Omni Engineering, Inc.

United States

• Thickness0.0020 - 0.0040"
• Width0.044" to 0.170"
• Length0.054" to 0.206"

Contact springs are manufactured utilizing OMNI Engineering, Inc.’s advanced micro miniature metal stamping capabilities. The customer’s original design required the use of multiple wire welded components. By utilizing our design and tooling capabilities we were able to lower cost, increase productivity, and improve quality with a one piece component. The contact spring is a component for use in trimming potentiometers. Several variations are manufactured: contact springs are stamped from 302 stainless steel andor C7700 nickel sliver alloy. Other variations are stamped using C17410 beryllium copper paliney 6 inlaid material. The parts are stamped using 2 up carbide progressive dies in high speed Bruderer presses. We currently stamp more than 100 million parts annually, holding dimensional tolerances of +-0.0005, and angular tolerances of +-12 degree. Quality is verified through dimensional, gram force, camber, and visual inspections. Real time SPC data is collected during manufacturing and data is supplied with each shipment.

• Volume50,000 - 500,000,000 annually
• Dimensional+/-0.0005"

Manufacturing of these intricate parts is performed with carbide progressive dies in high speed 30 ton Bruderer presses, which are capable of holding tolerances of +-0.0005”. The customer identified the pilot hole diameter, progression and camber as critical to their automated assembly operation. This we were able to hold in addition to dimensional tolerances of +-0.0005”. Stamped leadframes are then plated with tin, palladium nickel, or gold, quality control is maintained through the use of our F.O.V. Smartscope (automated inspection system), dimensional, camber, and visual inspections. In addition to our own stringent quality standards, this project also requires compliance to Mil-Std-202 and ASTM B571 standards. We currently manufacture 50, 000 to 500 million of these components annually.

• Turnaround Time2 - 4 Weeks
• Volume100,000 - 15,000,000 annually

At OMNI Engineering, Inc. we specialize in high volume, precision stampings. The project highlighted here exemplifies our ability to produce retainer clips and high amperage connectors designed for use in military and commercial aircraft. Composed of UNS C17200 beryllium copper, the finished products had to meet various ASTM, military, and commercial industry standards. The miniature and micro miniature stamping was performed with carbide progressive dies on 30 ton Bruderer presses. Manufactured in various sized, all meet tolerances of +-0.0005”, and angular tolerances of +- ½°, which was verified through dimensional, gage, and visual inspections, and through the use of our F.O.V. Smartscope (automated inspection system).

• Thickness0.0254" - 0.032"
• Length0.140" to 0.375"
• Width0.044" to 0.250"

An electronics customer contracted OMNI Engineering, Inc. to manufacture these current sensor resistor heat sinks to be used across various product specifications. The miniature precision stampings are produced on 30 ton Bruderer presses, which are capable of meeting tolerances of +-0.0005” throughout 20, 000 to 80 million heat sinks we produce annually. Stamped from C102 copper and C110 half-hard copper. After stamping the heat sinks are deburred, and plated with matte sulfamate nickel and tin plating. Additional components use inlaid andor clad materials in tin andor silver.

• Lengthup to .850"
• Thicknessup to 0.032"
• Widthup to 3"

As medical devices become more advanced and complex, so too does the precision of their internal components. At OMNI Engineering, Inc., we specialized in precision miniature and micro miniature stampings that are ideally suited for the specific requirements of the medical industry. The quality program for the medical industry is an essential part of our process; through the use of control plans, real time SPC data collection and reporting that provides immediate process performance to the production department, to use of a video inspections system (OGP F.O.V. Smartscope), laser and digital micrometers, comparators, toolmakers microscopes and a variety of hand held tools that are controlled through our calibration system.