As
product designers aggressively try to find better and more cost
efficient ways to produce products, one manufacturer stands out
with its processes as a choice that gets better over time.
Metal
spinning is an age-old art, but even high technology manufacturers
have rediscovered that Acme Metal Spinning has the solution to
many of their design problems. With an unusual ability to spin
a broad range of materials in very large diameters to 140 inches,
Acme stands out for its exceptional capabilities. Even in its
most basic form, there is no other process like metal spinning
as conservative with material, simple to tool up, yet produces
precision and repeatable quality. It's fast to produce and is
completely flexible in its application to many products in many
industries. Acme, as you will see, takes these metal spinning
processes even farther.
Over
Eighty Five Years of Spinning Knowledge Goes A Long Way To those
who know that Acme Metal Spinning dates back to 1908 may also
think this is when the process first began. Not true. 5,000 years
ago the Messopotamians discovered that spinning was an ideal
method for making pottery and eating utensils. The Egyptians
applied the technique to precious metal to produce containers
like chalices and cups. But it wasn't until the early 1860's
that the process really began to be accepted for manufacturing
parts. Just prior to World War I, the process began to compliment
metal stamping and lathe turning as a less costly and faster
alternative.
Acme
Metal Spinning originally began at North Star Speciality Company,
a general sheet metal shop with a metal spinning department.
In 1919, the metal spinning operation became a separate specialized
business and through many changes and expansions continues on
into the '90's.
Today's
parts produced at Acme bear little resemblance of centuries ago.
For example, Acme's parts are cryogenic tanks, decorative light
fixtures, filtration systems, chemical and food processing containers.
Acme's accumulated experience over 85 years has been enhanced
with the latest computerized spinning processes and equipment
with the result that its operations are highly cost-effective
with unusually fast part turn around. Acme's manufacturing approaches
not only make them highly competitive with metal stamping, but
spinning is often the process choice over deep drawing, hydroforming
and die casting.
WHAT IT IS
AND WHEN TO CHOOSE SPINNING
By
definition, metal spinning is a method of forming flat metal
discs or pre-formed metal workpieces on a metal spinning lathe
into conical, hemispherical and cylindrical shapes.
According
to Bruce Johnston, Acme Vice President, metal spinning is inherently
a low volume production process. As quantity requirements increase,
stamping becomes a more cost-effective choice, particularly if
the stamping tool requirements are nominal. However, as the part
diameter increases and tool costs for stamping increase, metal
spinning usually is the more economical choice.
Metal
spinning also competes favorably with a variety of plastic fabrication
processes, especially where the cost of metal is often less than
expensive petroleum-based material.
Quantities,
tooling costs and time-to-market are all important factors in
choosing one process over another, according to Johnston. Often
to launch a product, Johnston reports, Acme will spin part prototypes
or test market quantities while permanent tools are being made.
That's an economical way to launch a product, check its acceptance,
modify it if needed and then begin making permanent production
tooling.
Acme's
ability to turn prototype orders in just a few days wins over
many customers. A good example is Twin City Fan and Blower, a
Minneapolis-based manufacturer of heating, ventilating and air
conditioning equipment and long-time Acme customer. Its requirements
include prototype components for a variety of products in production
quantities of 100 or less. Acme's metal spinning processes provide
the ideal solution.
KEY TO ACME'S
SUCCESS IS COMBINING CRAFT EXPERIENCE WITH JUST THE RIGHT BLEND
OF MODERN TECHNOLOGY
To
say Acme's metal spinning operations are customer driven is an
understatement. There's a strong presence of the craft skills
that over 85 successful years in the business generates. But
there's been a steady transferral of hand skills to computer-controlled
operations with effective results.
This
really shows in the type of customers the company has retained
and grown with over the decades. Minnesota Valley Engineering,
a producer of cryogenic tanks, has been an Acme customer for
over thirty years. Acme first produced these tanks in the 1960's
with traditional spinning machines using flat stainless steel
discs and shaping them using hand tools to form the proper cylindrical
shape. The skill of the operator was critical to producing a
quality finished part. To do it repetitively with consistency
took not only skill but a totally dedicated operator with excellent
concentration skills.
Today's
metal spinning processes include computer-aided design and CNC
spinning equipment. The craft ability is ever-present but it's
translated into designing the computer programs which automatically
produce the parts and with far greater speed, higher quality
and consistency. The design and manufacture of these low temperature
storage tanks and vessels has become a highly sophisticated,
big business. The containers have a multiplicity of uses including
the transport of animal semen for breeding purposes through artificial
insemination. In this industry, Minnesota Valley Engineering
has grown to be one of the worlds largest suppliers of cryogenic
tanks. Acme is helping in this growth by supplying innovative
spinning processes to keep pace with accurate and acceptable
product prototypes and fast turnaround on production runs.
PROTOTYPES
TO LONG RUNS - ACME PROVIDES FAST SERVICE FOR BOTH
Acme
maintains a large inventory of tools for both prototype and production
run work. Tooling is made of both laminated wood and mild steel.
Both types are far less costly than the heat-treated tool steel
required for metal stamping or deep drawing. This tool inventory
gives the company an ability to respond very fast and economically
on a new project.
"We
can quote on a job one afternoon and deliver prototype parts
in a few days", says Mike Mokita, General Manager. "We're
not able to do that on all work, but we do it most of the time
when needed on a new product. Normal delivery is two to three
weeks with complex jobs requiring 4 to 6 weeks."
"Acme
is not afraid to try new things to help out a customer,"
Mokita added. This is particularly true in prototype work where
ACME is continually challenged with new materials, shapes and
sizes. The ability to make parts quickly from increasingly thicker
materials - 3/4 inch steel is one of the most notable -- has
made Acme's offerings even more appealing.
The
company's fast turnaround is enhanced because it does all tool
design in-house. Already-made tool components in a vast tool
library gives Acme a head start on many jobs. Add the skill and
experience of its tool makers to quickly design any missing elements
and it's easy to see how the company has kept pace with the growing
needs of customers like Minnesota Valley Engineering and Twin
City Fan Blower.
MATERIALS,
EQUIPMENT AND SIZE CAPABILITIES
Acme
manufactures parts in many standard and exotic materials including
various alloy steels, stainless, aluminum, copper and precious
metals. Its size capabilities range from less than an inch up
to140" diameter. The fact that it works with a broader range
of materials and in sizes that are beyond many metal spinners,
sets the company apart and is important for its long term customer
relationships.
Another
Acme strength is its excellent equipment. Acme's two-roller,
100 horsepower drive CNC controlled spinning machine has a capacity
of 48" diameter parts of .750" thick mild steel. The
company's 60" CNC controlled spinning machine has a capacity
of .250" thick mild steel while its recently-installed 140"
capacity, hydraulic-assisted spinning lathe gives it versatility
not found in most spinning plants.
In
addition to a wide range of hand, hydraulic and CNC controlled
spinning lathes, the company has support machines for performing
other operations such as trimming, beading, welding and hole
making.
CUSTOMERS
INCLUDE MANY INDUSTRIES
Acme
grew from a regional supplier to Midwest companies right after
World War II to a national manufacturer supplying many large
industries. It sells to giants like General Electric and 3M Company
and to aerospace leaders like Boeing and General Dynamics. The
industries it serves between both coasts include the heating
and air conditioning, filtration, architectural cryogenic, food
processing, agricultural, chemical and lighting, not to mention
a continuing stream of small emerging companies with new products.
FUTURE OF
ACME METAL SPINNING IS BRIGHT
