A customer came to Demsey Manufacturing Co., Inc with an HVAC sensing bulb that required deep drawn stamping of Type 304 stainless steel. After successfully completing this project and being in production for approximately one year, the customer mentioned that they were having difficulty with a secondary swaging process that had to be done to the part. At this point, Demsey asked if they could have a print of the swaged part to examine. It was determined that the part could be made complete with only two additional operations in Demsey’s existing tooling and little difference in the piece price.
Since there was a line of communication now open with the customer’s Engineering Department, Demsey asked about the assembly process that was done with the swaged part. There was a screw machine part that was welded to the top of the sensing bulb. Demsey examined the cap that was machined out of Type 304L Stainless Steel and felt that it could be converted to a deep drawn stamping. The customer found this to be much more economical while it did not sacrifice any functionality. Now Demsey makes both parts which also ensures a better fit between the two.

Product NameSensing Bulb & Bulb Disc
Volume100,000 Pieces Per Year of Each
Tightest Tolerances ±.001"
Straightness of .002"
Standards Met Customer supplied print, 2D CAD Drawing
ISO 9001:2015
Product Description These stainless steel components are used within HVAC applications.
Overall Part Dimensions Material Thickness:
Bulb: .020"
Cap: .020"

Bulb: .625"
Disc: .600"

Bulb: 2.060"
Disc: .200"
Material UsedBulb: 304 Stainless Steel
Disc: 304L Stainless Steel
Industry for UseHVAC
Estimated Part WeightBulb: .0210 pounds
Cap: .0023 pounds
Equipment Used to Manufacture Part20-10 Waterbury Farrel - Bulb
325 U.S. Baird - Disc
Delivery Time8 Weeks
Delivery LocationU.S.A.
Capabilities Applied/ProcessesPart Redesign
Tool Design & Manufacturing
Deep Drawn Stamping
Elimination of Customers Secondary Operation
Converted from Screw Machining to Stamping
Reduction in Raw Material Usage
Increased Production Rate
Cost Savings
Bulb: 304 Stainless Steel
Disc: 304L Stainless Steel
Disc to fit to bulb for proper clearance