How are metal anchor expansion tools manufactured?

5th March 2020

How are metal anchor expansion tools manufactured?


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		Metal anchor expansion tool are manufactured from steel using one of two main processes – stamping or casting – while the handle sleeves are made of plastic using injection moulding or PVC dipping.

		How are non-ratcheting models made?
		Non-ratcheting metal anchor expansion tools are made from sheet steel that is shaped by stamping. The stamping processes used to do this are blanking and bending.

		What is blanking? Blanking is a shearing (cutting) process that cuts the outline of the part you want from a sheet of metal in a single step. The sheet metal is placed between a punch and a die. The die has a cut-out shaped to the outline of the desired part, and the punch is the same shape as the cut-out in the die.

		As the punch and die are forced together a sheering (cutting) action removes a section of the sheet metal. This section is called a blank, which is how the process gets its name.

		After the blanking process the blank that is produced is placed in a bending machine which bends the metal into the shape of the metal anchor expansion tool.

		What is bending? As its name suggests, bending is a manufacturing process used to shape a part by bending it to the desired shape. Like blanking, bending uses a punch and die, but unlike blanking the die does not have a cut-out. Instead the die is formed to the outside shape of the bend required and the punch is formed to the inside shape of the bend.

		As the two are brought together the sheet metal workpiece is bent between them. A workpiece may undergo several bending operations to achieve the final shape.

		Once this shape is achieved the parts are ready to have a surface coating applied to protect them from corrosion before then being assembled to produce the finished tool.

		How are ratcheting models made?
		The handles of ratcheting models are produced in the same manner as non-ratcheting models, using stamping processes. While the heads of ratcheting models may also be produced using these stamping processes, they are sometime made using casting methods instead.

		What is casting? Casting involves molten metal being poured into a mould which has a cavity in the shape of the desired part. After the molten metal has solidified and cooled the mould is separated or broken up to reveal the part within.

		Which is better: stamping or casting?
		A metal anchor expansion tool with a head that has been cast will be stronger and likely to last longer than one that has been stamped. This is because the metal head of the tool will be made of thicker material. However, it will also be heavier, which could make it tiring to use if you have a lot of hollow wall anchors to install.



		How are the handle sleeves manufactured?
		The handle sleeves of a metal anchor expansion tool can be made by either PVC dipping or injection moulding.

		What is PVC dipping? PVC (polyvinyl chloride) dip moulding is a manufacturing process that involves a heated former, in the shape of the tools handles, being dipped in a bath of liquid PVC. As the former is gradually removed and left to cool the PVC solidifies on the former.

		Once cooled the PVC is then removed from the former by hand and compressed air, before being fitted on the handles of the metal anchor expansion tool.

		What is injection moulding? Injection moulding involves raw plastic beads (such as nylon) being fed from a hopper into a heated barrel chamber. This melts the plastic, which is then pushed though the barrel by a screw mechanism and into the cavity within the mould. The molten plastic solidifies within the mould cavity. When the two halves of the mould are separated, the finished part is revealed.

		Injection moulding can be used to make a wide range of products such as plastic toys and mobile phone covers as it’s a very quick and cost-effective way of manufacturing high volume products. It can also make bi-material parts such as the handles found on better quality metal anchor expansion tools. A second injection process using TPR (thermoplastic rubber) gives a rubberised grip to the handles for improved comfort and grip.

		What is the best type of handle sleeve?
		PVC dipped handle sleeves will only follow the shape of the metal handles so are not as ergonomically formed (shaped and designed for comfort, safety, productivity and efficiency) or comfortable to use as injection moulded handles. Bi-material injection moulded ergonomic handles will be the the most comfortable to hold and have the best grip.