The Definitive Guide to Custom Hinge Manufacturing


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The Definitive Guide to Custom Hinge Manufacturing was created to give customers a close up look at what custom industrial hinges are, how they are made, what equipment is used in the process as well as some practical advice about what to look for in terms of craftsmanship as well as important topics such as tolerances. You can find out more by visiting our website.

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The Definitive Guide to Custom Hinge Manufacturing

  1. 1. An Introduction to Custom HingesHinges – for some companies, hinges might be the last thing you think about when constructing anew product or trying to improve an existing one, but if you ignore these little pieces of metal it canmake life quite difficult! The goal of a custom hinge is to integrate a separate hinge application intotwo components of the finished product while maintaining functionality of the moving part(s).Custom hinges allow for the elimination of a hardware hinge and often can reduce the overallmanufacturability of the parts while significantly improving performance and reliability. What youwill find in this book is that hinges are not merely parts for functionality; they are also closelyrelated to design.People who are building a specific product must pay close attention to design. The quality of thedesign is just as dependent on good craftsmanship as it is on choosing the decoration of theproduct. Although custom hinges are generally used in an industrial or commercial setting, theprocess for designing and building one is not that different from any type of hinge. For instance, agood carpenter is not going to grab a bunch of shelf product hinges from a hardware store to fityour doors, cabinets, windows and cupboards. He is going to discuss with you exactly what youwant, how you wish your
  2. 2. The Most Popular Types of Custom HingesConstruction and manufacturing depends on hinges. Look around at your everyday objects, and youwill see the number of hinges involved, from your laptop computer to the thick metal plates on thedoors, trunk and hood of heavy machinery. Each type of hinge takes a special consideration as tothe weight of the object, distribution of weight, strength, durability, materials, use and design. Thehinges you choose in your construction and manufacturing can be the deciding point in the qualityof your product.ATM HingesThese incredibly sturdy hinges are built specifically for the banking industry for use in ATM kiosks orbuilt-in ATM machines. The unique feature of this maximum strength hinge is that it runs the entirelength of the door. One of the leaves and knuckles are integrated into the door, and the other intothe stationary machine, creating a fixed, nearly seamless component for high-security use. This typeof hinge design is
  3. 3. particularly beneficial for ATM machines and other structures that need to maintain high securitylevels and cannot afford any gaps or potential forced entry points in their construction.Because of its strength and resistance to corrosion, stainless steel is the most common materialused for this type of hinge. American steel and aluminum, however, are also sometimes useddepending on the type of project.There are many types of finishes used to complete the look, feel or aesthetic quality of an ATMhinge. Options include powder coating, passivating, mass media blasting and tumbling, plating, E-coating and anodizing.Butt HingesButt hinges are the most typical choice for mounting the doors in a house, building or other non-specific needs structure. Butt hinges are generally six inches or shorter in length and are used inmultiples for installation. They are usually comprised of two matching leaves; one attached to themoving element or door, the other mounted to the fixed structure. When the door is shut, the twoleaves are flush, exposing the “knuckle”, which is the curved barrel of the hinge.Butt hinges made from stainless steel are able to withstand marine abuse or harsh environment andare routinely used by marine industries. Additionally, they are generally the choice of fittings forcabinets, internal doors, fire doors, external doors, lids and many other products. Along withstainless steel, the materials offered in the manufacturing of butt hinges include cold rolled steel,hot rolled steel, aluminum, galvanized steel and galvanized steel. Preferences for finish includepowder coating, passivating, anodizing, plating and E-coating.
  4. 4. Concealed HingesThe practicality of concealed hinges is their use within closed or confined spaces. These hinges arenot visible when the door is shut, which is why they are referred to as concealed hinges. Theirconfiguration allows the door to swing out and clear of the frame when it is opened.Concealed hinges are most commonly used when the design calls for a smooth, unbroken surface,such as metal cabinets, storage lockers, ATM machines, office and marine applications, theoverhead compartments of airplanes and for automobiles. You can customize your concealedhinges from steel, stainless steel and aluminum, selecting a finish in a variety of colors and textures.Continuous/ Piano HingesContinuous hinges are popular due in large part to the technology of how they are designed andbuilt in a manner which distributes weight and stress in a uniform fashion across a long distanceand are very easy to install. One of the main reasons they are also called piano hinges is becauseyou will most commonly see them used hinging piano door covers into place. The weightdistribution allows the heavy lid to be opened with ease, without straining the perfect and delicateconstruction of the piano. They are the ideal choice for simple applications with cost restraints.Other applications where you might find this type of hinge used is in barn doors, warehouse doors,blast doors, electrical doors and toolboxes. The most common materials for continuous hingesinclude steel, stainless steel, and aluminum. All three materials can come with the metal finishing ofyour choice. Secondary operations i.e. cut to length, add holes to the leaves, stake the pin, or addforms to the leaves, can be applied to the continuous hinge to further customize the desired finalpart.H- HingesManufacturers often forget to include the specifics of the amount of weight involved when creatinga product. The end result may be using hinges that are too light for the specific application – a surefire recipe for product failure. H-hinges are designed to
  5. 5. hold up to several hundred pounds when correctly installed. In order to receive maximum weightproperties, your project may require more than one for more even weight distribution, however H-hinges are very easy to install, are versatile and can be used in a number of applications. This typeof hinge is identified by a strap that forms the letter, “H”, which is attached to the joint over thecrossbar, reinforcing the ability of the hinge to support heavy weight. H-hinges come in steel,stainless steel, aluminum and your choice of metal finish.Inset HingesInset hinges are very much like concealed hinges, in that both sides of the hinge are mounted on asingle side of the frame, giving a seamless appearance. However, inset hinges have an additionaladvantage. Depending on the requisites of the project, an inset hinge can be used to move bothhorizontally and vertically. Materials used for these hinges are usually steel, stainless steel oraluminum. The finishes are customized to suit the environment where the hinge will be used.Latch HingesLatch hinges do exactly what the name implies. It is a hinge with an in-built latch mechanism whichallows it to function as a single piece of hardware. Generally, latch hinges have a spring release, butthey can also be built without them. When combined with a spring hinge, it will have a single handleor set of handles that are loaded with the springs. This set of springs will release the door whenpulling it toward the center. When produced without the spring hinge, the latch will normally havea simple slot that can be easily installed with screws or rivets, although it’s recommended that forbest efficiency, the latch is welded. Custom made latches are offered with a variety of finishesaccording to the most appropriate for your application.Lift Off HingesFor a product that receives a lot of wear and tear and requires frequent maintenance, there isnothing more convenient than lift-off hinges. Lift off hinges are especially
  6. 6. designed for easy removal of doors that suffer routine damage. You just lift it from the hinge andrepair it. Lift off hinges are incredibly versatile in the style and type offered to suit your productneeds. They include loose joint butt hinges, stainless steel lift-off hinges, flag lift-off hinges, takeapart hinges, drive in hinges and hatch hinges.Marine HingesThe harshest condition for any metal equipment is constant exposure to moisture and salt water.For this reason, marine hinges must be manufactured to the tightest tolerance and highest-gradematerials for withstanding the corrosive conditions that invite rust, salt and grit, and hampers theability of hatches, doors and openings to function correctly. Primary safety concerns dictate thatthis cannot afford to happen.Marine hinges will also be found in use for lights and electronic mountings, seating, boat boxes andwindshield attachments. Only state of the art technology is acceptable in manufacturing hinges forthis - the most demanding of all environments.Non-Mortise HingesWhen would you use a non-mortised hinge? It’s most practical use is in the application of bi-folddoors, wrap-arounds, shutters, screens and cabinets, and as a lift-off non-mortise hinge. Its greatadvantage is that it does not require the additional work and precision of a mortised hinge. It sits onthe surface of the face or jamb of the door and can be easily adjusted if out of line by simply re-drilling the mounting holes. Furthermore, it leaves only a small gap between the door and theframe; however a poorly mounted non-mortise hinge might require filing, sanding and a re-cut tomake the hinge fit correctly.Some types of non-mortise hinges include a hinge with a finial tip, flag style hinges, tipped, non-mortise, steeple tipped, bell tipped, shutter hinge, lid hinge and locking bi-fold hinge.
  7. 7. Off-Set HingesOffset hinges change the swinging pattern of the unit as the two components attached to the hingeopen and close. The most common places you will see offset hinges are on the lead-lined doors inhospitals and clinics, on the bathroom doors of airplanes and for medical equipment. In an offsethinge, either one or both of the leaves are formed away from the pin. This allows for a decrease ofleaf width as well as a decrease of opening width. This makes the hinge useful when space islimited. It also insures that the hinge does not corrode or become damaged by the knuckles rubbingagainst the hinge. Common types of offset hinges include offset butt hinges, offset pivot hinges andoffset strap hinges.Removable and Slip Joint HingesRemovable, slip joint or take apart hinges as they are also known, are very similar to lift-off hingesin their application; that is doors can be removed easily for repairs and maintenance. Only thetechnique is different. Instead of sliding the door off its hinges, the hinges themselves areremovable. This allows for speedy and efficient door removal and re-installation withoutcompromising the integrity of its motion and path.While removable hinges are generally built from steel, stainless steel or aluminum, there is a greatdeal of variety in your choice of finish. These choices include silk screening, passivating, anodizing,E-coat, powder coating, mass media blasting or tumbling and zinc plating.Security HingesSecurity has become a highlight on everybody’s list; especially for banks, high-end industries,technology companies and office buildings. Security hinges are built to
  8. 8. prevent doors from being opened from the hinged side. They are especially resistant to breakingand can be designed to prevent or discourage removal.Security hinges come in a wide assortment of sizes, materials and functions based on theapplication for which they were designed. Examples of security hinges are those designed to allowelectricity to a door in a hidden manner, or the ability to self-close. Others may feature a non-removable pin, which incorporates a screw in the barrel that is accessible only when the door isopen. Other types of security hinges include an interlocking security stud pin, a secured hinge pin,or a hinge pin set screw type. Various types of continuous hinges can provide extra strength to aweakened area and do not allow a gap between the door and the jamb.Spring HingesThe unique feature presented by spring hinges is that they use the energy of a spring to return anopened door to its original position. Spring hinges can also be used to keep a door locked into anopen position without the necessity of doorstops or props. Spring hinges reduce the costs ofinstalling door-closing devices on industrial, commercial, institutional and residential applications.They are used in hotels, apartments, dormitories and other public service construction where doorsare required to be self-closing.Typically, the materials used for spring hinges include cold rolled steel, stainless steel, or aluminum,with choices in anodized, plated or passivated finish. Other considerations involved in choosing thespring hinges for your project are the amount of torque required, whether the spring will benormally closed or open, the spring’s life
  9. 9. cycle and the operating arc. You may also wish to know if the spring can be replaced if it fails to givethe maximum performance required.Staked HingesStaked hinges have a fixed or staked pin. This is a cost effective way of ensuring that the pin stays inplace and will not be affected during the course of normal use. Either staked or loose pins spun onboth ends are particularly useful in very unstable or high vibration environments such as in the useof industrial machinery. Staked pins are often used in many products and applications where thehinge pin needs to stay in place and where removing it is not advantageous. You will often findstaked hinges in vertically mounted equipment where the critical the pin does not fall out.Strap HingesStrap hinges are a very traditional type of hinge but remain popular for a number of reasons. Atypical strap hinge is made up of two unequal hinge parts, where one is longer than the other. Thelarger part, called a leaf, creates a mounting surface for the smaller leaf, which is used as theopening mechanism. Strap hinges are advantageous because they can be used for full surfacemounting to wood, metal or structural steel, and the design can be industrial or more ornate,lending aesthetic appeal. Strap hinges are often used for gates or enclosures, as they are able tosupport a great deal of weight. Heavy-duty strap hinges are able to stand up to a great deal of useand with their versatility can be fashioned into many attractive designs.Hinge FinishesTake some time to consider the finish you wish to add to the hinges you have chosen as this finaltouch can increase the value of your product in a number of ways. It can add an attractive touch,protect the hinges from corrosion or tarnish, create chemical resistance, modify electricalconductivity, remove burrs and other surface flaws and control surface friction. Protect yourinvestment and add the personal touch by choosing a compatible finish for the hinges you will beusing.
  10. 10. partitions and accessories to function, whether the hinges should be decorative or unobtrusive, andeven considerations to the type of building material you wish used, such as steel, stainless steel oraluminum.With all the different types of products, doors, machinery and industrial products available, there isa great need to find the right specialty hinges for particular design layouts and functions that youjust can’t find by visiting your local hardware store, or ordering generalized mass-produced hingesfrom a factory. For these purposes, you need custom manufactured hinges.There are a number of specialty hinges. In this short eBook, we will take a closer look at the mostpopular types of custom hinges, as well as the fundamentals of using them in manufacturing. Solet’s get started with the first section!Find more about hinges Click Here