Case Studies | Marlin Steel Wire Fabricated Wire Products

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Industrial Case Study | Medical

*A worldwide maker of orthopedic devices and other surgical products needed a specialized steel wire basket to cleanse small parts. Cost and delivery turnaround of the custom baskets were key factors. The design function of the fabricated wire products was even more crucial.

The customer told basket maker Marlin Steel Wire Products that it required a basket that could hold 20 pounds of small palm-shaped parts. It proposed angled insert dividers that would enable water to drain off the parts after washing. It also wanted a handled lid with no hinge so the lid could fit inside the basket and rest on top of the parts to hold them in place. The baskets also had to be made of stainless steel and coated with nylon to withstand 30-minute washings in soap and water at 150 degrees Fahrenheit.

The customer received eight of the steel wire baskets, built to order, before its holiday recess and was very pleased with the result. "Received the baskets before shutdown, just got the dividers this morning. Everything looks great!" it wrote Marlin.

Industrial Case Studies | Aerospace

* AAI Corp. needed specialized steel wire baskets to protect microphones that are mounted on military vehicles. The microphones are vital because they assist troops in locating the enemy by the sound of their gunfire. The welded covers had to be unfailingly dependable and able to stand up to extremely harsh conditions.

Marlin Steel Wire Products was able to replicate AAI’s design with speed and quality. As a result of its work on the microphone cages, Marlin was designated a preferred supplier by AAI.

* GKN Aerospace, one of the world's leading suppliers to the aviation industry, needed a quick solution for how to transport turbine blades. It turned to Marlin Steel Wire Products, which engineered baskets from stainless steel with separate compartments to contain 25 blades and a set of documents.

GKN required the carriers to handle two different types and sizes of blade parts. But the baskets had to do more than carry up to 20 pounds worth of turbine blades. They had to secure the blades when they were being washed as well. And they needed to be able to stand up to an Ardrox 185 soap solution and water for 20 minutes. The customer also instructed Marlin's designers that the baskets would be exposed to ferric chloride, hydrochloric acid and ammonia for up to 20 minutes at a time and at 185 degrees Fahrenheit.

Marlin turned to halar coating, which holds up well to those chemicals. The baskets were also designed with sizable cutouts to aid air-drying of the blades. Functionality and appearance were important, GKN told Marlin, but holding down the cost of each basket was job one.

Industrial Case Studies | Industrial

* The basket request from Alcoa was hardly typical. The manufacturer of components for aviation and other technology industries needed a circular wire mesh basket, four feet in diameter. The fabricated wire products needed handles so it could be lowered to fit inside a large tank, with the ability for the baskets to be stacked. The basket needed triangular hook attachments and no sharp edges. It would be exposed to extreme heat for short periods of time. And it had to be able to hoist up to 600 pounds of metal alloy parts.

It was an experimental design, but Marlin Steel Wire Products fabricated the baskets with economy and speed as the customer required.

* A producer of cylinders had an issue: As it experienced increased demand, it needed a more effective racking system to wash the cylinders. Photos of its existing system showed that the cylinders sometimes leaned to one side as they rode a conveyer through the wash system. That made it tougher for the cleaning jets to reach inside to clean them thoroughly.

The customer sought out Marlin Steel Wire Products to design a new racking system that would work more efficiently thru the wash cycle. The design challenge was heightened by the fact that the basket dimensions were restricted by the opening of the washer. The baskets also had to be designed to withstand a bath of acid and caustic cleaners used to sanitize the cylinders, as well as a heated drying process.

Marlin created a lid and tray system that could quickly accommodate cylinders of different sizes. Marlin designers devised a quick-release latch system that held the bottles in place more securely and maximized the number that could be washed per cycle. The latch system also ensured that the cylinders remained completely vertical so the cleaning jets could reach more thoroughly inside the cylinders. They needed 200 to 300 and Marlin delivered in full on functionality, speed, cost and appearance.

Industrial Case Studies | Other

*The firearms manufacturer Beretta needed a custom steel wire basket to transport newly constructed pistol slides during its gun assembly process. The basket that Beretta required wasn't a particularly complicated design, but the dimensions and wire gauge needs were fairly exacting to accommodate the delicate slides.

The baskets had to be stackable, up to four of them at a time, with handles on the sides that wouldn't interfere with stacking. The slides had to be protected from excessive shock or vibration as they moved along the assembly line.

Marlin Steel Wire Products of Baltimore put its designers to the test. The wire size needed was much smaller than Marlin's standard wire gauge requests. The designers also had only about a millimeter or two of tolerance to work with within the baskets or the slides wouldn't have fit securely onto the holders.

The baskets had to be resilient enough to withstand a lot of handling and movement on carts and dollies, while cushioning about 14 pounds worth of pistol slides inside. Marlin's designers relied on simple, but effective u-shaped pins to hold two dozen of the 9.3-oz. slides snugly in place. Marlin quickly devised a solution that was simple, cost-effective and durable in being able to transport the slides security and to help keep Beretta operating smoothly.

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