Manufacturing Engineering

 

Utilizing the correct balance of design, materials, and processes is critical in achieving the required quality and cost of a finished product. Barber-Nichols’ team of Manufacturing Engineers have extensive experience taking new designs into production. We will incorporate our industry leading knowledge and expertise into a Design for Manufacturing project tailored to your budget and schedule.

Barber-Nichols takes an iterative approach to manufacturing engineering, with level of effort driven by cost, quality, and risk mitigation.

Design for Manufacturing Process Map
Design for Manufacturing Process Map

6 kW High-Inertia Turbine Generator for Uninterruptable Power System
  • These turbine generators were used in telecommunication applications to maintain power in the event of grid failure. Numerous units were to be built, which offered cost savings opportunities.
  • The turbine wheel, the most complex component to manufacture, achieved near net-shape from a metal injection molding process. This reduced component cost and manufacturing time by several orders of magnitude for the turbine wheel, resulting in a notable cost reduction of the full assembly.
Manufacturing Engineering Turbine Generator
6 kW High Inertia Turbine Generator
Supercomputer Cooling Fans
  • A supercomputer cooling application required many high-performance fans in order to extract the heat generated by the processor cores.
  • Precision airfoils and flow path required to achieve low noise and power efficiency
  • Injection molded plastic parts were selected to reduce cost, production time, and weight while maintaining close tolerances needed for efficient operation
Manufacturing Engineering Computer Cooling Fans
Supercomputer Cooling Fans
Hydrogen Fuel Cell – Anode Gas Blowers
  • First models were fully machined from stainless steel and aluminum
  • The motor controller enclosure was replaced with a drawn aluminum can
  • Impeller housing and diffuser, complex shapes requiring 5-axis milling, were replaced with castings
  • A carbon-filled plastic stator can was used. This can isolates the motor from the process gas and water condensate typically found in fuel cell anode gas. The use of carbon-filled plastic also provides zero eddy current losses.
Manufacturing Engineering Fuel Cell Compressors
Fuel Cell Compressors
Electro-Chemically Machined Turbine Blades
  • Barber-Nichols machining expertise includes electro-chemical machining (ECM), a net-shape process.
  • Turbine design not constrained to milling tool sizes and deflection
  • Accurate reproduction of turbine blade shapes and other fine features with tight spacing
  • No wear of the machine tool

Manufacturing Engineering Turbine Blades

Turbine Blades