At Orbitform, 2025 has been a year defined by technical collaboration, performance optimization, and engineering innovation. Whether you’re designing a new product, improving an existing process, or troubleshooting equipment, the challenges manufacturers face are constantly evolving.
This year, our blog series focused on real-world assembly challenges and the solutions we’ve helped engineers develop to overcome them. Below, we’ve grouped our 2025 blogs by key themes, each rooted in supporting engineers with practical tools, design guidance, and process improvements that lead to better assemblies.
Aligning Design and Process for Functional Performance
Strong assemblies start with strong collaboration between engineering and manufacturing. Aligning joint design with the right forming process can make the difference between a product that performs and one that falls short.
Aligning Joint Design and Assembly Processes to Achieve Functional Requirements
This blog dives into how early alignment between engineering and manufacturing teams leads to more reliable assemblies. We highlight how access, joint geometry, and strength requirements all play a role in selecting the right forming method.
The Importance of Part Tolerancing in Part Assembly
Precision starts with tolerances. We walk through real-world scenarios where poor tolerancing created issues downstream and explain how to build tolerancing strategies that support consistent, repeatable assembly outcomes, often validated through testing in Orbitform’s Solutions Lab.
Engineering a Better Fastening Process
Not all fastening methods are created equal. This post helps engineers understand the pros and cons of different permanent assembly processes, like orbital forming, impact riveting, and roller forming, based on part requirements, materials, and production volumes.
Precision and Performance in Critical Assemblies
When you’re working with safety-critical parts or high-performance assemblies, tight tolerances and process control aren’t optional. This year, we focused on helping engineers solve for precision, speed, and real-time feedback.
Improving Assembly Precision with Orbitform’s Servo-Z Programmable Hard Stop Mechanism
For assemblies requiring highly repeatable depth control, Servo-Z gives engineers a programmable, position-based stop that reduces variation and increases part quality.
Meeting Torque Requirements with Pivot Joint Testing Equipment
When rotational resistance matters, in-process torque verification is key. This blog explains how our pivot joint testing equipment helps engineers ensure consistent torque, especially in automotive, medical, and hinge-based applications.
Boosting Speed Without Sacrificing Precision
Need to increase throughput without compromising quality? This blog highlights how servo-driven systems offer the speed and control engineers need for high-volume, precision-critical assembly lines.
Collaborative Assembly Innovation Across Battery, Medical, & Lightweight Industries
From EV battery packs to handheld medical devices, permanent assembly is evolving fast. These blogs explore how Orbitform supports innovation across industries by working directly with engineering teams to test, validate, and scale solutions.
Optimizing Medical Device Assembly Through Collaborative Design and Process Testing
We shared how close collaboration with a medical device OEM helped define a forming process that improved durability, minimized cosmetic defects, and passed rigorous validation testing.
Building Better Battery Packs: Why Permanent Forming Beats Welding and Screws
Battery assembly demands strength, safety, and thermal stability. This blog explores why many engineers are moving away from welds and fasteners in favor of forming processes for EV and power storage applications.
Lighter, Stronger, Smarter: How Orbitform Supports Lightweight Assembly Initiatives
As engineers design lighter, more efficient products, we’re helping them adapt their assembly methods for advanced materials and reduced part weight, without sacrificing structural integrity.
Supporting and Improving Existing Equipment
For many manufacturers, success isn’t about replacing equipment; it’s about getting more from what you already have. This blog is geared toward engineers responsible for troubleshooting, maintaining, and improving existing assembly systems.
Recognizing and Addressing Common Issues on Orbital Forming Machines
This practical guide covers common root causes of forming issues, like tool wear, inconsistent setups, and operator error. We outline how to identify problems early and keep your machine running at peak performance with assistance from our Equipment Support Team.
The Orbitform Experience: What It’s Like to Engineer Equipment With Us
For engineers specifying new equipment, understanding the process from quote to production is key. This year, we shared an inside look at what working with Orbitform really looks like.
Working with Orbitform: Your Partner in Assembly Equipment and Manufacturing Success
From first contact through process development, testing, installation, and beyond, we walk through what to expect when working with our team. Our goal is to be more than an equipment supplier. We aim to be your engineering partner.
Final Thoughts
Across every industry and product line, engineers are facing increasing pressure to deliver assemblies that are faster, lighter, safer, and more reliable. Our goal with this year’s blog content was to support that mission with real, experience-driven solutions.
Whether you’re designing new parts, refining your process, or trying to improve an existing line, we hope these resources have sparked ideas and offered clarity.
Let us know what challenges you're tackling next—we’re here to help.