Precision stamping and forming allow producing these flashlight parts in line.

The Problem:
This part was produced off-line because the tight bending tolerances needed constant tool tweaking. The parts were delivered to a large vibratory bowl attached to the flashlight manufacturing cell. The bends are critical because the 90 degree tabs are pressed into the plastic flashlight body. Less than a one degree deviation caused the tab to fold, resulting in the process being shut down.

The Solution: 
The high velocity Bullet Press technology makes precision forming easier because most of the spring back, common in conventional stamping, is eliminated. The precision 90 degree tabs were now possible. This coupled with the improved tool life allowed the stamping / forming process to be integrated directly into the flashlight assembly machine eliminating the very large vibratory bowl, operators, and off line press operations.