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Custom Metal Part Manufacturing

Norck, a leading digital manufacturing company, provides extremely reliable, and fast custom precision metal part manufacturing from a wide range of materials and with the top surface quality.

Norck is an expert company in the  assembly and fabrication of sheet metal parts, CNC machined precision metal parts, 3D printed parts, composite materials, and parts made with molding and casting for a wide range of industries including aerospace, defense, robotics,  industrial, automotive, electronics, energy, hardware, and consumer products. Our team of highly qualified engineers and cutting-edge facilities will provide you with quality products with the quickest turnaround time at a competitive price. Whether you have high volume production projects or rapid prototyping needs, Norck can manage it with the results better than expectations.

Click here to get a quote for your next sheet metal, CNC machining, 3D printing, or molding assembly project.

Let’s now give you some insight how Norck achieves custom metal part manufacturing.

What is custom metal part manufacturing?

Custom metal part manufacturing designates a set of fabrication methods used to manufacture a custom part in small quantities. Custom manufacturing is used in the following sectors:

   - Medical: surgical tools, implants, and orthopedics.
   -  Industrial: Welded structures, gears, shafts, jigs and fixtures, and enclosures.
   - Hardware: Hinges, handles, tools, screws, nuts, and rivets
   - Aerospace & Automotive:
Bodies of aircraft and cars, electrical cables
   - Robotics: Robots' bodies, gears, shafts, grippers
   - Consumer products:
home appliances, cooking utensils, PC enclosures, jewelry
   - Education:
Desks, laboratory equipment, prototypes

On Demand Custom Metal Part Manufacturing

What are the advantages of custom metal part manufacturing?

Custom metal part manufacturing offers many advantages over medium and high-volume production:

• Lower production costs: A custom part might cost more per part than medium or high-volume production. But it is cost-effective for two reasons:
   -  It doesn’t require a big budget for development, tooling, and fabrication
   -  It can be manufactured in smaller quantities

• Highly customizable: As the name suggests, a custom plastic part is customizable. Your product can be as custom as you can imagine.

• Convenient for startups and small businesses: Custom metal part is ideal for startups and small businesses since it helps them turn any idea into a tangible product and test the market before diving into mass production.

How is it fabricated?

There are several manufacturing processes to produce custom metal parts. Which can be divided into three types:

1.  Additive manufacturing

• Metal 3D Printing (DMLS):Direct metal laser sintering is a process used to produce custom parts by fusing metal powder particles using a laser beam. It uses different metal materials such as:

   • Used plastic materials include:
   -  Titanium
   -  Stainless steel
   -  Aluminum
   -  Nickel
   -  Cobalt
   -  Copper
   -  Platinum
   -  Gold
   -  Silver

   •Applications of DMLS: It is used in various sectors such as Aerospace, automotive, medical, and oil and gas. It makes complex mechanical shapes, gears, jigs and fixtures, prototypes, robot arms, and orthopedics.

   • Advantages and disadvantages:
   
+ Complex designs
   + Rigid components
   + Fast production
   + Vast material selection
   - Requires post-processing
   - High cost


2. Subtractive manufacturing

Sheet metal fabrication:
It is a set of manufacturing methods of cutting and forming metal sheets to produce parts. The mainly used materials are:
   • Steel alloy       
   • Stainless steel
   • Aluminum

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Applications of sheet metal fabrication:It is widely used in the automotive sector as it is used to make the bodies (BIW), home appliances, aircraft fuselage, and wings.

Advantages and disadvantages:
+ low production cost
+ fast process
- High cost of toolings 

Tube bending: Tube bending is a set of techniques to bend straight tubes into different shapes. The process can be performed by using cold or hot methods. Generally, round stock is used, but rectangular tubes and pipes can also be bent.

A post-process can be mandatory to remove burrs. It can also be used with laser tube cutting to add holes and shapes or to cut the edges

Applications of tube bending: It is generally used in piping for the gas and oil sector, stair rails, and welded structures.

Advantages and disadvantages:

+ Clean since there is no welding between tubes
+ No leak risk
+ fast process
+ low production cost
- High cost of toolings

CNC machining: CNC machining (Computer Numerical Controlled machining) designates a process that uses a computer to control the trajectory of the machining tool. It employs many machining techniques, such as milling, turning, and drilling. Used materials are:

   • Titanium
   • Stainless steel
   • Aluminum 
   • Nickel 
   • Cobalt 
   • Copper

Milling: Milling is a process that uses a rotating tool to remove material from the fixed workpiece. There are two types of milling, horizontal and vertical milling.

   •  Applications of milling: It is generally used to make squared machined parts in various sectors such as Aerospace, automotive, and medical. It makes jigs and fixtures, gears, and turbines.

   •  Advantages and disadvantages:
   
+ Accurate process with lower fabrication costs
   - High cost of tooling

   •  Turning: This method uses a lathe to turn workpieces at high speeds and a tool with a special shape to remove layers of material from the workpiece. The workpiece shape is generally revolutionary. If the workpiece is long enough, an extra part is used to support the weight of the workpiece.

   • Applications of turning: It is widely used in various sectors such as Aerospace, automotive, medical, and oil and gas. It makes shafts and revolutionary components.

   • Advantages and disadvantages:+ Accurate process+ lower fabrication costs- Manufacturability is limited to simple shapes

   • Drilling: It is a process used to make homes in the workpiece. The holes are generally perpendicular to the surface but can have angles with special tooling. This process includes taping, counterboring, and countersinking.

   • Applications of Drilling: It is used to make holes or taps in CNC machined parts, and it is used in various sectors such as Aerospace, automotive, medical, and oil and gas

   • Advantages and disadvantages:
+
Automated process with high accuracy and speed
- Requires special tooling for different operations
- Hole depth and diameter are limited

   • EDM: It is a thermal cutting process of metal parts using a high voltage electrical discharge, hence the name EDM (Electrical discharge machining). In this technique, electrical discharges (sparks) heat a metallic shape that engraves through the workpiece. EDM can use a wire instead of a shape to cut through the workpiece (wire EDM). Used materials are:
   • Titanium
   • Stainless steel
   • Aluminum

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   • Applications of EDM: It is generally used in mold design in Aerospace, automotive, medical, and home appliances.

   • Advantages and disadvantages:+ High tolerances+ Complex shapes- High-cost process- Operates only on conductive materials

2. Formative manufacturing

   • Die casting: 
Die casting is a process in which molten metal is fed into a mold cavity under high pressure. Mold is made from hardened steel and contains the shape of the part to be molded. The die-casting process is used for high and medium-volume production due to the high cost of mold fabrication.

   •Applications of Die casting:It is widely used to make rigid components with complex shapes in various sectors such as Aerospace, automotive, and oil and gas. It makes crankcases, shafts, gears, and locks.jigs, and fixtures, electronics.

   • Advantages and disadvantages:
   +  Complex shapes
   + High tolerances
   - Long development  time 

   • Waterjet, laser, and plasma cutting: It is a set of cutting methods that use heat or water to cut through almost any type of material to produce a part or product.

   • We offer the following finishes for custom-manufactured parts:

   - Surface finish
   - Deburring
   - Plating 
   - Anodizing 
   - Heat treatment 
   - Powder coating 
   - Painting 
   - Welding 
   - Riveting 
   - Assembly 
   - Testing

OUR SERVICES

WHAT NORCK DOES BEST

WHY NORCK?

Artificial Intelligence Augmented

Artificial Intelligence Augmented

Norck gathers and uses thousands of data points to augment its engineers with a state of the art artificial intelligent system for better design and manufacturability.

Innovation at Work

Innovation at Work

Besides being an artificial intelligence augmented digital manufacturing company, we also develop extremely innovative manufacturing tools, fixtures and of course software applications such as RapidCAD, a highly intuitive and innovative web based CAD application.

Chain Resilience

Creating Supply Chain Resilience

Working with Norck effectively reduces your risks against supply chain shocks, unforeseen delays, price fluctuations, and quality issues, thus increasing your company’s resilience in its outsourcing and supply chain . Besides its own capacity, Norck has premium access to hundreds of sheet metal fabrication, CNC machining, and 3D printing partners across the United States, Germany, and Europe.

Access to Huge Capacity

Access to Huge Capacity

Besides Norck's own production capacity, Norck has access to hundreds of top quality sheet metal, CNC machining, and 3D printing service providers across the United States, Germany, and Europe, making it one of the leading digital manufacturers in the world.

Green Driven

Green Driven

Norck encourages its partners to be carbon-neutral, and gives carbon neutral compliant suppliers priority over non-compliants.

EUROPE’S AND U.S.’ LEADING DIGITAL MANUFACTURING COMPANY