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Ultrasound Enclosure Prototype Results
In Multiple Manufacturing Efficiencies


	BENEFITS IN BRIEF: • Secondary plating process eliminated • Welding simplified and streamlined; no metal finishing required • Material usage improved • Secondary fasteners eliminated • Manufacturing costs lowered

Apr 2004

A prototype for the sheet metal chassis of an ultrasound machine not only helped to prove out a general design concept, but it also shed light on several ways to improve efficiency and reduce costs in downstream manufacturing.

Design for Manufacturability innovations, developed during the prototype process at Maysteel, included the use of pre-plated material secured with small, nondeforming fuse welds. These carefully spaced 3/8" welds replaced an original concept of full seam arc welding that required a follow-on metal finishing step, then post-plating of the entire chassis.

The prototype also demonstrated how "pierce and extrude" features, in combination with inexpensive threadforming screws, could replace separately purchased self-clinching fasteners. Finally, the prototype process uncovered a means to form smaller components from scrap generated during production of larger chassis pieces, rather than having to use separate material.

The chassis prototype was designed and built at Maysteel's secure prototype center in Allenton, Wisconsin, and delivered in less than a week. This center, which focuses on Design for Manufacturability improvements, incorporates the same systems and equipment used in Maysteel's manufacturing plants, allowing for seamless transition from prototype to production. In addition, prototype teams typically include key members of the production staff who will be involved in a product's final manufacturing.

Maysteel's prototype (left) allowed formation of the round component at bottom out of scrap, and the bracket at top directly from parent material. Original design (right) required additional material for both parts, plus a welding step to attach the bracket.