Powder coating produces a durable, smooth, and appealing finish for part surfaces and equipment. It is one of many industrial coating methods commonly used by manufacturers to increase the sturdiness and longevity of their manufactured components. While all coating techniques have advantages, powder coating is more effective and favorable in many cases.

This article will dive into what sets powder coating apart from other coating techniques and when to apply it to your project.

Industrial Coating Best Applications

Materials able to withstand 400 °F can be powder coated, including thermoplastics or thermosets. This is one of the reasons manufacturers prefer this method over others.

Powder coating offers the following advantages:

Defense Against Moisture

Powder coating can protect against many environmental stressors, including moisture. It reduces the likelihood of rust and corrosion by keeping moisture from penetrating your metal equipment. Powder coating is the best option for manufacturers who want their equipment to be completely protected.

Fast Application

Liquid finishes such as paint require time to dry and set. This is a significant con for many companies looking to expedite their operations to increase product turnout and revenue. Thus, quickly applying the coating is one of the main advantages of selecting powder coating. This technique also allows easy reapplication to cover spots missed during the first coating layer.

Eco-Friendliness

Several industrial coating types call for using chemicals and solvents that require strict disposal methods to prevent environmental harm. Violating these protocols can result in fees and legal problems for manufacturers. Meanwhile, powder coating is environmentally friendly, allowing businesses to adhere to EPA rules without hassle.

Moreover, powder coatings generate substantially less waste than traditional liquid coatings and hydrographic printing techniques.

Other Industrial Coating Options and Their Applications

Before selecting powder coating for your project, it is crucial to first understand the other types of industrial coatings and how they differ. This will allow you to acknowledge the pros and cons of powder coating and asses how suitable it is for your application.

Painting

Paint coatings are cheaper upfront than powder coating, making them the practical choice for low-volume and non-intricate applications. However, this technique doesn’t offer the durability of powder coating, so it may still cost more money to tend to repairs in the future.

Thermal Spraying

Paint and powder coating are effectively combined in the thermal spray method. When a type of paint is sprayed, a heat source and high-pressure applicator help the paint adhere to the part more effectively. Metals and plastics can both be treated using thermal spray.

Anodizing

In the anodizing process, the aluminum surface is made to oxidize quickly rather than being coated with another substance. The process thickens the metal’s protective natural oxide layer and prevents damage to the core.

Hot Dip Galvanizing

In hot dip galvanizing, the process requires a vessel filled with molten zinc wherein iron or steel will be dipped. Some iron and steel components — such as exposed steel nuts and bolts — can be given a protective layer of zinc, which resists rust and corrosion better than paint or powder coating. However, this may not be the ideal process for large-volume projects.

Phosphating

A comparable substitute for galvanizing is phosphorating. Here, metal components are submerged in an acid bath with metals dissolved in them. The acid encourages the dissolved metals to cling to the part and form a shielding layer.

Farris Group: Your Trusted Partner for All Industrial Powder Coating Needs

With over 40 years of precision fabrication experience under our belt, we at Farris Group offer start-to-finish contract manufacturing services that exceed customer expectations. We provide industrial powder coating solutions alongside our fabrication, machining, and prototyping services.

Contact us to request a consultation or to learn more about our industrial coating services.

Kitting, or the bundling of separate goods or materials into one package, comes in multiple forms. Subscription boxes, for example, utilize kitting to pull together multiple products that then sell in a single package. In manufacturing, kitting refers to a company grouping a collection of items, parts, or materials into one unit, or kit, with its own individual stock-keeping unit (SKU) number. That company then delivers the bundled components to their point of use for assembly prior to final sale.

Material kitting, as this process is commonly known, saves OEMs both time and money because it effectively consolidates shipments of several items that they can now ship as one package. This, in turn, helps with the following:

• Streamlining processes for added efficiency
• Reducing labor costs and fulfillment fees
• Increasing output
• Controlling quality
• Managing inventory and warehousing
• Expediting shipments

Learn more about the various ways in which kitting is advantageous in different sections of the manufacturing industry.

Kitting Improves the Manufacturing Process

For manufacturers, kitting is more than just a cost-reduction strategy; it can actually speed up the manufacturing process. This procedure decreases the overall processing and material handling time by reducing the number of stops in the production line and eliminating touch points. Also, kitting minimizes the risk of error and boosts efficiency as the worker responsible for a product’s assembly has all of the parts at hand that are necessary for the task. By consolidating to reduce the number of individual deliveries, this also helps manufacturers streamline their distribution processes.

Kitting Saves Warehouse Space

Warehousing costs are tied to how much space a product occupies in a facility. Storing a single kit takes up less space compared to storing several products separately, allowing warehouses to optimize their functional facility and shelf space and saving the manufacturers money. As bundled components with a single SKU can be shipped as one item, the predetermined nature of a kit’s contents simplifies calculations on cost predictions. Kitting also makes it easier for warehouse employees to monitor inventory levels because they only have to keep track of one unit rather than several, and workers can carry out kitting ahead of time, meaning that they can effectively get a jump on order fulfillment for greater operational efficiency.

Kitting Helps Manage Inventory

Kitting as an inventory technique allows manufacturers to bundle products and, in doing so, improve their flexibility. Like in warehousing applications, manufacturers can more easily track their inventory, especially if they employ software inventory control. Kitting reduces the number of items in stock, which reduces the SKU numbers in the system. Keeping accurate inventory allows companies to avoid stockouts or backorders and helps to streamline the supply chain, all while reducing labor costs. This method also presents a unique opportunity for manufacturers to increase their product sales. Rather than purchasing a single item, kitting encourages customers to instead purchase a grouping of related products as one unit.

Kitting and Assembly Services at Farris Group

Ultimately, kitting is beneficial for both businesses and consumers. Businesses can control shipment quality, manage their inventory and warehousing capacity, and save on labor and production costs. Consumers will receive all of their desired components in a single shipment for a positive interaction with your organization.

At Farris Group, we are dedicated to offering our customers comprehensive services from quality assurance inspections to assembly and distribution to simplify your installation procedures. We will deliver all of the high-quality parts you need, on time and intact, to enhance operational productivity and reduce costs. Contact us today for more information about our range of kitting solutions and assembly services to support your business.

Before manufacturing a product and bringing it to market, there are multiple steps to take to ensure that it will be a success. After coming up with a concept and completing the first designs on paper, making an initial model, or prototype, will allow manufacturers the chance to evaluate their product idea and make any necessary improvements before placing it into full production. It is important to confirm that the final product will be capable of its expected functionality and to address any concerns prior to manufacturing, when any errors would be costly and time-consuming to fix.

While the prototyping process can be straightforward, a linear journey from concept and prototype to production, the process often requires going back to the design or even product ideation stages with multiple rounds of prototype creation as manufacturers identify unexpected problems. Companies that offer prototyping services can help guide you through the various steps of prototype production, determining solutions, redesigning to accommodate new data, and making suggestions for optimizing your model.

Conceptualizing the Product Idea

New inventions and products all stem from a single first step: the idea. This is often the most challenging part as you not only have to come up with a concept, but you must also figure out how to make it a reality, designing it and manufacturing it with future customers in mind.

Much planning and innovative thought go into idea execution prior to production. You must thoroughly research and consider:

• Any existing competition in the market
• Target audience
• Market value
• Budget versus overall cost of the project
• Manufacturing options

To be successful, the goal of a new project should typically be to solve a problem that many people face. Brainstorm with your design team to figure out what your customers need, how they will use your product, and how it will compare to the competition. Then you can use that information to decide if your product will have a favorable position in the market and be worth manufacturing.

Designing the Prototype

Now that you have a viable concept in mind, you can proceed with designing the product. Begin with a simple drawing or an outline of attributes that you wish for your product’s design to include. Once you have a clear vision for your product, you can then digitize the model with computer-aided design (CAD) software or create a 3D replica of the product. If your computerized model works well in theory and meets all aesthetic requirements, you can move on to producing a physical prototype.

Creating and Testing the Prototype

Creating a working prototype may be the longest part of the prototyping process. Trial and error, adjusting measurements and attributes, and gathering the necessary materials and funds to produce the parts that the project requires may take some time.

Consider how the materials you choose may affect your product. For example, thermoplastic prototypes are a common choice for enhancing function, durability, and stability. Prototyping material options include:

• Metal
• Acrylic
• Acrylonitrile butadiene styrene (ABS)
• Polycarbonate
• Polyphenyl sulfone
• Nylon
• Wood

Once you have decided on metal prototyping, plastic prototyping, or another method, you can produce and assemble the prototype and begin testing. During this phase, take meticulous notes on functionality, reliability, etc. If there are any problem areas, the design team will work to suggest solutions and modify the prototype accordingly. This may even involve scrapping the current plan and redesigning the product, optimizing it until you are satisfied with the result.

Manufacturing the Finalized Prototype

Achieving prototype success means moving into the last phase of production: manufacturing. Here, you use your marketing data from the ideation stage to decide on the appropriate quantity for your first production run. You will also determine what tooling is necessary and what material will best suit your product’s needs. Finally, your perfected prototype can move into manufacturing as the next step to market.

Comprehensive Prototyping Services From Farris Group

At Farris Group, our design engineering experts will guide you through the prototyping process and help you determine the optimal materials, design, and tolerances for your project to adhere to best manufacturing practices and pinpoint cost-saving opportunities in production. With over 40 years of experience, high-tech equipment, and the capability to handle almost any fabrication project, trust Farris Group to get you from prototype to production quickly and efficiently.

We utilize CNC mills and lathes, MIG and TIG welders, press brakes, injection molding equipment, and more for precision prototype production in metals, plastics, and wood with quick turn times. Our prototyping services include everything from design assistance to assembly and finish treatments for prototypes that allow you to evaluate form and fit as well as function. For more information about our prototyping capabilities, contact us today.

Metal fabrication is a fundamental skill that dates back to the dawn of civilization. This process of converting raw metal materials into tools, machines, and structures has allowed humans to survive and thrive. Most mechanical and technological advancements pioneered by humankind required metal fabrication, such as hand tools and blades for hunting, machine components for creating vehicles, electronics, and construction materials. Today, metal fabrication remains a crucial part of manufacturing and development across countless industries.

To work a raw metal material into a specific object, metal fabrication shops enlist the services of experts, welders, ironworkers, blacksmiths, boilermakers, and other professionals. They then work on various metals through cutting, bending, and assembling. In addition to these three basic techniques, metal workers also use machining, welding, shearing, and casting to achieve a product.

Common metals for fabrication include gold, iron, aluminum, steel, carbon steel, stainless steel, silver, bronze, brass, copper, and magnesium.

The Beginnings Of Metal Fabrication

Humans have benefited from metal fabrication for centuries. The earliest evidence of metal fabrication dates back to 8700 BCE in the Middle East, where a copper pendant was discovered underground in Northern Iraq. In America, the earliest sign of metal fabrication was back in 4000-5000 BCE when copper mining was documented.

Metal also played a significant role in ancient civilizations. The seven types of metal that early civilizations knew of were identified with seven celestial bodies. Gold was paired with the sun, silver was paired with the moon, mercury was paired with Mercury, copper with Venus, iron with Mars, tin with Jupiter, and lead with Saturn.

As time progressed and humans realized the vital part metal plays in society, these materials became more than just references to celestial bodies. Metals that were primitive back then were worked into jewelry and used for construction. And in the Bronze Age, people started combining different forms of metal to achieve advanced raw material properties. They were melted, integrated, and forged.

Soon after, metals and metal fabrication techniques became prominent and influential. It defined how far ahead a civilization was, as it was used as a symbol for the elites and to create weapons for war.

The Modern Benefits Of Metal Fabrication

Today, metal fabrication is used for a wide array of applications. Aside from hand tools, machines, electronics, and construction, it also benefits the transportation sector, produces intricate jewelry pieces, creates household products, and serves military purposes.

As an industry, metal fabrication is very beneficial for a business as it helps create durable end products and cater to specialized designs. In addition, metal fabricators provide a convenient solution, offer access to skills and advanced methods, allow access to an array of modern equipment, and reduce overhead materials costs. Therefore, it is crucial for businesses to partner up with the right metal fabricators.

Work With Farris Group For Your Fabrication Needs

Farris Group’s Farris Fabrication division is dedicated to providing precision wood, plastic, and metal fabrication services! Our operation is among the leading metal fabrication plants in the United States, and we work with our clients from start to finish.

Having invested in the latest equipment and technology, we have the tools and equipment to complete any metal fabrication projects. In addition, our engineers provide expert engineering advice to ensure the success of your project.

Let us know how we can help you! Get in touch with us today.

Point-of-purchase (POP) displays are an effective way for businesses to market their products by placing eye-catching, in-store displays near the merchandise they are trying to sell. POP retail displays are often located near the checkout lane where customers make purchasing decisions, but they can also be found throughout the store. This method of advertising strategically draws a customer’s attention to specific products. POP displays come in a variety of designs and can be manufactured in both print and digital formats.

Things to Consider When Choosing a POP Display

When choosing an effective POP display for your product, it’s important to consider several factors. Your design should effectively advertise the product while remaining true to your sales and marketing goals. Below are some factors that can help you customize your POP display to more effectively market your product:

• Intent: What do you want your POP display to communicate to the customer? You may want to promote a deal or advertise special features. Clearly state your intent to the consumer in your design.
• Basic display types: POP displays can be broken down into three categories: temporary, semi-permanent, and permanent displays. Each type of POP display is made of unique materials that offer different advantages for creating engaging product marketing.
• Your intended audience: Consider your ideal customer and design your display with them in mind. Your target audience can determine where in the store your display is located and even the height at which it is displayed.
• The store’s decor: Consider the store’s interior layout and design and choose a POP display that complements the store’s decor and setting, but still draws attention.
• The location of your POP display: Are you placing a floor POP display somewhere in the store, or would your display be more effective as a counter display located near the checkout lane? These questions will help you choose the best design to successfully market your product.

Types & Examples of POP Displays

As mentioned above, POP displays can be separated into three categories: temporary, semi-permanent, and permanent. Temporary POP displays are often made to promote a new product or seasonal item for a short time, and they are made of less durable materials like corrugated cardboard, making them the cheapest display option. Semi-permanent POP displays are designed with more durability and can withstand frequent handling. They are constructed of materials like acrylic, glass, or co-polyester, and they typically last up to a year. Permanent POP displays are designed to last for up to three years, and they often look like a kiosk located inside a store. Constructed of materials like wood, glass, metal, or plastic, permanent displays are the most costly option.

Several types of POP displays can effectively showcase and encourage customers to purchase your product. They include:

• Floor stands
• Counter displays
• Dump bins
• Shelf talkers
• Banner stands
• Display cases
• Interactive displays
• End caps

Before committing to a POP display design, make sure it adequately markets your product to optimize sales.

Benefits of POP Displays for Your Business

POP displays offer a variety of benefits for your business. A successfully designed display will catch the customer’s eye, encouraging them to give your product a second glance. POP displays can help educate consumers about your product by providing additional information or FAQs not found on the product’s packaging. They are a great way to draw attention to your brand by displaying your product in a way that is appealing and unique. POP displays encourage impulse buyers to purchase products that they may not have considered without the help of effective advertising. Most types of POP displays are inexpensive to manufacture, boosting your ROI.

Choose POP Displays at Farris Group

Farris Group is the industry leader in durable, engaging POP displays that showcase your brand. We offer a variety of POP displays including permanent and semi-permanent in-store fixtures, as well as end cap displays, inline displays, and branded environments. Our expert engineers at Farris Group will provide you with individualized service to create the perfect display to effectively market your product. 

If you are interested in partnering with our company to create an effective marketing tool for your product, contact us today or request a quote. 

On July 23, “Educators in the Workplace” highlighted Farris Group, located in Cherryville, NC.  The company has been committed to precision fabrication for over 40 years. This rapidly growing company continues to invest in technology and its skilled employees. Farris currently has three Gaston County locations and over 300 employees.

Sponsored by Gaston County Schools and the Gaston Regional Chamber, with support from area businesses, Educators in the Workforce gives educators an opportunity to visit local companies, learn about job opportunities in Gaston County, and take career information back to their schools to share with students.

The educators began their visit with a presentation about all aspects of the manufacturing and full-service capabilities of the company.  After an enlightening session of questions and answers, the guests toured the Cherryville facility to better understand the manufacturing processes of the various divisions. The visit ended with more discussion about what educators could do to help prepare students for successful futures in the workplace and how Farris could work directly with local schools to allow students hands-on opportunities to explore fabrication and manufacturing careers.  Partnerships like this are invaluable for educational and economic development.

Farris Fab comes to you equipped with a variety of CNC mills and lathes. These customizable machining tools come with 100% accuracy that can handle any size component. Big or small, your job will be handled with extreme care that fits within the Farris Fab approval requirements.

CNC machining is a fully automated service that involves the production of parts via pre-programmed software. Dimensions are given and the software cuts away until you get the exact component you needed, with perfect dimensions. There are two types of CNC machines: Mills and Lathes. Farris Fab currently has 9 mills and 5 lathes for the maximum efficiency in completing your jobs! CNC mills are capable of running prompts which guide pieces across various sections of the machine. Basic machines will operate on a three-axis system, but some newer mills work with six axes. Some common CNC processes include welding, hole-punching, and laser cutting. On the other hand, Lathes are used to cut in a circular direction with indexable tools. With CNC tech, the precision on the circular cutting is unmatched. These machines are used to create complex designs that are not possible for manual versions of the machine. Mills and Lathes are actually very similar, but lathes only employ 2 axes on their designs.

CNC Machining produces components for a variety of industries, including:

• Aerospace
• Agriculture
• Automotive
• Construction
• Dental
• Electronics
• & More!

Conventional machining and CNC machining are two means to the same end. Both will start with a large piece of metal or plastic and they will shape and cut it down to the right dimensions for commercial use. The biggest difference is that CNC is automated, so speed, production rate, and accuracy are a major selling point for CNC Machining. Overall, CNC is cheaper and is used for mass production, while manual machining is for smaller jobs.

Overall, CNC machining has a variety of advantages over normal means. It requires less labor to execute tasks, as it is an automated service. CNC has more capabilities since it can create precise cuts that just aren’t possible with manual machining. This aspect also achieves a greater safety aspect as it doesn’t need to put others in danger during a cut. With many more advantages in store, there is no wonder why CNC Machining is the way to go when commissioning your components with Farris Fab!

Adding Functionality, Power, and Speed to Farris’ Fabrication Abilities

The Muratec Motorum 2558 T is Farris Fab and Machine’s most recent cutting edge machine tool addition. This state-of-the-art- machine facilitates process integration, decreases power consumption, improves part accuracies, and faster punching rates.

This high volume punch is virtually unbeatable, it utilizes a advanced Fanuc CNC controls for sheet metal processing up to a quarter inch mild steel. Unlike lasers, the Motorum turret punch has the ability to do secondary operations, such as: forming, tapping, and deburring.

With the implementation of our newest machine, the Muratec Motorum 2558T we are able to reach optimum RAM speeds which leads to fast and accurate forms, while maintaining minimal distortion to the work piece.

The Muratec ram drive technology incorporates a toggle mechanism driven by the AC servo motor. A single rotation of the crank arm gives 2 punching strokes; therefore, exerting more power while using less energy. This innovative technology has resulted in accomplishing higher productivity, environmentally friendly operation, and energy efficiency.

Projects for custom metal fabrication are common for any business that deals with loose parts, structural projects, and metal equipment. Farris Fab has the tools to complete any custom metal fabrication project, no matter the scale! The expertise of any fabrication company is governed by their acquisition of raw materials, cutting/forming equipment, and assembly techniques. Farris Fab will not rest until you are satisfied with your parts!

The raw materials are what to start within custom metal fabrication. Some forms of material include plate metal, expanded metal, and welding wire/rods. Once the material is collected it has to be cut down to size. Farris Fab utilizes their laser cutting equipment to cut faster and more accurately while also being able to cut thicker materials. Even more exotic materials can be cut using their water jet cutting process, which involves highly pressurized water currents capable of slicing a variety of materials.

In custom metal fabrication, once the material is cut it can undergo forming or machining. Forming is the process that converts flat sheets into a 3 dimensional part. This process involves the metal being bent and formed without the removal of any material. It requires a great amount of force to form metal like this. Formed parts are used in a variety of industries, including jewelry, automotive, construction, aerospace, and much more.

Machining is different from forming in that it does involve the removal of material. Custom metal fabrication requires a variety of processes to get the right final product, and sometimes removal is the only way to achieve such a result. Often machining has been called subtractive manufacturing. Subtractive manufacturing is a common process in the world of custom metal fabrication. It is when raw material is cut and parts of the material are removed to create the desired shape. The most common components made by machining include gears, bolts, screws, and nuts, but there is no limit to the designs created by machining.

One of the main focuses of steel fabrication is welding. The custom fabricated parts are assembled and welded into place to create the desired product. Once the parts are in place it is re-checked for the accuracy of the welding. Farris has over 50 welders hired and trained within the company. There is even robotic welding equipment for large-scale projects.

Once a product has been assembled, the custom metal fabrication is complete. This is assuming there are no extra processes like sandblasting or painting are specified. Once the product has been inspected, the parts are shipped out. Farris Fab are experts in each part of the process and will work with you to ensure your custom metal fabrication is completed to your specifications!

At Farris Fab and Machine we are devoted to staying well-informed of the newest technologies to ensure quality and exceed customer satisfaction. We are pleased to announce the addition of 2 state-of-the-art quality measuring tools, the 4 ft. span Faro arm and the 12 ft. span Faro Arm. The Faro Arm is a portable coordinate measuring machine (CMM) that allows easy verification of product quality by performing 3D inspections, tool certifications, CAD comparisons, dimensional analysis, reverse engineering, and so much more.

Due to the Faro Arms portability, the tool can be brought to the site of the inspection; therefore, reducing non-value added material handling. The Faro Arm helps in reducing onsite measuring time, which ultimately reduces overall costs. These savings are then passed on to our customer.

It is our ongoing attention to quality and innovative technology that has made us one of the most prominent contract manufacturers in the Southeast. Our goal was to end the sole reliance on fixed CMMs and the Faro Arm has done just that. By offering high accuracy levels, improving measurement consistency, reducing inspection time, and generating automatic reports, this technology has contributed to our ongoing improvement processes, quality, and our continuous movement toward customer satisfaction.