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Reverse Engineering

  • General Capabilities Consulting Dimensional Inspection Design Gage Calibration Prototyping Rapid Prototyping Research & Development
  • Software Catia Autodesk Inventor MasterCam PowerInspect Pro Engineering Rapid Works Solid Works
  • Industry Focus Aerospace Automotive Biotechnology Chemical Construction Electrical Electronics Food Processing Genetics Machinery Marine Mining Nuclear Oil, Gas, Petroleum Optical Packaging Pharmaceutical
D-K Manufacturing Corporation: Prototyping & Reverse Engineering

Possessing full design, material selection, and CMM inspection capabilities, we offer comprehensive prototyping and reverse engineering services. Specializing in 3D Solid Works, we can accept most standard software files. And, through a client submitted drawing or part, we can offer a variety of solid model types, such as parametric, hybrid surface, and shrinkwrap surface replicas.

From consulting and dimensional inspection to gage calibration and design, we offer complete prototyping competencies on all parts weighing up to fifty pounds and measuring up to 24 inches in height, length, and width. Using a client-supplied blueprint, we can select the best materials to meet your product capability needs, and design a model that meets customer specifications and offers trouble-free manufacturing. And, our prototyping and reverse engineering services are ISO compliant and have happily served the needs of diverse industries, ranging from biotechnology and construction to marine and mining.

And, possessing CMM inspection equipment, we ensure that all our prototypes are of the highest-quality production. Please contact D-K Manufacturing Corporation today to inquire after our superior prototyping and reverse engineering capabilities.
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CNC Vertical Milling Services

  • Customer List GOULD PUMPS CARRIER CORPORATION BIRDSEYE FOODS PARKER HANNIFIN CORP THE ELLIOT COMPANY UNITED TECHNOLOGIES DRESSER-RAND TYCO THE BLACK CLAWSON COMPANY
  • Cutting Tools High-speed steel (HSS) Carbide Carbon Steel Cobalt High Speed Steel
  • Width Max 20 in
  • Length Max 40 in
D-K Manufacturing Corporation: CNC Vertical Milling Services

Equipped with four axes, vertical machining centers (VMC's) possessing a 40X20X20 inch work envelope, our advanced CNC milling machinery can work with a variety of substances, ranging from titanium and zinc to fiberglass reinforced plastics and nylon. Our CNC milling service can be applied to a broad range of applications, including hydraulic and turbine components, construction equipment, shafts and forgings. And, we cater to discontinued part manufacturing, as well.

Possessing a variety of equipment capabilities, our advanced machinery can uphold a (+-) 0.0002 inch precision tolerance and can process parts up to 40 inches in length and twenty inches in width and height. Working with many professional clients, including The Elliot Company, United Technologies, and Tyco, we provide superior CNC milling services that are ISO compliant and always meet high customer expectations. Contact D-K Manufacturing Corporation to learn more.
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CNC Machined Replacement

  • Product Description This lever is used in a large valve
  • Industry for Use HVAC
  • In process testing performed Inspection: SPC CMM
  • Material Used CDA 360 Brass
CNC Machined ReplacementPutting our CNC milling experience to use, DK Manufacturing machined this replacement lever casting to replace an out-of-stock part. The lever is used in a large HVAC valve, and the customer required the single-piece order to be delivered within a week. Working from a CDA 360 brass base material, we used our Fadal 4040 VMC to complete the CNC machining processes, first CNC milling one side of the billet to profile shape, and then milling the other side to complete the profile. We also used vertical milling to drill and tap a 14" NPT for attaching the lever to the valve. The brass material was then finished to 32 RMS.

This lever was CNC milled to its final size from bar stock measuring 2-12" x 3-12" x 12". In keeping with the supplied customer print and requirements, tolerances including parallelism of .001" and perpendicularity of .002" were maintained, and SPC and CMM in-process inspections were utilized, both to ensure the high quality of the product and to meet the fast turnaround time.
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Industrial Pump

  • Product Description This Coupling Guard is used on a pump and motor assembly
  • Typical Operations Stamping: Blank Cut Out Flat Shape to Size 31.8mm Wide R 38 R 6mm R 2mm Form Large Radius and Sides R 79mm 2x ΓΈ5 Thru Holes Use Rubber Form to Produce Shape Finish: Wash Clean Any polishing or coating? no
  • Delivery Time 3 days for prototype; 7 days for short run tooling (soft tooling) 7 weeks for production tooling.
Precision Stamped Coupling Guard for the Commercial and Industrial Pump Industry

When contracted by a client located in Auburn, New York to manufacture a series of coupling guards used on a pump and motor assembly, D-K Manufacturing Corporation employed our advanced stamping technology to produce these units in two different sizes. Based off a customer supplied 2D print, we first spent three days building a prototype of the coupling guard, ensuring that our design met precise customer specifications before beginning full manufacturing procedures.

Once we received client approval on the prototype, we began mass manufacturing all units by employing our superior stamping equipment. Each guard was constructed from bright annealed, twenty-four gauge stainless steel material. We blank cut the rough shape of each unit using a gap frame 60 ton press. Then we used a rubber form to produce the exact shape of each part. We employed rubber material during this second production phase in order to construct this final shape with minimal scratches. After the parts were fully manufactured, we then washed all units clean.

Upholding a () 0.1 mm tolerance, we manufactured each unit to measure either 104 or 120 mm in length. All parts measured 150 mm wide and 29.6 mm high. It took our engineers seven days to complete all short run tooling (soft tooling) and seven weeks to complete all production tooling. We now manufacture four hundred coupling guards per month for this client, producing these two different sizes from the same tooling.
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CNC Machined Contact Sleeve

  • Product Description This Contact sleeve is used in a Compressor seal application
  • Max Material Finish 4 RMS
CNC Machined Contact Sleeve for the Compressor Industry

A customer contracted D-K Manufacturing Corporation to produce twenty five contact sleeves to be used in a compressor seal application. Employing a combination of our craftsmanship and services, we were able to successfully manufacture these parts within a short lead time of 12 days.

Using an automatic horizontal Doall Saw to cut each sleeve from seamless HRS tubing. We then employed our Methods Slant3 CNC lathe to turn each unit, leaving .005 inches of extra material behind for later grinding operations. Additionally, we turned the inner diameter of the contact sleeves in order for the parts to have a snug fit on a grinding arbor. Parts are then sent out to our heat treaters for stress relief.

After each contact sleeve was turned and stress relieved, we then use our Fadal 4020 VMC equipped with a 4th axis to vertically mill a series of thirty six equally spaced slots near the front rim of each unit. We also cut a slot entirely through the top towards the back of each sleeve. During these machining processes, we were able to uphold a concentricity tolerance of .0005 inches TIR, which is key to establishing finish tolerance of parallelism and perpendicularity tolerance of .001 inches, and a flatness tolerance of .000011 inches.

Next, we had to ensure that the contact sleeves possessed an ultra-smooth, 4 RMS finish. In order to provide this finish to each part, we employed a combination of our grinding, plating, and lapping technology. Using our Heald rotary grinder to finish the sleeves' faces and our TOS cylindrical grinder for both the inner and outer diameter of each unit, we then proceeded to flame plate the sleeves, providing each part with a carbide coating measuring anywhere between .004-.008 inches in thickness. After the sleeves were plated, we utilize our Speedfam lapping machine to provide the final finish to each unit.

After manufacturing was complete, we performed a series of quality control inspections using a variety of bore gages, CMM, profilometers, and optical flat equipment, ensuring that each contact sleeve met precise client specifications. Basing our design off of a customer supplied print, we constructed each sleeve to measure 5.25 inches in outer diameter by 3.5 inches in inner diameter. The flange on the sleeve possessed a maximum outer diameter of 4.9375 inches.

By combining our craftsmanship and years of knowledge a long with our outstanding supplier services we were able to construct this series of contact sleeves for our customer, we were able to produce superior product that met precise client specifications. Within a twelve day lead time, all twenty five parts were successfully manufactured and shipped to our customer.
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Stainless Steel Diaphragm Cover

  • Product Description This diaphragm cover is for the bottom of a submersible water pump motor
  • Typical Operations Stamping: Blank Cut Out Formed Shape Finish: Wash Clean
  • Material Used AISI 304 Stainless Steel 16 Gage
  • Standards Met Customer supplied print, CAD file
Stamping of Stainless Steel Diaphragm Cover for the Field Pump Motor Industry

DK Manufacturing used our stamping capabilities to manufacture this stainless steel diaphragm cover, used by a customer in the field pump motor industry. This particular cover is used for the bottom of a submersible water motor pump, so proper material selection and tight tolerances were important. Using several of our stamping presses to carry out various stamping operations on a 16 gage AISI 304 stainless steel base, we successfully manufactured this part, keeping to the tolerance requirement of .005".

The first step in stamping this product was blanking, which we carried out in a gap frame 60 ton press, drawing the cover's outer shape. Next, the forming step defined the cover's outer radius and established a .940" height. We used an 80 ton gap frame stamping press for this. A 3rd press operation pinch trimmed the outer flange to that lower height, and finally a 45 ton press performed two perforation operations: one to perforate three holes in the top of the cover and set the .44" top radius, and a second to perforate 6 holes around the flange. The form dies used in stamping this piece were coated with vanadium carbide, lessening friction and galling between the die and the piece.
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Cnc Turning Services

  • Industry Focus HVAC Compressor Manufacturers
  • Part Diameter Max 14 CNC 24 Manual in
  • Industry Standards ISO - Compliant International Organization for Standardization
  • Equipment Capabilities CNC Control Capabilities Large Swing Lathe Bar Feed Milling CAD Design Services CAM Programming Services Reverse Engineering
D-K Manufacturing Corporation: CNC Turning Services

Offering a variety of machining processes, ranging from broaching, splining, threading and boring, our turning machines are equipped with a maximum 24 inch manual chucking capacity, up to 29 inches between centers. And, we can use our advanced CNC capabilities on parts measuring up to fourteen inches in diameter. Catering primarily to the commercial compressor and turbine rotating assembly industries, we work with a wide range of companies, including the Elliott Companies, Carrier Corporation, and Dresser Rand.

Our two axis turning machines come equipped with bar feed, a large swing lathe, CAD design, and CAM programming capabilities. Upholding a (+-).0002 inch precision tolerance, our turning equipment offers tighter tolerances with shorter lead times. And, our machines possess a large material capacity, able to work with a broad range of substances, such as plastics, cast iron, stainless steel, and aluminum.

Offering a variety of applications, ranging from machine and engine components to jewelry, valves and fasteners, we invite you to contact D-K Manufacturing today for further information about our advanced CNC turning capabilities or any of our additional service options, including, but not limited to, insert plastic molding, centerless grinding, welding, drilling, and assembly.
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  • Fulton, NY 13069 map, United States
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