Stud Punch Design & Manufacturing in Phoenix
KNOCKOUT PUNCH FOR STEEL METAL FRAMING - 98% EFFICIENCY IMPROVEMENT
PROBLEM
A manufacturing client came to CMF Engineering with a desire for improved efficiency on their stud and c-track roller machine. The area they noticed significant downtime was during the procedure of punching knockouts. Knockouts are designed to allow passageway for electrical wiring, HVAC, plumbing, and other utilities in metal stud framing.
Considering the punch creates a 1½" diameter circle, it was taking them up to 15 punches to make a standard 1½" x 4" knockout. With a programming limitation of 23 holes per stud, they could only achieve one knockout per stud - a major bottleneck in their production process.
SOLUTIONS
CMF's Phoenix engineering team reverse engineered the existing punch attachment and designed an innovative alternative that creates a complete knockout in a single punch operation using the hydraulic ram. Our CAD design services team developed the new punch using existing bolted connections, allowing for seamless installation without machine modifications.
Through a series of prototyping iterations at our Phoenix facility, our engineers determined suitable materials and calculated precise die clearance based on material thickness. The project utilized our complete manufacturing capabilities, from initial design through precision CNC machining of critical components and final custom fabrication and assembly.
Our Phoenix-based team's approach combined engineering analysis with hands-on prototyping to ensure the final product met all performance requirements while maintaining compatibility with existing equipment.
RESULTS
With the new punch tool incorporated, the knockout process now takes an average of 1.4 seconds versus the previous 1.2 minutes per punch - a dramatic improvement in cycle time. With only 1 operation required per punch, the client can now utilize all 23 available punches per stud, maximizing their machine's programming capacity.
This engineering solution achieved remarkable results:
- 98% reduction in punch time (1.2 minutes to 1.4 seconds)
- 50% increase in overall machine throughput
- 23x increase in knockouts per stud (from 1 to 23 possible)
The successful project demonstrates CMF Engineering's problem-solving capabilities and complete Phoenix manufacturing services, from reverse engineering and custom design through precision machining and fabrication - all delivered from our advanced Phoenix facility.
This efficiency improvement transformed the client's production process, showcasing the value of partnering with a Phoenix manufacturing team that combines engineering expertise with hands-on fabrication capabilities.
Need custom tooling or manufacturing efficiency solutions in Phoenix? CMF Engineering specializes in reverse engineering, custom tool design, and precision manufacturing. Our Phoenix-based team delivers complete solutions from concept to production.
Contact CMF Engineering today for your custom manufacturing and engineering needs: (602) 823-7611