M.B. Naegle
Diamond
- Joined
- Feb 7, 2011
- Location
- Conroe, TX USA
Our company makes industrial sewing machines for heavy leather applications like saddles, rigging, etc. Our machines were first introduced between 1882 and 1900, and we're still building and supporting them, although in lower numbers. Ours use an awl and a hooked needle to sew as opposed to a needle with an eye such as you would see on a home sewing machine. It's what sets the machines apart from more modern alternatives, but also can lead to issues with economically producing parts. Each machine has a variety of sizes (shank diameter) and a round, diamond, or chisel shaped point for both the needle and the awl.
The needles and awls our machines use have always been made by companies that specialize in them. In recent years though, their minimum quantities have made it hard to stock all but the most popular sizes. So I'm curious about the possibility of bringing part of it in house.
You can Youtube video's about sewing needle manufacturing. It's done by the 1000's involving many steps from drawing, molding, grinding, plating, stamping, etc. Lots of automation. I'm wondering how hard it would be to get into it in much lower numbers however. If we made 50 pieces a day, we'd be good.
Instead of mass producing these things in all the different stages, I'm thinking about grinding all the features from steel rod in a single machine like a 5 axis micro CNC grinding center. I've never worked with such a machine so I'm wondering if such exists, what to expect in machine and tooling costs, control language learning curve, etc. Our CNC experience has been with 3+1 milling and 2 axis turning using Fanuc based G-code or conversational controls.
These needles are often made from plated spring steel, but I'm wondering if pre-hardened stainless could work (skip the plating). The machine would only need a 5/32"x3" work envelope (not counting the tooling or work head). It could perhaps engrave the sizes on the pieces too, or we could have a second op lazer engrave or acid etch it in.
I know the price of these pieces could go up 500% or more, but for the less popular special application sizes, that might not be an issue. It comes down to the cost of meeting a minimum quantity order that leaves us stocked for 200 years, or having them custom made on demand.
The needles and awls our machines use have always been made by companies that specialize in them. In recent years though, their minimum quantities have made it hard to stock all but the most popular sizes. So I'm curious about the possibility of bringing part of it in house.
You can Youtube video's about sewing needle manufacturing. It's done by the 1000's involving many steps from drawing, molding, grinding, plating, stamping, etc. Lots of automation. I'm wondering how hard it would be to get into it in much lower numbers however. If we made 50 pieces a day, we'd be good.
Instead of mass producing these things in all the different stages, I'm thinking about grinding all the features from steel rod in a single machine like a 5 axis micro CNC grinding center. I've never worked with such a machine so I'm wondering if such exists, what to expect in machine and tooling costs, control language learning curve, etc. Our CNC experience has been with 3+1 milling and 2 axis turning using Fanuc based G-code or conversational controls.
These needles are often made from plated spring steel, but I'm wondering if pre-hardened stainless could work (skip the plating). The machine would only need a 5/32"x3" work envelope (not counting the tooling or work head). It could perhaps engrave the sizes on the pieces too, or we could have a second op lazer engrave or acid etch it in.
I know the price of these pieces could go up 500% or more, but for the less popular special application sizes, that might not be an issue. It comes down to the cost of meeting a minimum quantity order that leaves us stocked for 200 years, or having them custom made on demand.