Design for Reliable Manufacturing (DRM)

To ensure top quality, reliability and cost efficiency, Top Tool offers Design for Reliable Manufacturing using the most recent version of Solid Works that enables modeling, virtual manufacturing and validation of product design.  In doing so, we’re able to raise the quality of our products while reducing your costs for prototypes and testing. In addition, Top Tool also provides sustained support on long-term development from initial design and prototying to full-scale production using JobBoss and Unipoint.

Wire Electrical Discharge Machining (EDM)

Wire EDM is an ultra-precise computer controlled method of machining metal parts and tooling components using a spark erosion process.

A thin metal wire is constantly fed from a large spool and electrically charged to a voltage. When the voltage reaches a certain level, a spark jumps the gap to the part or work piece, and melts a tiny bit of material away with filtered water, continually flushing away microscopic particles of removed material.

The Wire EDM cutting process is computer controlled and extremely accurate, with no cutting forces or burrs created.

Our highly experienced craftsmen achieve very tight tolerances on extremely delicate micro miniature parts that can only be seen and measured under a microscope.

Our EDM capabilities include:

• Wire sizes from .0008" to .012"
• Cut size up to 14" x 20" x 12"
  

Work Cells

Precision and efficiency (both material and cost) are two key hallmarks of Top Tool's dedication to providing the finest complex precision components in the industry. We achieve this by using standardized work cells that arrange resources in an efficient manufacturing environment to improve the quality, speed and cost of the process and eliminating waste. Processes like quick-change precise tooling (same die size/same die clamp height and the use of standard mounting plates) enable Top Tool to maximize production and speed to market to get you the products you need on time and on budget.

Primary Processes

Many of our systems use computer-integrated manufacturing and the latest innovations … from vision systems performing in-process inspections to ultra-high speed stamping processes and integrated work cells.

Sizes & Tolerances

• Thin and ultra-thin materials down to:
  • .0005” thick foils & paper
  • .0015” 301 stainless steel
  • .002” beryllium copper
  • .002” pure platinum ribbon
• Production part tolerances to +.0005” or tighter in many cases
• Micro … frequently produce components, which if sold by weight, would total 3,000,000 components per oz. (105,000 per gram)

Manufacturing Controls & Efficiencies

• Computerized preventive maintenance programs
• Closed-loop materials management to ensure lot integrity
• Real-time tracking of production operations
• Tool life management
• Reel-to-reel production
• In-die sensing for tool protection & part reliability
• Where appropriate, utilize manufacturing cells to efficiently meet high volume requirements

Metal Stamping Presses

• Conventional … up to 160 strokes-per-minute
• High speed … up to 1000 strokes-per-minute

Wire EDMs

• Wire sizes from .00078" to .012"
• Cut size up to 14" x 20" x 12"
• CNC Hole Popper w/electrode from .004" to .134"

Secondary Processes

Top Tool accomplishes value-added secondary operations using in-house capabilities or through approved subcontractors. Top Tool can deliver a completely finished piece, ready for your final assembly.

• Prototyping
  
• Cleaning (Ultrasonics)
  
• CNC machining
  
• Countersinking
  
• Deburring (Tumbling, Cyrogenics, Harperizing / Centrifugal, Electro-Deburring)
  
• Degreasing
  
• Electropolishing
  
• Forming
  
• Heat treating
  
• Painting (including electrostatic)
  
• Passivation
  
• Plating (including reel-to-reel plating of pre-formed components)
  
• Riveting (in-tool assembly)
  
• Strip Inlay
  
• Tapping (in die)
  
• Secondary tapping
  

Packaging and Documentation

Finished Top Tool components can be packaged to meet your specific requirements. Options include loose, formed trays, layer packs, tube packs, on-reel packs and others. We also provide full lot traceability and are fully dedicated to safeguarding confidential and sensitive customer information at all times.