Variable Valve Timing Plate

Lap Tech Industries developed a high-precision finishing solution for VVT stamped metal components for Aisin Automotive to solve a severe rusting problem from a Japanese supplier. Lap Tech Industries not only had the expertise and equipment, but also had a solid track record as a reliable partner to the metal stamping industry. The results included 100% rust-free components with no additional quality inspection required along with JIT delivery and a cost-competitive process.

The high cost of gasoline has made fuel-efficiency a top priority for automakers and consumers alike. Variable valve timing (VVT) is an exciting technology that can improve automobile fuel efficiency by up to 8%. While only about 10% of all new cars in the United States currently have VVT technology, it is projected that this could grow to 80% or more in less than five years.

VVT technology is built with high precision steel components. The VVT components for Aisin’s U.S. facility were originally produced in Japan, where they were finished in a single grinding process. Unfortunately, the steel parts experienced severe rusting problems during shipment to the United States and needed to be 100% visually inspected. Lap Tech Industries not only had the expertise and equipment, but also had a solid track record as a reliable partner to the metal stamping industry.

The part specification not only called for tight tolerances for flatness (SPEC) and surface finish (SPEC), but also needed to be finished in the most cost-competitive manner possible. Lap Tech engineers determined that a multi-stage finishing approach would be needed.

The process began with double disk grinding, followed by fine grinding / flat honing, and then finished with brush deburring.

The results were impressive. The plant’s ISO 9001:2015 certified quality process ensures that parts now meet or exceed all specified tolerances. In addition, the efficiency of the finishing process ensured that the parts were highly cost-competitive.

Lap Tech can deliver the high quality and low cost demanded by the global automotive market. Our close partnerships with metal stamping companies enable us to deliver complete solutions to customers.

World-Class Ceramic Parts for Faucets

A major international corporation approached Lap Tech to provide finishing services for ceramic components used in leading brands of washerless faucets. These components needed to meet stringent quality targets for both flatness and surface finish in order for faucets to operate trouble-free for many years. In addition to meeting the quality standards, Lap Tech was able to reduce inventory costs for the client and provide 100% on-time delivery.

A major international corporation approached Lap Tech to provide finishing services for ceramic components used in leading brands of washerless faucets. These components needed to meet stringent quality targets for both flatness and surface finish in order for faucets to operate trouble-free for many years.

Lap Tech analyzed the component-specific ceramic material, size, shape and required dimensions. They identified the key challenge of achieving the critical surface finish without imparting stresses that could cause micro fractures in the ceramic. A custom-made part carrier was developed for use in the fine grinding machine.

The customer then decided to switch the parts back to Lap Tech, which developed into several production innovations that further increased production speeds and reduced costs without hurting quality. In addition, Lap Tech established a JIT stocking program at their facility in Lake Wylie, South Carolina, in order to provide 100% on-time delivery and reduce the customer’s inventory cost.

Lap Tech has the experience and manufacturing capability to compete effectively in the global marketplace. We work closely with our customers, both large and small, as a world-class supplier supporting their success.

Ink Jet Cartridges

Lap Tech Industries was approached by the leading international supplier of heat sinks for ink jet cartridges. This company needed a supplier that could produce large quantities of heat sinks, but still maintain sub-micron tolerances for parallelism, flatness and thickness. Lap Tech engineers used their decades of finishing experience to develop a process which combined fine grinding and flat honing to achieve and exceed all key tolerances.

Ink jet printers can be found in nearly every home and office. These devices, which revolutionized, desktop printing, rely on disposable cartridges to dispense ink in a highly-controlled manner. These cartridges generate a significant amount of heat which must be dissipated in order to ensure problem-free operations.

Lap Tech Industries was approached by the leading international supplier of heat sinks for ink jet cartridges. This company needed a supplier that could produce large quantities of heat sinks, but still maintain sub-micron tolerances for parallelism, flatness and thickness.

The challenge was especially difficult because the heat sinks are made of ceramic, but are very thin. This made the parts prone to micro-fractures or even breaking if the finishing process produced too much stress.

Lap Tech engineers used their decades of finishing experience to develop a process which combined fine grinding / flat honing to achieve and exceed all key tolerances. Custom part carriers were constructed to ensure that each component was held firmly in place throughout the process, providing the stability needed to avoid stress on the parts. In addition, the proper oils where selected to lubricate the parts
during the finishing process, while minimizing absorption by the ceramic’s porous surface.

Do you have demanding, high-volume finishing requirements for your electronics application? Call Lap Tech and let us deliver the right solution at the right price.

Power Steering Component

The reliability of automobile power steering systems is dependent in large part on small, but critical components that must be extremely flat and also have precisely parallel top and bottom surfaces. Even small variations or defects can lead to a failure of the entire system. One of the largest power steering system suppliers in the world faced a severe problem when a finishing company was consistently unable to produce parts to the required tolerance. Lap Tech was able to finish every part within a much tighter tolerance than the specified 2.0 CPK tolerance.

The reliability of automobile power steering systems is dependent in large part on small, but critical components. Such components must not only be extremely flat, but also have precisely parallel top and bottom surfaces. Even small variations or defects can lead to a failure of the entire system.

One of the largest power steering system suppliers in the world faced a severe problem when a finishing company was consistently unable to produce parts to the required tolerance. In fact, the problems became so frequent and expensive that the finishing company went out of business.

Lap Tech Industries was asked to step in and solve the problem. Lap Tech evaluated the requirements for the steel parts and determined that fine grinding / flat honing combined with brush deburring could not only provide the needed quality, but also higher throughput.

If you have problems with a high tolerance part, let Lap Tech provide the solution!

Diesel Fuel Injectors

A leading producer of heavy equipment and a major supplier of diesel motors produced the critical valve seat and plate components for diesel fuel injectors in house. The company’s grinding method was only able to process a single part at a time, yielding only 150 parts per hour. The company turned to Lap Tech Industries to find a more efficient finishing method for the components. The increased efficiency exceeded all expectations. Lap Tech was able to finish 1,500 parts per hour – an 800% improvement!

The transportation industry faces strict control on diesel particulate emissions. New diesel vehicles now have to meet a near-zero particulate standard that is among the toughest in the world. These strict regulations are a key reason for the growing use of diesel fuel injectors.

A leading producer of heavy equipment and a major supplier of diesel motors produced the critical valve seat and plate components in house. The companys grinding method was only able to process a single part at a time, yielding only 150 parts per hour.

The company turned to Lap Tech Industries to find a more efficient finishing method for the components. Lap Tech carefully reviewed the specifications and determined that batch procession of the steel components was possible, using a combination of fine grinding / flat honing and brush deburring.

The increased efficiency exceeded all expectations. Lap Tech was able to finish 1,500 parts per hour – an 800% improvement!

These components operate under extreme pressure up to several thousand PSA. The parts therefore have sub-micron specifications for flatness, parallelism and thickness, as well as a zero-burr requirement for holes as small as 1 mm. Lap Techs finishing process met and even exceeded all of these requirements.

Lap Tech is a trusted supplier to the most demanding transportation equipment manufacturers. Let us find a way to lower the cost and improve the quality of your vehicle components.