Blue Photon Workholding Case Studies

Blue Photon Technology & Workholding has been successfully implemented in many applications using delicate ceramic parts, near net shaped castings, and composite parts.

Case #1

The Part: A 16” X 18” aerospace cover.

The Material: Magnesium casting.

The Problem: The entire top portion of the part is a gasket surface that needs to be flat within .005”. The manufacturer previously had chatter problems because of limited possible clamping areas.

The Solution: The manufacturer designed and built a transfer tool with locations for grippers that are used to hold the part. Grippers are placed where needed along the periphery of the part. This totally eliminated the chatter.

Additional benefits: Increased feed rates, lower cycle time, less operator fatigue, better increased part quality.


Case #2

The Part: A turbine nozzle segment.

The Material: Superalloy.

The Problem: Limited access to the part for processing.

The Solution: By creating a transfer tool to hold the part on one side, outside of the airfoil footprint, the manufacturer was able to process the part in one tool unhindered by datum placements on the part.

Additional benefits: Lower tool costs, elimination of an operation, lower scrap rate, lower labor costs, allows for easy automation, better quality.


Case #3

The Part: A Mounting Bracket.

The Material: Aluminum Casting.

The Problem: Casting variation and distortion from clamping caused excessive scrap.

The Solution: A transfer tool was designed with included grippers to hold the workpiece and eliminate part distortion due to clamping induced stresses.

Additional Benefits: The new transfer tool fixture increased machine utilization 26% and reduced labor by 33%.


Case #4

The Part: A Turbine Part.

The Material: Ceramic.

The Problem: Due to the brittle nature of ceramics, they are easily damaged when clamped or gripped other traditional workholding methods.

The Solution: Blue Photon designed photo-activated adhesive workholding transfer tools that eliminated scrap caused by fixture induced damage and part movement during processing.

Additional Benefits: By implementing the Blue Photon System the manufacturer was able to eliminate clamping induced scrap. Part movement was eliminated. Output was increased due to increased feed rates. Overall quality improvements were seen. The new tools allow for easy automation of this high value part.