A full line of customizable flange shaft collars that incorporate an integral clamp, maintain their perpendicularity, and are easy to adjust has been introduced by Stafford Manufacturing Corp. of Wilmington, MA.
A broad line of mechanical components for use as stops, spacers, shaft connectors, and versatile mounting devices in warehouse automation systems has been introduced by Stafford Manufacturing Corp. of Wilmington, MA.
A wide range of standard and custom shaft collars, couplings, and mounting devices that are suited for use in robotic systems and equipment have been introduced by Stafford Manufacturing Corp. of Wilmington, MA.
For OEM applications, standard shaft components may not always be the best fit. Standard options may have long lead times or not be available in the right size, material, or coating. To solve this challenge, OEMs often turn to customized solutions.
As a precision OEM supplier, Stafford Manufacturing specializes in quality products that meet your unique application requirements. Our custom-designed shaft components help OEMs obtain all of the features they need, without having to compromise on performance.
The Advantages of Customized Shaft Components
Customized shaft components offer numerous benefits to OEMs compared to standard options. These include:
Enhanced performance. OEMs have specific dimension, tolerance, and performance requirements. Custom-designed shaft collars and couplings are tailored to your exact needs to improve your product’s overall efficiency, durability, and accuracy.
Cost savings. Custom shaft component designs are optimized to minimize waste, reduce assembly time, and lower costs overall.
Improved reliability. Since custom components match your specific requirements, they operate seamlessly with your system’s other elements, reducing the risk of failure and extending system longevity.
Reduced time-to-market. Customization streamlines the development process, improves manufacturability, and accelerates your product launch.
The Stafford Manufacturing Advantage for OEM Parts
Stafford Manufacturing has been a trusted source for fast and affordable OEM parts since 1975. We meet demanding industry needs with custom products that match your specifications and standards. Whether you need to design a new component from scratch or modify a standard product, Stafford has the experience and resources to deliver your finished parts quickly and easily.
Standard Component Modification
While we offer an extensive catalog of standard parts, these options may not be an ideal fit. If you’ve found a product that is similar to your needs, our team can easily modify it to match your specifications. Some of the most common modifications we make to standard components include:
Flange modifications
Custom configurations for shaft-extenders and couplings
Modified bores
Modified outside diameters
Fully Customized Components
In addition to component modification capabilities, Stafford offers completely customized shaft components that adhere to your unique specifications. This allows customers to find a component that fits their exact application.
Wide Variety of Materials
We work with an extensive variety of materials to create durable products capable of withstanding any environmental challenge. Some of the most common materials we work with include:
Alloy steels
Aluminum, with anodizing in bright colors
Brass
Bronze
Delrin
High-temp alloys
Nylon
Stainless alloys
Titanium
Surface Treatments
Surface treatments improve product performance, durability, and appearance. We offer:
Anodizing
Hardening
Laser etching
Painting
Plating
The Benefits of Choosing Stafford
Stafford Manufacturing is your one-stop shop for quality, custom shaft components. Our team has decades of experience supporting the OEM industry, and we work closely with customers to develop a product that matches all of your project requirements. When you partner with us for your custom shaft component needs, you’ll gain access to the following benefits:
Expert design and prototyping. Our engineers collaborate closely with your team to create customized designs and prototypes.
Quality manufacturing and testing. We implement rigorous quality control and testing procedures to ensure the highest standards. We also offer 3D models for proof-of-concept testing.
Fast turnaround and flexibility. Whether you only need one component or large production quantities, Stafford works quickly to transform your idea into an expertly manufactured product. We answer RFQs in 24 hours or less.
Quality you can trust. We pride ourselves on exceeding customer expectations. As an ISO 9001:2015 certified business, we deliver exceptional quality products that match your specifications.
OEM Applications for Custom Shaft Components
Our customized shaft collars and couplings solve a variety of challenges, including compatibility issues with conveyor components, packaging systems, and mechanical drives. They can be used in a variety of consumer and industrial OEM applications, such as:
Assembly
Automation
Renewable energy
Pumps & fluid power
Linear motion
Packaging
Food processing
Medical Devices
Material handling
Motion control
Contact Us for Custom Shaft Collars & Couplings for Your OEM Needs
Custom-designed shaft collars and couplings allow OEMs to overcome application-specific challenges while meeting their production timeline goals. At Stafford Manufacturing, we offer all the resources you need to bring your design idea to life, quickly and affordably. Review our full custom manufacturing capabilities on our website or view our product catalog to learn more about how we can assist you. To get your next project started, contact us or request a quote today.
Stafford offers several types of general precision products including both machined components and sheet metal components and enclosures. A wide variety of options are available and can be custom designed to meet your unique applications.
Machined components. Machined components are created using various precision machining processes, such as CNC milling, waterjet cutting, laser engraving, welding, CNC turning, and more. Machined components are used throughout demanding industries that require extremely tight tolerances and high part-to-part repeatability.
Sheet metal components. Sheet metal components are produced using techniques like bending, cutting, punching, welding, and more. Whether your application requires simple parts, mated assemblies, or full enclosures, Stafford’s sheet metal fabrication meets your exact requirements .
Enclosures. Off-the-shelf enclosures can be modified with processes like laser cutting, MIG/TIG welding, robotic welding, and more. Many industries like biomedicine and aerospace rely on fabricated enclosures to protect sensitive components.
Applications
Our machined and sheet metal components are used in countless industries, especially those requiring highly accurate and repeatable parts. Depending on the particular industry, general precision products can be either simple or complex and can be made in a variety of sizes and shapes to fit different needs.
Examples of industries that rely on general precision products from Stafford Manufacturing include:
Aerospace
Biomedicine
Construction
Mining
Pulp & Paper
Medical
Optical
Automation
Capabilities: Stafford Manufacturing
At Stafford Manufacturing, our general precision capabilities include a range of machining and sheet metal fabrication processes. We can produce components in various sizes, shapes, and complexities to meet the needs of diverse industries.
Our precision machining capabilities include:
CNC Milling
CNC Turn Mill
CNC Turning
CNC Bar-Fed Lathes
Waterjet Cutting
Laser Engraving
Welding
3D Prototyping
Prototyping Machining
Our sheet metal fabrication capabilities include:
Bending
Cutting
Laser Etching
Punching
Welding
Hardware Insertion
Additionally, we deliver a range of secondary processes, including painting, plating, assembly, silk-screening, and more.
Finished Products for Complete Applications
Many advanced industries rely on precision products for various applications. At Stafford Manufacturing, we have the capabilities to deliver high-quality, accurate products using various machining and sheet metal fabrication techniques. Through our expertise and extensive capabilities, we can deliver the components you need with the utmost precision and repeatability.
For more information about our general precision products and other capabilities, contact us or request a quote today.
Since 1975, Stafford Manufacturing Corp. has been a leading manufacturer and distributor of shaft collars, rigid shaft couplings, and specialty mechanical components. Our products are used for industrial, consumer, OEM, and MRO applications, including automation, power transmission, motion control, and many others. We have unique expertise in designing components with non-standard materials that meet the needs of unique or challenging applications. Some of the non-standard metals we work with include:
Titanium
Nylon
Bronze
Brass
Delrin
High Temp Alloys
Titanium
Titanium is a natural element with the highest strength-to-density ratio of any metal and a tensile strength ranging from 30,000 psi to 200,000 psi. This low-density, strong, and lightweight material exhibits a high melting point, low heat-induced dimensional change, good heat transfer, and high electrical resistance. Titanium is commonly used for airplanes, missiles, rockets, and various other applications such as springs and medical manufacturing due to its excellent elasticity, non-toxicity, and biocompatibility.
Nylon
Nylon has high abrasion resistance, good thermal resistance, high machinability, good fatigue resistance, and noise dampening capabilities. The different nylon grades include 66, 11, 12, 46, and 6, which are named for the length of their polymeric chains. Key benefits of nylon include low internal stresses, lower water absorption, more crystalline structure equating to higher mechanical strength, and a higher melting temperature.
Bronze
This copper and tin alloy is brittle, highly ductile, has low friction, doesn’t produce sparks when struck, expands as it hardens from liquid to solid, and produces a colored patina as it oxidizes. It is used in architectural structures and design elements as well as coins, bearings, electrical contacts, ship propellers, and shaft collars. Bronze can also be made into wool, avoiding some of the problems that steel wool presents, such as rust, broken filaments, and magnetic characteristics that can affect equipment.
Brass
This gold-colored copper and zinc alloy has excellent electrical conductivity, good machinability, and low friction. It is commonly used in architecture and manufacturing of gears, locks, pipe fittings, and musical instruments. There are many subtypes and finishes available, including electroplating, powder coating, painting, and polishing. Tolerances are +/- 125 μm (standard), as well as +/-100 μm and +/- 50 μm (achievable).
Delrin
Delrin is a plastic alternative to metal that offers good dimensional stability, excellent machinability, and high fatigue endurance. Natural-grade Delrin is NSF, FDA, and USDA compliant.
Other qualities include:
Tensile strength of 6,000-22,000 psi
Impact strength of .75-2 ft-lb/in.
Heat deflection of 180-300ºF
Chemical resistance to fuels and solvents
Low moisture absorption
Good wear and abrasion properties
Superior impact and creep resistance
High strength and stiffness properties
Common components made from Delrin include gears, bearings, bushings, shaft collars, rollers, fittings, and electrical insulator parts.
High-Temperature Alloys
High-temperature alloys are a mixture of at least one metal and another element that can withstand temperatures above 500º C. High-temperature alloys are used extensively in the military, medical, aerospace, and electronics industries. The alloys were designed for use in conveyors, furnaces, ovens, and oil and gas applications. They are costly and difficult to machine and shape. However, they are necessary for certain conditions. Stafford offers high-temperature alloy shaft collars in one piece, two piece, hinged, and flanged designs.
Specialty Mechanical Components from Stafford Manufacturing Corp.
Stafford Manufacturing Corp. is a leading manufacturer specializing in custom-manufactured shaft collars and rigid couplings in non-standard materials. To learn more about our products, please visit our product overview page. For pricing, please request a quote.
Selecting the right welding process requires consideration of many important factors, such as:
Joint analysis Determining the size, position, and thickness of the base metal must be done to understand if the needs of the joint are fast-fill, fast-freeze, fast-follow, or penetration.
Type of materials Different types of materials call for the use of particular welding processes. While MIG and TIG welding works for copper, other welding types may not suit the material.
Structure of parts Checking base-metal conditions and arc visibility helps to decide the appropriate welding technique. Knowing the fixturing of equipment can also lend a hand in choosing the appropriate method.
Application If a welding process does not fit the weld specifications necessary to provide the desired weld properties, it should not be used. Additionally, availability and cost of equipment should be taken into consideration.
Volume of parts to be welded Because so many welding types rely on high-cost equipment, the volume of parts to be welded should be examined alongside the amount of productivity or work and expertise necessary.
Welding Equipment
Welding requires a checklist of basic equipment, namely:
Welding machines Each welding method has its own specialized machinery.
Consumables Used for welding the base materials, consumables such as electrodes, fillers, and flux play an essential role in the welding process. The specific type selected for a job depends on the base materials.
Safety equipment Since welding involves working in close proximity to high electrical currents, noise levels, and temperatures, welder safety should remain a paramount concern. Personal protective equipment such as welding helmets, shields, goggles, gloves, earplugs, and fire-resistant overalls often prove essential in ensuring welder safety.
Materials We Can Weld
Steel, especially alloys of mild steel, is a popular choice for manufacturing weldable parts with high strength and low costs. We commonly weld the following steels:
AISI 1018 steel A low carbon steel, this material is considered the best choice for manufacturing carburized parts because of its malleability and weldability, while still maintaining strength and toughness.
1215 steel This mild steel suits parts requiring machining and case hardening.
C1026 steel Its chemical composition resembles 1215 steel, except that this material has more carbon and lower machinability than 1215 steel.
316 stainless steel As a marine-grade, corrosion-resistant steel, this material sees wide use by the food processing industry since it performs well at high temperatures.
We recommend the above metals because they don’t contain lead. While the cost-effectiveness of some other steels may be appealing, welding these alloys can produce toxic fumes welders may inhale during welding processes. Plating materials like zinc or chrome may produce the same noxious results. Sulphur, which improves machining in some stainless steel, does not have strong weldability.
Welding at Stafford Manufacturing
Stafford Manufacturing Corp. manufactures a variety of mechanical parts such as coupling adapters, rigid couplings, and shaft collars used in clamping, motion control, mounting, and power transmission applications. With good welds, these parts can work reliably for their lifetime and help to ensure the safety of the people who depend on them. We prioritize quality in all of our parts and services, and we can provide standard parts with excellent weldability or create custom parts with the right weldability required for specific applications.
Please contact us with your questions about the weldability of our products and how they are suitable for your applications.
Once you’ve decided to design and build a custom part to suit the unique specifications of your application, figuring out where to begin can be overwhelming. There are several factors you need to consider, such as:
Construction materials
Finishes
Tolerances
Manufacturing operations
The following article will walk you through some of the key considerations to keep in mind when partnering with a third-party custom manufacturer to design and develop a custom part.
Product Specifications Checklist
When you’re making decisions about your custom part, it may be helpful to have a checklist of specifications to consider. Here are a few of the things you’ll need to decide on:
Product type. What product do you need? Is it an adapter, collar, mounting, coupling, or something else?
Product style. How should the part be built? Should it have solid, split, or mixed construction?
Construction material and grade. What type of material and grade will be used for construction? Is it aluminum, nylon, brass, weldable metal, or an alternative material?
Product finish. How will the part be finished? Will it feature a plain, plated, standard black, or custom finish?
Product size. What are the requirements and restrictions on part size? Are there specific internal and/or external dimensions that must be met?
Production quantity. How many parts do you need? Is there a minimum quantity or range required, and are you making a single or blanket order?
Production timeline. What is your expected timeline for product delivery? Do you have a specific lead time in mind, and does your manufacturing partner offer options for expedited or emergency part shipment?
Additional Steps to Consider
Once you’ve determined the above part requirements, it may be helpful to download 2D and 3D CAD drawings in your desired format and generate product prototypes. You can then shop around to compare manufacturing costs and test your product design with customers.
Quick and Quality Custom Parts From Stafford Manufacturing
Manufacturing companies generally turn to third-party manufacturers for custom parts when they need the part quickly and cannot dedicate the time to produce the part themselves. This issue frequently arises when they have a major project release on the horizon and need to meet tight deadlines. By reallocating excess part or product orders to a third-party manufacturer, they can fulfill production obligations.
At Stafford Manufacturing, our expert team can take your product concept—whether it’s a print, sketch, or brief description—and turn it into a completed product. We specialize in custom orders, producing more specialties than standard products. Within 24 hours or less, we will respond to your request for a quote. Regardless of whether you need a single part or thousands of pieces, we can serve as your “in-house” machine shop.
By partnering with us for your custom part needs, you benefit from our industry-leading:
For years, we have supplied high-quality standard and custom products to thousands of customers. Our ISO 9001:2015 certification demonstrates our dedication to customer satisfaction and constant, ongoing improvement.
We are similarly committed to providing a high level of service to customers. Our parts are generally in stock and available for same-day shipment. If you want to speak to someone, our toll-free number is always staffed by friendly professionals who are ready to help. You’ll never need to listen to an automated message or wait for someone to call you back.
If you require assistance, we can match our lineup with your needs and work with you throughout the entire production process to ensure that you’re getting exactly what you want.
We keep our prices fair and competitive without skimping on value and always deliver on our promises.
Whether you need to alter a standard product or create a part from scratch, our experts have the experience and equipment necessary to provide you with a finished part that meets your needs in your specified budget and timeline. If you’d like to learn more about partnering with a custom manufacturer to design and develop a custom part, download our eBook, “Key Questions to Ask Your Custom Manufacturer.”
