A manufacturer of a smokeless cigarette device was having difficulty with getting a consistent product from an overseas supplier. There was lack of consistency with the flange flatness that had a tolerance of +/- .001. In addition, there was excessive color variation with the anodize process. The flange not being flat was causing excessive downtime and failures in the foil seal process that the customer was performing. Demsey Manufacturing Co., Inc was able to design a tool that maintained the customer requirement, thus improving throughput and reducing the overall cost of the product.
The anodizing process was important as the particular type of product that was being sold was identified by a specific color. Cost was of concern so a rack process was unable to be performed. Demsey along with their finishing partner was able to come up with a process that would not damage the part and would produce a consistent color while being cost competitive.

Product NameDisposable Pod Cups
Product Description These deep drawn cups are used to hold tobacco and non tobacco products.
Capabilities & Applied/ProcessesTool Design & Manufacturing
Deep Drawn Stamping
Improved Customers Assembly Operation
Anodized in different colors for identification
Improved Product Performance
Equipment Used to Manufacture Part10-12 Waterbury Farrel with Special Attachment
Overall Part Dimensions Material Thickness: .012"
Width: .350"
Height: .395"
Width: .678 | .925 | 1.185

Height: .600 | .600 | .725
Tightest Tolerances ±.001"
Material Used3005 Aluminum
In Process Testing/Inspection PerformedFlange Flatness, Uniform Specific Anodize Colors
Estimated Part Weight0.00045 pounds
Industry for UseSmokeless Cigarette
Volume1,500,000 Pieces Per Year
Standards Met Customer supplied print, 2D CAD Drawing
ISO 9001:2008
Delivery Time10 Weeks
Delivery LocationU.S.A.