house kirksite foundry enables us to keep the entire process under our roof, from tooling to part. This allows us to produce tooling and incorporate changes very quickly to meet your tight time frames.
  • Tool Machining – High-quality castings poured from our in-house foundry are precision machined on our CNC mills. Forming tools weighing over 30,000 lbs and as large as 8’x19’ can be manufactured without ever leaving our facility.
  • Sheet Metal Stamping – With 33 presses and the ability to work with a wide range of metals, we can provide the structural solution your project needs. For our automotive customers, we stamp everything from small brackets to closure panels, including full size body sides, floor panels, A-frames, hoods, and battery trays, among other parts.
  • Hot Stamping – Our state-of-the-art hot stamp cell and metallographic lab allows us to provide you with superior products and validation results. Metals we hot stamp include boron steel, usibor steel, Titanium, Inconel®, Waspaloy®, and Hastelloy®.
  • Sheet Metal Fabrication – We will tailor our solutions to your program’s specific needs, such as joining aluminum to steel. From cutting and bending to stamping and assembling, each program is unique. We manage your complete program in-house, vertically integrating all processes and technologies while maintaining a single point of contact.
  • Laser – We are equipped with the latest technologies in 5-axis and flat pattern laser cutting to cut a full range of materials. Utilizing CO2, O2, nitrogen, and fiber machines, we are able to trim precision metal components with speed and minimal burr. Our machine configurations allow for complex shapes and sizes and accommodate the full range of metallic options with both online and offline programming capabilities. We employ cutting capabilities that allow us to work with a wide range of metals, including carbon steel, aluminum, stainless steel, Inconel, titanium, coated metals, mild steel, and high strength metals.
  • Assembly Process – We are a full service sheet metal supplier that specializes in production joining and welding technologies. We employ a wide range of complex robotic joining methods based on your project’s specific needs and requirements, including resistance welding, hemming, adhesives for structure and bonding, and an onsite curing oven large enough for a completed BIW.

Our Sheet Metal Stamping Capabilities:

sheet-metal-presses

We have stamping presses to manufacture virtually any of the sheet metal stamping parts you need. Our 33 presses range from 150 to 4,000 tons with bed sizes from 42” x 60” to 240” x 96”. Our equipment allows us to manufacture parts of various material specifications and thicknesses. This includes hand and coil fed transfer and tandem line presses. We feature a 2,500 ton coil fed transfer press allowing for a faster, more automated process for large stampings and assemblies. Our brake press uses v-tool forming, reducing tool costs for straight, less complex bends. We also have 500 and 600 ton presses with roll-out bolsters that use multiple dies and minimize change outs over time. Combined, this gives us the ability to stamp the parts you need to get your product to market faster.

We are a leader in the production industry with 60 years of experience working on a wide range of programs. See how our experience can benefit your next production program.

#qmcemi #metal #production #sheetmetalstamping #automotiveproduction

Inconel® is a registered trademark of Special Metals Corporation.
Waspaloy® is a registered trademark of United Technologies Corp.
Hastelloy® is a registered trademark of Haynes International.

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