Engineering and DFM Solutions for 3D Scanning Tool Backplate in Oil & Gas Pipelines
Overview
CSG recently partnered with a client in the Oil & Gas industry to develop a backplate for electronics and a camera for a 3D scanning tool designed to detect pipeline damage. The client encountered significant delays due to multiple design changes, which affected their product launch timeline. CSG stepped in to provide engineering assistance and Design for Manufacturing (DFM) options to optimize the process and facilitate a successful launch.
Our Features
The Challenge:
The client’s 3D scanning tool, critical for detecting damage in pipelines, required a precision-machined backplate that could house sensitive electronics and camera systems. With the product facing multiple design changes, the client was experiencing delays and cost escalations. The backplate needed to meet tight tolerances, be durable enough for oil and gas environments, and integrate seamlessly into the larger tool assembly.
Some of the specific challenges included:
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Frequent design revisions that disrupted the manufacturing schedule.
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Ensuring tight tolerances for the 6061 T6 Aluminum backplate, crucial for the accuracy of the 3D scanning tool.
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Balancing the need for structural integrity with cost-effective production methods.
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Managing complex manufacturing processes, such as milling, drilling, and tapping.
Our Solution:
CSG's engineering team took a proactive approach by engaging early in the development process, offering comprehensive Design for Manufacturing (DFM) options, helping to identify design choices that can reduce manufacturing complexity, cost, and lead time while ensuring product quality.
Key Steps Taken:
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Engineering Assistance: CSG’s experts collaborated with the client’s design team to understand the technical requirements and constraints. They provided insights into how certain design elements could be modified without compromising performance, thereby facilitating easier and more cost-effective manufacturing.
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Material Selection: CSG guided the client in selecting materials that provided both durability and cost efficiency. The choice of materials had to consider the corrosive environments pipelines often face, while ensuring the backplate’s structural integrity remained uncompromised.
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Design Optimization: Through DFM principles, CSG suggested design tweaks that simplified assembly and reduced the number of required manufacturing processes. This involved:
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Streamlining the backplate design for easier machining and assembly.
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Reducing unnecessary complexity in the shape and structure.
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Ensuring consistency in part tolerances for repeatable manufacturing.
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Process Development: CSG leveraged its advanced CNC machining capabilities to refine the manufacturing processes, ensuring high precision while reducing turnaround time. They also incorporated efficient quality control measures to ensure every backplate met the required standards for reliability in oil and gas pipeline inspections.
The Results:
Thanks to CSG’s engineering and DFM solutions, the client successfully launched their new 3D scanning tool product line. The backplate design was optimized for manufacturing, reducing production costs, improving assembly time, and maintaining high quality. CSG’s involvement in the design process not only shortened the client’s time to market but also allowed for smoother transitions between design revisions and production.
This project exemplifies how CSG’s expertise in engineering and manufacturing can turn complex challenges into streamlined solutions. By integrating DFM principles early in the development process, CSG helps clients optimize their designs, reduce manufacturing risks, and launch innovative products with confidence.
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At CSG, we specialize in delivering innovative solutions across a wide range of industries. From automotive fastening and engineered fastening systems to CNC machining, assembly, and kitting, we are equipped to handle complex manufacturing challenges. Whether you're in need of precision machining, custom fasteners, or full assembly services, our team of experts is ready to collaborate on your next project.
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