BC Instruments takes the prototype phase very seriously, because we know just how important it is to our clients and their peace of mind. It also serves as the linchpin for the final production run, which means perfection is a must. Here’s how we approach the prototyping process, and why it should interest you.

THE PURPOSE

A design is nothing if it doesn’t function well in a real-world application. Many things look great in theory, but only through application do we discover flaws in the design process that require fixing. This is always in our minds at BC Instruments when we first initiate the prototype phase. It’s important for clients who are committing to a project, and need to be sure that timelines are not missed due to errors in the production process.

At the same time, we recognize that no two product runs are ever truly alike, nor are the prototyping methods. Variances occur constantly, which is why we approach each new prototype as if it were the first. For instance, BC Instruments recently worked with mass spectrometry leader SCIEX on the creation of specific machined parts. Both SCIEX and our team understood the vital importance of prototyping when it came to adhering to geometry limitations and standardized processes to create said parts. This guaranteed that BC Instruments was able to serve the needs of SCIEX by determining the correct processes needed for final output. None of this could be achieved without prototypes that allowed BC Instruments and SCIEX to confirm the final designs.   

THE INITIAL PROTOTYPES

Prototyping can involve one, or several different models depending on how well the design translates to a real-world part. Oftentimes a prototype will serve to confirm the accuracy of a design, while others will point out flaws that require correction. During this phase, our prototypes don’t need to look perfect or polished – they simply need to function, and be accurate. The focus is on communicating the validity of a design before we move to the production run.

This approach can save massive amounts of time, as well as money. The former is sometimes more important than the latter, especially when it comes to the clients BC Instruments services in high demand industries such as Electro-Optic, Medical and Nuclear. 

TESTING & RE-TESTING

BC Instruments implements a rigorous testing process to make sure that products move from the prototype phase to production in a seamless transition. This testing involves putting each prototype through its paces to guarantee that it adheres to the exact specifications laid down by the client. Each piece must fit the greater sum of the final project, which is why we eliminate any inconsistencies and issues long before the production run begins.

Clients play an active role in the prototyping phase, as well. Their surveys and opinions are vital as we move into the production phase, and this is especially true during the R&D process. Once the prototype is complete and the client is satisfied, we move into the planning phase to prepare the entire production run. This involves optimizing our workflow and machinery to guarantee on-time (or in many cases, before) delivery, done to precise specifications.

For more information on how BC Instruments can prototype your next design, please contact us today. We’d love to walk you through your process so you can see how we approach this most important of phases.

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So, how does BCI navigate these pitfalls and prevent them from popping up during our production process? First, we need to identify the five most common problems with CNC machines, before we generate fixes for them. Here’s what they are, and how we deal with each one.

#1) CHUCKS AND FIXTURES

There are times when chucks and fixtures on CNC machines cannot adequately hold the machined piece. In this case, vibrations and shifting can occur which can spell big trouble for the production process. Our solutions are rudimentary, and usually involve an elevated approach to the problem. For instance, we first check to make sure the piece has indeed been secured correctly before moving onto other things.

We check to make sure the grips can adequately hold the piece, we check the hydraulic pump and pressure, and we check to make sure other technical issues like foot switch problems or lubricant issues aren’t at play. Since improperly gripped machine parts can lead not just to damage, but operator injury as well, we make absolutely sure our CNC machines clutch their materials correctly, the first time.

#2) OVERHEATING

Due to the extremely high volume orders we take from our clients, our CNC machines are running almost constantly. This means overheating is a factor that we must take into account. Thankfully, we plan ahead on this to make sure all of our machines are working in tip-top shape. It’s important to remember that the basic function of CNC machining means that heat will be a natural result. Our machine tools can hit temperatures as high as 150 degrees, or more. Care must be taken to make sure that this doesn’t affect our machine, or the part in question.

Cleanliness is key, and we make sure our machines are thoroughly wiped down, and that all dirt and debris have been removed. Metal shavings can contribute greatly to overheating, which is why we adhere to a strict cleaning schedule. Overheating can occur from other sources, however. Running a CNC machine at high RPMs for a prolonged period of time means adhering to some standards.

#3) OPERATOR TRAINING

Human error is a constant in any business, but it can be mitigated through proper training and adherence to guidelines. In the case of CNC machining, this means training our operators on how to use the CNC software which runs each machine, plus a thorough understanding of G and M codes, setup and the inputting of data.

We consider this to be of maximum importance, and it shows in the skill of our operators. Machines can only do the job, but the human element is what counts. This is how we continue to please clients the world over, throughout a multitude of important business sectors.

#4) POWER SUPPLY ISSUES

Believe it or not, sometimes the most common problem is also one of the most basic. CNC machines are quite complex, and they can be hobbled by power supply problems. This can often take the form of incompatibilities between the machine and the power socket in question.

We make sure that our CNC machines are running on compatible power supplies with correct voltage settings required for the input side. If we do experience power supply issues beyond that, we bring in certified electricians to make sure there are no faults to our power supplies on the opposite end of the connection. Stable power flow is an absolute must during a CNC machining run, and we do regular checks to make sure ours are running at peak efficiency.

#5) WRONG TOOLS OR SETTINGS

This is a common issue with many precision machining companies, and it really shouldn’t be. In order to successfully complete a production run, one must choose the appropriate cutting tools and settings before the job begins. Failure to do so can result in damage to the finished product in the form of burn marks, rough edges and corners, or visible cutter marks, all of which are unacceptable.

Thankfully, BCI is ahead of the curve on this issue, thanks to over 40 years of experience in the business. Still, it is considered one of the biggest problems faced with CNC machines. The solution lies in the planning stages. Make sure to determine early on the best tool for the job, and do a trial run just to make sure everything is Okay. If not, one may be wearing out their tools faster than anticipated, while ruining their client’s job in the meantime.

For more information on how BCI’s attention to detail and quality excellence has made us a prime player in the Precision Machining industry, please contact us today.

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Technology has come a long way in our field, but there’s simply no substitute for a skilled CNC machining operator who knows the ins and outs of the job. Like any skilled trade, CNC operators must possess and demonstrate several key skills required to succeed at B.C. Instruments.

Due to the highly precise nature of the parts we manufacture for some of the world’s most demanding industries, second-best is simply not acceptable. Here are the skills our CNC operators apply every day at BC Instruments.

CAD/CAM KNOWLEDGE

CNC machining is a process driven primarily by CAD/CAM technology, which stands for “Computer Aided Design�and “Computer Aided Manufacturing,�respectively. Anyone who has worked with this type of software before knows how precise the designs must be. This is where the process starts, and if the design is wrong, the end product will also be wrong, even if it’s off by a few millimeters.

Our operators know how to navigate this interface to guarantee that designs are double-checked before a run is produced. Their experienced eyes can spot errors and defects in the design before the final product is created, thereby saving time and money. This is absolutely vital when it comes to sticking to strict deadlines.

TRADE SKILLS

It’s important for our operators to understand all the processes of CNC machining, including the hands-on work. This means possessing knowledge of physical skills such as manual grinding and drilling, which are vital for many product runs. They must also be able to check and verify (and if necessary, check again) product dimensions using precision tools. This is mostly done in the prototype phase where any and all defects and kinks are worked out before the final run is produced.

TECHNICAL KNOWLEDGE

Our operators may know the software, and they may be good with their hands, but gray matter is just as important. These skilled workers can read technical blueprints as if they were travel brochures, not to mention technical instructions and models. Without a solid understanding of these fundamentals, it’s impossible to move onto the crafting process without error.

Those proficient in math tend to have a field day with CNC machining. This is especially true when it comes to calculating schematics to ensure correct sizes, shapes and designs of target products. For example, B.C. Instruments serves the Nuclear Energy industry, so one can imagine the level of peak precision required for a product run.

We are proud of our CNC operators who continue to form the backbone of our operations at BC Instruments. With decades of experience, we know what our clients require, and failure is not an option. For more information on our CNC machining services and how they can serve your company during its next production run, contact B.C. Instruments today.

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Cost savings aren’t the only thing a company must consider when searching for the right precision machining company to work with. After all, said projects require extreme attention to detail, and the experience to match. Making decisions based purely on the pocketbook could end up harming your bottom line in ways you didn’t expect.

To choose the right precision machining company, one needs to look beyond the cost of a run, and deep into their history. Company culture, team, longevity and other criteria play a vital role in the selection process. Here’s how to choose a precision machining company based on the right criteria so you can be sure you’ll get the job done right, the first time.

EXPERIENCE IS KEY

This is perhaps the most important part of choosing the right precision machining company. This is a highly detailed and demanding field that requires a know-how of multiple industries in order to succeed. The right company will have cut their teeth on all of them, and grown throughout the years to better themselves as technologies and techniques evolve. This experience helps companies adapt on a year-by-year basis so they are always ready for the next big thing. Better yet, an experienced company can take on a brand new project run with full confidence by implementing the strategies and techniques they’ve amassed over the years. Never underestimate experience – it’s the single-most important thing to look for a great precision machining company.

CERTIFICATIONS

Precision machining companies come in different sizes, each with their own unique set of specialties. However, it’s important to make sure that your company of choice is certified to handle jobs required by particular industries such as those B.C. Instruments are involved with. These include aerospace, nuclear, plastic injection molding, electro-optic and medical. None of these industries should be taken lightly, and precision machining companies need to be fully certified in order to make sure that their project runs are up to standard, and beyond. Make sure to inquire about ISO and similar certifications to make sure you’re dealing with a reputable entity.

INTERACTION

The best companies are the ones who are easy to work with, and precision machining is no different. It’s difficult to start out on a negative note with companies who are rude, impatient or indifferent to your needs. Similarly, keep tabs on how a company communicates with you when it comes to information and requests. If they’re taking a day or two to get back to you, this could spell trouble down the road. Conversely, if they’re responding to inquiries within an hour or two, they’ve definitely got your best interests at heart. None of this is a guarantee of quality, but it’s a step in the right direction, and a good signal that you’re dealing with a company that is used to making clients happy.

LEAD TIMES

Precision machining companies need to be on the ball when it comes to lead time evaluation. Missing dates is unacceptable, and the right companies know that they have to set a mark, and work within it. This does not mean that complications won’t arise during the production run, but the best companies will utilize their experience and commitment to customer satisfaction in order to pull double duty, re-evaluate a process, or re-think the run while still committing to the original date. The best precision machining companies are the ones who sometimes deliver before the delivery date. At B.C. Instruments, we’re proud to have such a track record when committing to client satisfaction.

ASK ABOUT EQUIPMENT

Your particular production run might be dependent on particular tools and machinery, which is why it’s a good idea to do a deep dive into a company’s offerings. The latest technologies are nice to have, but they’re worthless if your project requires CNC machining with a particular axis, or a laser engraver that the company does not possess. Knowing what a company is using is just as important as knowing their level of experience.

Second, it’s wise to inquire about the quantity of particular machines, as well. This can make or break a deadline. When speaking to a precision machining company, analyze the projected delivery date and measure it against the amount of machines they use. If something feels sketchy, inquire further rather than signing on the dotted line.

With a little know-how, you can locate the right precision machining company to trust with your next production run. B.C. Instruments prides itself on 40+ years of top-notch surface across the most prolific industries on Earth, and we continue to grow with the times. We’re trusted by our clients for good reason, and we invite you to contact us to discuss your next project with us.

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The term “Precision Machining�is a reference to the process that produces many of the objects we use both in our daily lives, and in high-tech industries. The world’s most complex engineering feats require a multitude of precise parts that work together to create a final product. This is as true with medical devices as it is with nuclear reactors that provide us energy.

One would be hard pressed to find a tool used in our modern world that did not require precision-machined parts. Therefore, it remains one of the most vital cogs of the world’s major industries. For some, this field can be hard to understand, which is why we recommend reading on to learn more about the process.

Precision Machining requires the ability to work within a set of drawings and models, either hard copy or electronic down to the finest detail. Even the most minor deviations are not acceptable and can ruin a project. Therefore, it’s especially important to work with a company that knows the business inside and out, and has the experience necessary to tackle the most demanding jobs. These skilled individuals often take 2-dimensional data, produce 3-dimensional models, generate required toolpaths and produce an actual part from a solid billet or bar to the designer’s original concept using the Precision Machining process. How does this work, one might ask?

Choosing the right size of raw material is the first step. The idea is to subtract away superfluous materials to form a shape. This is accomplished via machining tools such as sophisticated computer-controlled lathes, milling machines and grinders that whittle an item down to its exact print specifications. It’s an extremely technical procedure requiring strict adherence to guidelines. Some popular and common materials used in Precision Machining include carbon steels, stainless steels, engineered plastics, ceramics, glass, to name but a few. As substrate material is removed, these various materials are shaped to produce their end product. Once completed, these components are cleaned, sharp edges removed, cleaned again, dimensionally inspected. They offer require subsequent non-destructive testing to ensure base material integrity and protective coating to prevent unwanted oxidation. Then inspected once again and finally shipped to the client to be used in the assembly of larger-scale projects.

The process goes far beyond just these steps, however. The right producer needs to understand prototyping and volume manufacturing in order to service client’s needs correctly. For instance, B.C. Instruments employs a system which allows us to rapidly prototype a client’s required project and quickly work out a timetable for completion and delivery. This system has allowed us to stay robust as we service clients across a huge span of industries.

The types of tools used in Precision Machining are varied and highly complex pieces of machinery requiring the use of a skilled operator. These include the following:

• MILLING MACHINES – These machines are used to shape materials to their exact size using moving parts that subtract from the base material. These are some of the most common forms of Precision Machining.

• LATHES – These rotating tools are controlled by a CNC computer which is designed to carve intricate designs out of base materials. Some are customized depending on the project in question.

• LASER ENGRAVING – High powered lasers are able to make cuts into specific materials in order to further shape the final product. They may also be used to mark particular materials with pertinent info such as instructions, trademarks or product codes.

There’s so much that goes into Precision Machining that it’s impossible to go over every aspect, and that’s to be expected of a field so closely linked with everything that makes our world function as one would expect. For more information on the process of Precision Machining, we invite you to contact us today so we can discuss your next project.

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Understanding how the CNC Turning process is achieved can help one better understand the applications for industry. Typically the process involves taking a bar of metal material and securing it in a chuck which is rotated. While this is happening, a tool is inserted into the piece in order to shave off material and create a shape that will be used for the final product. This can be accomplished with a machine that creates one shape, or multiple shapes.

The base materials are typically round in shape, but this is not a hard requirement. What’s more important is the length of the material bar. Certain feeders can only handle particular lengths which affects the handling process. To determine the feasibility of a part before it is worked on, there are a few factors to consider.

1. CNC Turners tend to focus primarily on prototyping and smaller volume runs, so consider how many are needed for your particular application.
2. Check the maximum OD on the part to determine if it’s appropriate for the machine in question. Certain turning centers have particular maximum ODs and will not work beyond that size.
3. Lead time and projected volume are good requirements to work out beforehand, so the appropriate machines can be used.

CNC Turning is different from CNC Milling in a few ways. While both allow for patterns and details to be added to the material, the process is quite different. CNC Milling uses computer-controlled codes and commands that tell the mill how to drill and turn in order to cut materials to specification. By contrast, CNC Turning uses a single-point cutting tool system that is computer-controlled for a specific purpose. Materials are rotated and cut at varying speeds in order to perform the task.

The key takeaway from CNC Turning is volume, which is perhaps the most important factor to consider. The bigger the run, the more problematic the job will become. Make sure to double-check before proceeding so you can receive a proper estimate on the timeline and feasibility of using CNC Turning for your job.

For more information on the CNC Turning process and how you can get started, please contact us today so we can help.

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B.C. Instruments was pleased to deliver impeccable service and the highest machining standards on behalf of Western Formula Racing. The team is part of Formula SAE, a student design competition showcasing the best and brightest young minds in conceptual stock car production. Western Formula Racing faced an uphill challenge due to the 2020 global pandemic, but our dedication to delivering the best service helped them overcome and succeed.

Western Formula required pinpoint and precise machining of uprights for the production of their WFR20-E stock car. As a result, they became the only team out of 750+ across the world to complete their car during the midst of the global pandemic. Though they were not able to compete against other teams due to global circumstances, Western Formula did manage to compete in local AutoX events where they achieved the fastest lap times in every single event. 

The team is now prepping for the design phase of their followup WFR21-E in 2021, and we look forward to working with them in the future for all of their machining needs.

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Laser Engravers come in a variety of different formats that are best suited for particular industries and product materials. CO2-based lasers work well for items such as woods and plastics, while ND:YAG and Fiber-based lasers work best on materials such as steel, nickel and aluminum. Typically, Laser Engraving machines operate based on a mixture of frequency, speed and focus in order to work properly. The machine fires laser energy at the desired material which creates heat at the point of focus, while the beam itself has no temperature. As such, it’s important to achieve a proper focus, or the laser simply cannot mark the material.

The lenses in Laser Engraving machines typically operate in one of two ways – fixed lens radius or track size. The latter is relegated mainly to CO2 and certain Fiber-based laser systems and involves the use of a bed-style laser where products can be set up single, or multiple at a time. A track mechanism marks products by moving the laser back and forth across the bed at high speeds to draw out the final design. Fixed lens radius lasers are typically stationery and involve the use of galvo-driven mirrors that adjust at blinding speeds to properly mark the material. Both types of lasers have their advantages and disadvantages. Fixed lens lasers do not need to physically move back and forth as a track-based laser needs to, but tend to offer smaller marking sizes in comparison.

Laser Engraving machines are considered a Class IV laser device, and require the use of specially designed safety goggles with proper filtering material in order to prevent severe eye injury or even blindness. This pertains mostly to open units, while many of today’s models include a door or hatch mechanism with special shielding so operators can keep tabs on a job without succumbing to eye damage. Most laser machines are incapable of damaging human skin given the necessary focusing properties mentioned before. However, care should still be exercised to provide mild or severe burns, depending on the intensity and power output of the laser. In short, don’t place your skin in the direct path of a laser.

B.C. Instruments uses 2 FOBA G10 Laser Engraving units which provide state of the art advancements in laser marking technology. This incredible machine is capable of not only marking products in the 2-dimensional space, but 3D deep engraving as well. At 100 watts, this is one of the more powerful lasers on the market with a rotary axis and a 120 x 120mm2 engraving field. This allows for large sized products or multiple smaller items to be engraved at a moment’s notice. We also utilize a Fiber Tower marking system from PTG Industries which features a powerful fiber-based laser to create 2D symbologies, linear barcodes, OCR code marking, alphanumerics, logos and more. 

For more information on how B.C. Instruments can take care of your product marking needs, get in touch with us today. Our superior laser systems and skilled operators guarantee precise quality work with high cost-effectiveness and a quick turnaround time.

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One of our long term clients informed us that they wished to reduce the amount of time taken to receive product parts from the standard turnaround of 58 days. This would help mitigate inventory and quality issues moving forward. 

To compensate, B.C. Instruments created a unique pull system custom-tailored specifically for our client that would analyze the inner workings of their operation to identify any gaps or inefficiencies which could be optimized. This would end up reducing bottlenecks, lead time and quality control issues. 

In the end, B.C. Instruments created a total of three unique pull systems to increase speed and efficiency, while decreasing the amount of negative issues previously hampering production. As a result, turnaround was reduced from 58 days to 14 days – a 75% decrease in delivery time. This positive accomplishment also brought along a few extra benefits including the freeing up of extra manual hours while increasing efficiency for other projects on our client’s schedule.

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Our client Liburdi required a very unique supply chain for their components which involves welding material onto the fins of industrial turbines after they are spent in order to refinish them. A second aspect of production involves grinding and welding to join pieces of piping together.

B.C. Instruments was able to hit Liburdi’s desired goals while simultaneously gaining new experience with slightly unfamiliar materials and how to work with them. This was done within a record-breaking 72-hour work window – a testament to the team’s versatility and adaptability when it comes to new projects.

The project manager kept Liburdi in the loop throughout the entire project while hitting all desired delivery dates and maintaining that consistency with client expectations. This has fostered a fantastic relationship between B.C. Instruments and Liburdi as both companies move forward.

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