When a leading medical device manufacturer approached Orbitform with a new part design, they were evaluating two potential joining methods: laser welding or orbital forming. The challenge? Determine whether orbital forming could meet their strict strength, cleanliness, and aesthetic requirements, and, if so, refine the part design to achieve the best possible results.
The Challenge
The part required flaring a hollow internal component outward as part of the assembly. The manufacturer’s primary goal was to confirm whether orbital forming could match or exceed the strength of laser welding while delivering a smooth, easy-to-clean, and aesthetically pleasing finish.
In preparation for Phase 1 testing, Orbitform’s engineering team reviewed the part design and suggested two adjustments to optimize the orbital forming process:
Increase material stickout during manufacturing so we could trim it down later to find the optimal forming height.
Add a steeper angle on the internal chamfer of the flared part to improve material flow and prevent swelling into the bore.
These changes set the stage for accurate and meaningful testing in the Solutions Lab.
Our Solutions Lab Approach
Phase 1 – Coupon Testing
We began by running sample coupons in Orbitform’s Solutions Lab that replicated the key forming area of the part (but not the full assembly). This allowed for evaluating aesthetics, forming consistency, and potential material flow issues without committing to full assembly builds.
The manufacturer reviewed the coupons with their end customer, and both were impressed with the look and quality of the formed joint. From there, we moved on to full assembly testing.
Phase 2 – Full Assembly Testing
We then produced eight full assemblies in the Solutions Lab for durability testing. This step allowed the customer to evaluate not just aesthetics, but functional performance and long-term strength.
The Result
While final durability testing is still underway, initial feedback is promising:
The appearance of the formed joint exceeded that of the laser-welded alternative.
Collaboration between our engineers and the customer’s design team led to part geometry changes that made orbital forming more effective and repeatable.
The process provided a clear pathway to production, with both performance and manufacturability in mind.
Why It Matters
This project illustrates how Orbitform’s Solutions Lab helps customers not just test a process, but make informed manufacturing decisions. We work side-by-side with our customers to validate designs, test different processes, and recommend changes that lead to better performance, better manufacturability, and better-looking parts.
Whether you’re evaluating joining methods, troubleshooting an existing design, or looking to improve performance, our Solutions Lab is equipped to help you find the right solution before committing to full-scale production.
Interested in testing your parts in our Solutions Lab?
Let’s collaborate to find the best assembly solution for your application.