Custom components fill the gap whenever standard automation parts fail to meet the requirements; but they come with their own challenges. Choosing the wrong custom-part can slow production and raise costs. Therefore in this blog post we will help you select, document and source non standard equipment parts. By following this guide you can achieve dependable performance and prepare your operation for future growth.
Understanding the Landscape of Non Standard Parts
Non standard parts are made for specific automated systems. Unlike standard parts they are not mass produced or easy to find. Engineers design these components for unique tasks. Some examples are custom fabricated frames, bespoke actuators, special purpose sensors and unique jigs or fixtures.
Industrial Applications
Many industries depend on these custom components. In the automotive sector, they support parts manufacturing and assembly. Similarly electronics assembly, food production & packaging as well as aerospace also use them. These parts solve problems that standard equipment cannot handle.
Non Standard vs Standard Automated Equipment Parts
Key Differences
- Production Volume: Manufacturers produce standard parts in large quantities. In contrast non-standard parts come in small, custom batches.
- Customization: Non standard parts are especially made for one specific job. Whereas standard parts are made for many different uses.
- Integration Complexity: Addition of custom parts to a system mostly takes more work and expertise as compared to using standard components.
Why Proper Selection Matters?
- Reliability & Uptime: The right part keeps your system running smoothly. You will see fewer jams, misalignments or drifts—which helps maintain strong cycle time and OEE.
- Maintenance & Cost: Picking the right part lowers long term maintenance costs and helps avoid costly downtime.
- Scalability & Obsolescence: Good choices make future upgrades possible. Similarly poor choices can make a system obsolete much sooner.
Pre Selection Checklist for Non Standard Automated Parts
A clear understanding of the part’s intended use is necessary before choosing non standard automated parts. Use of a detailed pre-selection checklist reduces the risk of costly redesigns and also supports reliable performance.
Step 1 – Understand the Process/ Application Requirements
Start by defining exactly what the part must do. Write down its particular role in the automation line such as assembly, inspection or material handling. Think about the environment where the part will operate. Will it face chemicals or high and low temperatures?
Also note the required production volume and how the part will connect with current control systems, sensors and safety measures. Cover these basics early so that you can avoid miscommunication and redesigns later.
Step 2 – Document Technical Specs & Tolerances
After that, prepare thorough technical documentation. Include 2D & 3D models that show all important dimensions and geometric details. List the materials and surface finishes needed. State tolerances clearly, since custom parts demand high accuracy. Add performance data like cycle speed, load limits as well as the expected lifespan.
Step 3 – Define Future Proofing & Flexibility
Think ahead to possible changes. Will the production line need to grow or handle new products? Design the part so it can adapt. Modular designs make upgrades and part swaps easier. This strategy prevents you from getting stuck with a design that cannot change as your business evolves.
Step 4 – Budget & Lead Time Constraints
In the final step, consider both budget and delivery time. Custom tooling and slower manufacturing make non standard parts more expensive and they also take longer to produce. Therefore recognize these costs and timeframes from the start.
Work with your supplier to set a clear budget and a realistic timeline for design, prototyping and production. Because planning early helps set expectations and keeps the project on track.
Material & Manufacturing Considerations
Selection of the right material and manufacturing process is crucial for success. These decisions influence cost, durability and how well your part performs over time in an automated system.
1. Material Selection
The part’s function guides your material choice. Metals like stainless steel and aluminum are popular because they offer strength & reliability. For situations needing low friction or corrosion resistance, plastics such as POM, PTFE or PEEK work well. However higher performing materials like PEEK mostly cost more. You need to weigh durability, wear resistance and environmental needs against your budget.
2. Manufacturing & Machining Aspects
Part design has a direct impact on production complexity. Advanced machining is often needed for intricate shapes or tight tolerances which raises both time & cost. To keep expenses down, use standard, off‐the‐shelf components in your design when possible. This approach reduces the need for fully custom fabrication.
3. Cost vs Performance Trade‐Offs
It is usually difficult to balance cost and performance. Non standard parts become expensive because of small production runs and specialized materials. To manage costs you can simplify the design or select a less expensive base material with a special surface coating. This method gives you the needed durability or corrosion resistance without paying for a costly base material.
Manufacturers who assist with material and finishing choices, like RICHCONN, can help you get the best performance for your budget.
4. Maintainability & Serviceability
Plan for maintenance early in the design process. Make parts easy to access, inspect & replace to cut down on downtime. Modular sub‐assemblies are a smart choice because they allow quick swaps instead of complicated repairs. This keeps servicing simple and helps your automation line run proficiently.
Supplier & Vendor Selection Criteria for Automated Non Standard Parts
Choice of supplier matters as much as the part’s design. This decision directly impacts your project’s outcome, expenses and schedule.
Choosing A Qualified Supplier for Non Standard Parts
Start by checking if the partner has strong technical skills and established quality systems like ISO 9001 certification. You should also look at their financial health and review their previous projects. These steps help confirm the supplier’s reliability.
A partner with a solid track record is more likely to deliver consistently and support your automation needs over time.
Supply Chain Risks for Non Standard Parts
Non standard parts bring special supply chain risks because they are custom made. Relying on just one supplier makes your production vulnerable to disruptions. Moreover you need to manage issues like unpredictable lead times and changing prices.
To reduce these risks, select partners who can help you manage inventory effectively. Always keep a backup plan in place.
Contractual & Quality Aspects
A detailed contract is essential for controlling quality. The contract should list all technical details, materials along with required tolerances. It must also set out quality standards, inspection steps, warranties as well as SLAs to assure accountability. This legal agreement protects your investment and makes expectations clear.
Integration, Testing & Validation
To make sure your custom part works as intended, you need proper integration and careful testing. Use these steps to check both the design and the performance.
I. Fit Into the Automation Line
Start by checking the physical fit. All mechanical interfaces, like mounting holes, must line up with the existing equipment. After that, look at electrical compatibility. Sensors, actuators and control systems should communicate without issues to prevent integration problems.
I. Testing/ Validation Approach
After integration, use a step‐by‐step testing method. Build a prototype first to find any early problems. Next, carry out functional tests to see how the part performs in real conditions. For this run load, cycle as well as endurance tests. At last, finish with environmental checks to confirm the part can handle the needed temperature & humidity levels.
II. Quality Assurance & Standards
Standard quality assurance methods help assure the part stays reliable for a long time. Perform stress analysis and fatigue tests to check the design’s strength. Keep records of all test results to track how the part performs and to help with future upgrades. Always follow industry standards, such as those from ISA, to maintain best practices.
Richconn applies FEA simulation and statistical process controls on every run so that you receive repeatable quality every cycle.
III. Maintenance Planning
Set up a maintenance plan that uses your test data. Design parts so that they are easy to reach and replace. Modular components make this easier. You also need a clear strategy for spare parts. Decide how many spares to keep, where to store them and how long replacements will take. Careful maintenance planning is the last step to keep your operation running smoothly for the long term.
Cost, Lead Time & Life Cycle Management
Managing cost, lead time and the full life cycle of custom parts is vital for any automation project’s success.
Cost Drivers for Non Standard Parts
Non standard parts mostly cost more than standard ones. Small batch production and the use of unique materials are the main reasons. The design and engineering phase also takes more time & resources— which increases the initial cost.
Lead Time Considerations
Custom components take longer to produce because of their unique requirements. Their manufacturing process is more involved than that of standard parts which leads to longer delivery times. Project schedules should allow extra time for design changes, supplier input and tool creation.
Life Cycle/ Obsolescence & Flexibility
Early management of the life cycle of custom parts helps avoid future problems. Custom made parts need a clear plan for maintenance and upgrades to stay useful over time. Modular designs help reduce obsolescence to make parts easier to reuse or swap. This method keeps a single part from causing problems across the system.
At Richconn, we always track revisions, manage engineering change orders (ECOs) and control design freezes. These steps keep your custom part dependable and easy to maintain throughout its life.
Tips for Cost/ Lead‐time Mitigation
You can control both cost and lead time by making careful design decisions. Choose standard modules when possible to cut down on custom work. If you keep geometries simple and use consistent specifications then it will also speed up manufacturing and lower costs.
Best Practices & Pitfalls to Avoid When Selecting Non Standard Automated Industrial Parts
Best Practices
- Involve your mechanical, controls and maintenance teams from the beginning.
- Prepare thorough documentation that covers all functional needs, technical details as well as interface controls.
- Emphasize modular designs and standardized interfaces. This approach makes maintenance, repairs and future upgrades easier.
- Use simulation tools like FEA to check structural designs before starting manufacturing.
- Select suppliers who have a strong track record in custom automation and offer reliable technical support.
Common Pitfalls
It’s better to pay attention to common mistakes before starting work. Watch out for these issues
- Starting the design process without clear requirements often causes redesigns and higher costs.
- Failing to plan for maintenance and spare parts can result in expensive downtime.
- Adding unnecessary exotic materials or complicated shapes can drive up expenses without real benefit.
- Ignoring future scalability limits your system and prevents it from meeting new needs.
Richconn Non Standard Automated Parts Manufacturing Facility
Richconn specializes in making custom metal and plastic parts for automated equipment. Our facility houses more than 100 advanced CNC machines, including 3, 4 and 5 axis systems. With this equipment we produce complicated metal and plastic parts with very high precision. Feel free to contact us for a quote on your upcoming project.
To Sum Up
Choice of the right non standard automated parts has a key role in your project’s success. Define your requirements clearly and pick suitable materials. Working with qualified suppliers like Richconn helps you create dependable solutions. Following best practices keeps your system scalable, easy to maintain and affordable over time.
Related Questions
3D printing now serves as a common method to prototype and make lightweight, low‐load custom parts. Materials like PLA, ABS and nylon composites are often used for these applications.
Prices depend on factors such as design complexity, material choice and order size. Costs can range from just a few dollars to several thousand for highly customized parts.
Necessary standards depend on the industry. Common certifications include ISO 9001, CE marking, RoHS compliance and ASTM material standards to assure safety & quality.
