Engineering & Metal Stamping of a Mounting Bracket for the Safety Restraint Industry

Application Overview:

Our client was using a cast aluminum mounting bracket to hold a canister filled with inert pressurized gas. The existing bracket was expensive and heavy because it had to support the canister when it was actively filling a large safety bag in less than 1/100th of a second.

Solution:

A.J. Rose’s engineers assessed the existing product’s material makeup and manufacturing process to help them develop alternative solutions. Our zinc-plated High Strength Low Alloy (HSLA) stamped steel alternative had enough yield to be formed into an intricate shape while providing the required strength. We also conducted a finite element analysis (FEA) to ensure the new design would withstand the various forces that could be involved and ensured it passed all testing with a 2.5x safety factor.

Results:

We created the prototype for the client to test. The prototype bracket took on the production manufacturing and progressive die stamping of the part which measures 7″ long, 3″ wide and 2″ high. The new bracket design, material and manufacturing process proved to be lightweight, high strength and cost-effective

We manufacture over 300,000 brackets a year for delivery across the U.S. Details on our engineering and metal stamping capabilities.

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Engineering & Metal Stamping Project Highlights

Product Name Explosive Canister Mounting Bracket
Product Description Mounting bracket is used to hold a canister that houses inert gas under pressure.
Capabilities Applied/Processes Engineering

·       Existing bracket was made of cast aluminum and was heavy and expensive

·       Our engineers designed a solution from HSLA stamped steel

·       Must pass all testing with a 2.5x safety factor

·       Finite element analysis (FEA) was conducted to be sure the design could withstand the forces involved

Manufacturing

·       Prototype creation for client to test

·       Production manufacturing

·       Stamping (Progressive die was built)

Overall Dimensions Length: 7″
Width: 3″
Height: 2″
Material of Component HSLA Steel

·       Had to be Strong Enough to Withstand Forces

Material Finish Zinc Plated
Benefits Light Weight
High Strength
Cost Savings
Industry for Use Safety Restraint Industry
Volume 300,000/ year
Turn Around Time 16 weeks
Standards Met Customer Supplied Specifications