Dimension Bond Corporation

Lifetime Bonded Bearing Surfaces with Micron Accuracy

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ValveShaftsCam RingsShock Absorber PistonsSolenoidsMinature PartsYoke BearingsWhat We DoWhat We Do We Create Precise, Bonded Bearing Surfaces - Permanent Bearing Surfaces Combined with Optimized Dimensions - All in One Operation!Parts that require permanent lubrication and additional parts and operations, such as wear bands, inserted bushings and sleeves, or confined spaces that require a lubricant surface, are perfect candidates for Dimension Bond. This includes the dynamic component(s) of products like fuel pumps, shock absorbers, valves, air and hydraulic components, pumps, air and gas springs and solenoids.The Dimension Bond ProcessThe surface of your parts, and mating parts, are inspected and analyzed to determine the most appropriate Dimension Bond nanocomposite bearing surface.With the utilization of micron-accurate measuring devices such as laser micrometers and air gauges, we simultaneously add the optimal bearing material and verify the dimension of the parts surface.All parts are then heated to temperatures ranging from 300° F to 780° F in order to permanently bond the bearing surface to the part. Each part is dimensionally inspected to micron-accuracy before shipment. Using this patented technology, we are able to bond almost any liquid-based coating material that is post or heat-curable with micron accuracy. Turning Potential Scrap into Dimensional Correctness Customers come to us with parts that vary from dimensional correctness by as much as 0.071mm (.0028) to +/- 0.035mm (.0014"). Using precise computer-controlled Dimension Bond application technology and micron-accurate measuring devices, we are able to customize the thickness of material being bonded to each individual part. This results in improvement of all parts to within a final finished dimension as accurate as 0.010mm (.0004") or +/- 0.005mm (.0002") = dimensionally correct production-ready parts. A Variety of Bonded Bearing Surface OptionsThe Dimension Bond R&D Team continuously formulates, develops, and endurance tests higher strength lubricant composites based on engineering polymers and nanocomposites. Additionally, we are able to apply DuPont, Whitford, Fuchs, and many other dry film lubricant coatings with the same micron-accurate results.Manufacturing Cost and Component Design BenefitsBy producing accurate bonded-part dimensions on customer parts, the Dimension Bond process eliminates the need for secondary machining and for inserting wear bands, bushings, etc. This dramatically reduces both our customers material and labor costs. It also enables them to design and manufacture lighter, smaller parts with less complication, manufacturing, and assembly costs. What We DoDimension Bond HistoryCost EffectivenessClick on the Flyer below forMore Detailed Information

Dimension Bond HistoryDIMENSION BOND® HistoryThe Challenge that Led to New TechnologyIn the 1980s, a Gerotor fuel pump manufacturer provided an extremely challenging opportunity to apply a special fuel resistant, low friction polyphenlyenesulfide /polytetrafluoroethylene (PPS/PTFE) coating to the 25mm inside bore of a powdered metal housing. Several problems existed because two suppliers provided parts that were consistently larger than could be used. The initial solution was to apply more PPS on the oversize bores of some parts. However, the unique bearing surface - after oven curing the PPS coating - was impossible to change and therefore no coating could be added to the undersized parts post-oven curing. Several technical hurdles needed to be solved to provide a CPK of the finished parts of 1.33 when all lots had CPK values of less than 1.0. The DIMENSION BOND® SolutionFundamental to the solution was to pre-measure each part and then meter a precise amount of PPS material during the bore coating process to all parts with additional material on the larger bore parts. This required research into precise measuring and air gauging, and the results proved to be very accurate based on multiple Design of Experiments (DOE). The dimensional values were computer acquired to qualify measurements before and after the bore coating process.The PPS coating needed to be sprayed into the bores. Conventional spray equipment could not possibly meter, for example, .65 cc to some bores and .66cc to .89cc to selected oversize bores. DIMENSION BOND® staff members embarked on a very arduous task; how to change the amount of material deposited in a bore on each and every part as determined by the dimensional measurement of the part before the spraying process. DIMENSION BOND® New TechnologyAfter two and a half years, DB staff finally had created and manufactured, in house, a pumping/metering system that could meter the liquid PPS material to an accuracy of .01cc per part. This robust system has been proven over more than 35,000,000 parts with the goal of changing the dimensions of the final coated part so all parts in a lot are within the dimensional requirements, irrespective of the dimensions range of the raw, uncoated parts. Continuous Process ImprovementPart of this success is due to Moores Law of computer processing power. As computer processing power increased in the 1990s DB had the ability to not only measure sizes but also add gravonometric (weight) measuring of parts throughout the DB process as a further in-process accuracy test. Later, temperature correlation of the measured parts and mathematical computational correlations further enhanced the overall accuracy of the DB process. US Patents were filed for the DB process in 2000 and in 2004 the first patent, 6,738,680, was granted for the unique and effective DIMENSION BOND® process. This was followed by several more patents between 2002 and 2006 ( 6,832,577, 6,860,947, 6,997,683, 6,997,992, and 6,998,147) expanding the DB Processing to not only bores but now outer diameters. Laser micrometers played a large part in the dimensional measurement of outer diameters, which were integrated into the DB machine code software and machine controls. DIMENSION BOND® Uniqueness and SuccessAll the DB processes use the principles of the metering devices. These liquid/slurry metering devices are unique in that they can meter coating materials containing PTFE and other soft fluoropolymers without agglomeration or coagulation of the coating. The reliability of the metering components has been extended to provide a mean-time-to-failure of more than 2.5 million individually metered part coating applications per maintenance cycle. The coating formulations qualified by DB now surpass 100 different types of coatings including those from Whitford, DuPont, Dow Corning, Fuchs, and many more. From the initial automotive fuel pump processed by DB in the 1980s, the range of parts currently processed by DB machinery includes the most complex shapes. Successes include automotive and industrial rotary, screw type air compressor rotors, bearings for NASCAR® racing engines, Jeep® pistons, Honda/Acura V-Tec® engine shafts, fuel pump parts for Mercedes Benz, TI Automotive, Blackstone, Dana Corp, Airtex and an ever expanding universe of customers who need perfectly and precisely applied bonded bearing surfaces. What We DoDimension Bond HistoryCost EffectivenessCost EffectivenessSaving You Money While Improving Your Product Dimension Bond Processes Offer Significant Design and Manufacturing Cost SavingsThe Dimension Bond Processes provide operating, engineering, design and functional benefits, along with significant design and manufacturing cost savings through the elimination of the need for inserted bushings, outside wear bands, and inserted thrust bearing surfaces or loose inserted cradle bearings (please scroll down for examples).This unique process can be applied to any rigid surface; metal, plastic or ceramic. Almost any internal or external bearing surface, shaft, wear plate, or thrust surface can be processed. Ferrous and non-ferrous, solid or sintered metals and ceramics are ideal substrates. Engineered structural plastics strengthened with glass and other abrasive fillers can now be lubricated for life in dynamic applications. Some Successful Applications Include:Automotive steering systems and bearing cradles Fuel system pump parts, shafts and pivots Hydraulic, and air cylinder and gas strut components Office imaging/copying equipment Rotating and reciprocating pump parts Shock absorber rod guides and pistons Solenoid components Valve components Automotive pistons

No More Inserted Bushings - Dimension Bond Eliminates:Insertion and cost of the bushing or bearing retaining devices, snap ring and retaining grooves or adhesivesAll secondary machining steps required to create shelves, steps or two diameter bores to retain one end of a inserted bushingCoining or upset of metal in effort to keep the bushing from moving Reaming, honing or machining after insertion to size the hole Assembly labor, tooling, inspections, inventory and floor space related to inserted bushingsNo More Costly Attached Wear Bands - Dimension Bond Eliminates:The cost of the band The need for oversize metal parts requiring machining of grooves or lands to retain the band Leak paths if split bands are used Misalignment of the band during assembly Assembly labor, tooling, inspections, inventory and floor space related to outside wear bandsHydraulic forces displacing shrink fit band designsNo More Inserted Thrust Bearing Surfaces, or Loose, Inserted Yoke Bearings - Dimension Bond Eliminates:Cost of the bearing components Assembly labor, tooling, inspections, inventory and floor space related to the bearing componentsComplicated bearing retention designs Dimension Bond Provides Operating, Engineering, Design and Functional Benefits:Freedom from vibration and loosening of bearing Consistent dimension of the bearing surface No leak paths from split or Dry Unlubricated style bushings or bearings Absolute control of clearance between bearing surface and the counterface No inconsistent or random fluid/air leak paths Concentric, permanent bearing surfaces Design is lighter and stronger, yet parts are less expensive and have a greater bearing area Higher and/or lower temperature limits (i.e., temperature will not loosen the bearing) No bearing or band to push out by fluid or hydraulic pressure Unaffected by solvents, lubricants and most chemicals* (is there a list of chemicals that you are aware of that you should list in a disclaimer on this site and link to from here?I am ok with the text only as our forms cover this later before we get to testing)No lubrication or maintenance required Resists G- and dynamic forces in any position FDA and USDA listed grades available Formulations available that allow post processing welding or painting Reduced or eliminated warranty claims or use the link to the left and complete and submit a free Engineering Evaluation Request form today so we can get started on a solution that will save you money while improving your product. What We DoDimension Bond HistoryCost EffectivenessEngineering EvaluationRequest Form

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Engineering Evaluation Request Form

To get started on a solution that will save you money while improving your product open the form below and complete the appropriate fields. Then print a copy for your records and either:Fax to (773) 282-9307Scan and e-mail to info_dimensionbond.comMail a copy to Dimension Bond Corp., 5190 Northwest Highway, Chicago, IL 60630Engineering Evaluation Request form

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