We Got the Wrong Material in Our New Shop-It Cost Us Big Time! | BAPM Ep.14

[@davidhorsley1149]

To my way of thinking, hard copper would be a dream once you realized it was hard. I had the occasion to build a trellis for the side of a customer's house out of pure electrical grade copper and that was a nightmare. As far as cutting and machining it was ok, but drilling and tapping was a different story. It would grab and snap drill bits and the taps tried to load up and lock in the hole. I had tried several cutting and tapping fluids to no avail. A machinist friend suggested kerosene, and although it was a little better it still didn't help. I finally, out of desperation tried bar and chain oil from my chainsaw and that enabled me to drill and tap the holes without breaking drills or taps. The finished product was extremely pretty, if I do say so myself, but it was a learning and a losing experience. Due to tool consumption and delays I lost money but my customer was pleased with both the finished product and staying at the quoted price, and she became a repeat customer afterwards.

[@pb68slab18]

Worked for one of the biggest defense contractors. We use 'certified' materials, and a copy of the 'certs' from the metal supplier follows the job from saw to finished product.

[@MachiningandMicrowaves]

I make a lot of copper parts, I mostly use Tellurium Copper and a bit of Sulphur Copper and some of the OFC grades. I've never accepted customer-supplied material. If anyone wants C101 copper, I explain politely that the machining cost will be almost doubled to cover tool damage, and that a more suitable grade would reduce the product cost. Packaging heavy copper items to survive brutal international transport is quite an art. I design the packaging to survive a 6 foot drop on to a corner down to a concrete floor, or for the smaller packages, being thrown into a truck by a thug in a depot. I'm using custom laser-cut EVA foam individual packaging to try to ensure the parts survive. Luckily, most of the parts I send overseas are small or are made from aluminium or engineering plastics, and are high-value enough to let me use custom lasered wood enclosures or 3D printed mounts. When the finishing involves anodising and laser marking, or a silver or gold electroplate finish with laser-fused markings, the extra effort in finishing and careful package design pays off.

[@MockBrainworthy]

Made quarter million heatsinks for diode lasers using OFHC with diamond turned top and face. Avoided machining by using blanks stamped to near net outline and turned only two surfaces. No burrs, edge radius< 10 um.

[@charleswelch249]

I shop similar items daily. Get a rack with bubble rap and dense foam and packing paper. First wrap part in foam, then bubble wrap. Then box. Use packing paper to pack the parts tightly. Then you please the cardboard for the next layer. We ship military and private parts worldwide. Another tip. Make labels with parts numbers and other information that the customer needs and put on each individual part after rapping. I'd suggest getting plastic banding to fasten parts to pallets and then strecwrap the whole pallets before shipping. Hopefully, this helps.

[@jsteifel]

That's still not going to survive the trip internationally. The side walls are not strong enough. Consider thin ply to all sides, top and bottom, and none of the interior can move. Good luck on that.. Also more tape. FG tape needs more length to grab more. The strength comes from the strands grabbing areas that are not impacted. So short does not help.

[@CNCGuy]

I am literally in love with the idea of a home machine shop. Just like the old days where everyone had a milling machine and lathe in their garage.

[@ClydeShelton-fv1lf]

got 2 lathes 2 mills a shaper and drilll presses......

[@joshualegault1095]

We started using triple corrugated heavy duty boxes recently for anything over 12 cubed. Also individually boxing up the parts with a layer of foam on the inside and outside helps. It may seem expensive until you scrap out 20k in parts during shipping

[@foxacoustics]

You're going to have a very expensive lesson one day when one of those boxes get damaged or destroyed and UPS and Fedex won't pay the claim. They require 2" of padding on all 6 sides. You might have 1/4" of padding. They will deny that claim. You need to box them then put that box in a box which is at a minimum 4" larger "2 inches per side" and use peanuts or crushed paper for padding between the boxes. If you aren't comfortable lifting the box head high and dropping it on the concrete, it's not packed well enough.

[@wiretamer5710]

Packing is NOT an unskilled job! It's actually an ambassadorial role on behalf of the business: as important as client management.

[@0dbm]

I love team work ! You two are the best Congratulations

[@tcs9787]

I suggest doing drop tests for expensive part to make sure they will make it 100% of the time. That’s what all large manufacturers do to guarantee their product gets to their customers in one piece. And make any changes beforehand not after the fact.

[@scotiaservices9078]

I never machine jobs where the value of the material is far in excess of my machining charge. Too great a risk. I'm a very small shop.

[@JS-cs8gz]

Agreed. Top heavy jobs will sink your ship.

[@bluegreenash]

It could be a good idea for your tool storage wall to put some “French Cleats” up it’s then super easy to create custom storage that integrates with the cleats

[@christopherleubner6633]

Get that silver bubblewrap insulation stuff. It is extremely tough but will protect your spendy parts. Used to use it to ship fragile edm'd carbide parts

[@Vytor01]

I used to be a domestic/international shipper. Anything you ship must be able to survive being dropped off a conveyor belt 3ft off the ground and survive after hitting any corner or side. Double wall boxes are more expensive but help heavier items survive better. Metal items will find their way outside the box if they can move around. Also, when shipping internationally, you need to have a Harmonized Tax Code number that tells the governments what metal the part is made from, its source etc. There are certain countries that are embargo countries while others will not take a box over a certain weight through regular shipping and it must go on a pallet.

[@jimsvideos7201]

It's your life but if anyone wants something made out of beryllium copper, I suggest you politely decline and then run for your life. For the copper parts you have, talk to your local print shop; photo paper comes on notably sturdy cardboard cores in about 2" and 3" diameter, and you could print end plugs to suit.

[@christopherleubner6633]

Yup also beryllium copper pretty much requires a dedicated machine to process it as scrap yards treat beryllium copper chips mixed in with regular copper alloy chips like toxic waste unless it's all beryllium copper. The stuff is awful to machine too.

[@paintnamer6403]

We ordered more than one hundred formed and punched out electrical enclosures, lids and ends and we would weld them. They sent everything pickled stainless when it had have a grained finish and there was no doing that with the tight breaks in everything but the ends. That was about $100,000 of scrap.

[@MockBrainworthy]

Why no spec. on prints? CDA alloys definitions are easily found online.

[@oishisakana]

it would not add any speed but you could get a 3dprinter, a cheapy,= and just in fusion take the part and put it in a block and cut the part from the block and then 3d print the result, giving you a custom hard plastic case for each part that would be stacked top and bottom sothen stacked in the box. might make it more survivable over seas,

[@wallbawden5511]

Nice job on the lay out of the shop practical N efficient packing is all ways important as this is what the customer sees and gets if damaged in any way then they won't use you again if they receive this sort of product and the way its packaged they will say to themselves nice will use them again but of course you never receive any of this feed back is what it is Anyway nice all round look see thanks Cheers from North Queensland Australia

[@Factory400]

I am very curious if those parts made it to the destination. The packing seems WAY underbaked. I have shipped very high value stuff all over the planet and seen first hand how it gets pummeled. First, for me, is that I try to split orders in 2 or more containers. If one is lost or damaged, you still have other boxes that may survive. For heavy parts/equipment - 3" bottom/sides/top is my minimum. Cardboard boxes with heavy contents need strapping all around too.

[@tinwizard6447]

First time watching. A little surprised handling polished copper with bare hands. Won't they be marked from skin oils?

[@Kompound_Machining]

Great vid, Keep up the good work.

[@JS-cs8gz]

You may want an enclosed office space. During the hotter months you get a lot of humidity and whatever else (think deburring dust) in the air. Of course this avoidable if you add a mist collector to the machine and vent the exhaust to the outside.

[@lindsaybrown7357]

I'd be shipping that in a sturdy wooden box / crate or buy a blow-molded double wall storage box from your local hardware store.

[@common_c3nts]

That is a horrible way to pack unless you put that in a large boxer box with foam around the sides. The reason is what box will get constantly dropped and hit, all the copper pieces will be dinged up. If you wanted to use one box then you should have put the foam board on the insides of the box as a double wall before putting in the copper pieces. Sadly the way you did it, the outside pieces will get dinged easily. That thin layer of cardboard is not enough.

[@CrankyOldMachinist]

Packages have a habit of being thrown around like footballs. Heavy packages more so. I suggest you double box something that expensive that is going international.

[@TheYtTurks]

one word to describe this video's background music: vapid

[@asbcustom]

My 2 cents for what it's worth: Greet customers with long pants, no ball cap, and a tucked-in shirt. In other words, dress for success if that's your goal.

[@billstrahan4791]

Machined some c110 and lots of c145. Man, c145 is almost as easy as brass c360 with just 60% feed rates by comparison. C110 is nasty stringy gummy. C110=unhappy shop, C146 is happy.

[@seymourpro6097]

You will want a wall between the works and the office, cutting fluids are NOT a socially acceptable smell, and one customer may not want to see you make things for a commercial rival of his.

[@richardedgerton1852]

You should write a cuneiform complaint.

[@Vankel83]

Dislike customer supplying material. Wrong material sent like you mentioned. Dimensioned wrong from supplier that you would purchase. You need to get a Marsh tape machine. Ebay there's many on there. The tape is super strong. Unline is a great supplier for boxes and all shipping products neeeded.

[@nela9994]

Was the copper company run by an “Ea-nāṣir”?

[@Beechnut985]

C 110

[@SillyPutty3700]

Pirate Ship, & uship

[@SillyPutty3700]

Also run that tape all the way around the box and make sure the heavy items are locked in place so they can't shift. If the heavy items shift they will cut their way out of the box.

[@common_c3nts]

Calling yourself "mil spec" is lame.

[@ClydeShelton-fv1lf]

as qc.... always confirm maternal certs before op 1