Conversion examples

Heater core connector
Fuel connector
Fuel filter
Threaded transmission fluid connector
Fuel filler neck
Cam sensor
Notched electronic sensor housing
Radiator core connector

When a customer presents us with a part that's being produced using another process, we routinely find we're able to produce that same part faster, more efficiently, and more cost-effectively using our deep draw technology.

We take complicated multi-piece and welded assemblies and produce them as a single component, and successfully produce formerly machined parts as deep drawn components, saving time and money.

Heater core connector
Previously extruded aluminum tubing of various lengths and geometry all connected into the heater core dual ports with specific formed ends. The universal connector shown in the center is now used and brazed to the core as shown on left, increasing brazing efficiency and simplifying the tubing installation post braze.

Fuel connector
The fuel connector on the left is a machined part that includes two rubber o-rings inserted around the base. Metal Flow produces a one-piece drawn component eliminating an expensive machining and utilizing formed steps rather than the two o-rings. Just an example of how the deep drawn process can save you both time and money.

Fuel filter
These are fuel filter assemblies. The two parts on the left are fuel filter shells. The left-rear shows a brazed connector attached to the dome. The left front shows a one-piece Metal Flow drawn component eliminating both the brazing operation and the connector which Metal Flow draws out from the shell itself. On the right similarly the end plate at the top right shows a brazed on connector and the end plate at the bottom right displays a single one piece end plate that includes the connector. In summary, reducing part numbers per assembly from four to two. While eliminating expensive brazing operations. At Metal Flow we do believe its possible to save time and money while increasing quality.

Threaded transmission fluid connector
On the left is a machined part used as a transmission fluid connector that is threaded on the outside. Metal Flow replaced the expensive component by drawing the tube and roll threading the components for weight and cost savings.

Fuel filler neck
This fuel filler neck on the left was originally welded tubing expanded at the base end then welded to a lower flange. In addition, three dimples at the top of the part were done as another secondary operation. Metal Flow was able to manufacture this part shown on the right as a one piece component eliminating welding, flaring the base and off line dimpling creating a more robust product as a one piece drawn component.

Cam sensor
This cam sensor was previously a machined part which Metal Flow was capable of producing in the press. This significantly reduced weight and resulted in a 30% reduction in piece part price.

Notched electronic sensor housing
On the left is a machined electronic sensor housing. Metal Flow was capable of producing this as a one piece housing significantly reducing the piece price while maintaining all critical features like the stepped shoulder and side pierce.

Radiator core connector
The radiator core connector on the left (with the seam) was produced from welded tubing that is beaded as a secondary operation. The part on the right is a drawn metal component that is formed, beaded and necked down all in one transfer press resulting in a savings of 22% to our customer.

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products : fluid handling, fuel systems, decorative wheel trim, emissions, air bag inflators, ABS brakes, powertrain
 

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