Three Production Methods for Custom Hinges

• Modify a stock hinge: cut down a standard length or width, punch holes in choice of size, spacing and shape (e.g. round, square, rectangular, obround - countersunk or plain). Additional operations are available, such as pin retention, bends, swages, PEMs and notches. This is the best option for small quantities, rush delivery or experimental samples.
  
  
• Secondary operations on a custom-run base hinge: run the base hinge in a hand blank and curl operation (usually for heavier gauges) or on a scrapless automatic line (for lighter gauges). Finish with offset or swaged leaves, rounded corners, stamped part numbers, PEM™ fasteners, springs, staked or spun pins, holes, etc. This is the most common method for moderate quantities, and generally takes longer than the first method.
  
  
• Full custom manufacture: scrapless automatic production with custom-made tools or laser cutting machinery. Eliminates the need for secondary operations. Longer lead time on first order. Quick production and lowest cost on reorders of large quantities. Note: This method may involve tooling costs.

Custom Hinge Design Considerations

1. Start with a standard product from our catalog. We have over 600 in-stock items from which to choose.
   
   
2. For most items (up to .074 thick) it is most economical to choose an even multiple of the knuckle length. For heavier items that are hand blanked and curled, this is less important. We may suggest a different knuckle length, number of knuckles or overall hinge length if it turns out to be a cost effective change.
   
   
3. Partial end knuckles on lighter hinges (below .074") can bind because they are deformed in the cut off operation, but this can also be used as pin retention on the hinge.
   
   
4. Unequal leaves on lighter hinges are sometimes less expensive when the total width is equal to a standard width. For example, leaves of .50" and 1.50" (2.00" total - a standard) are preferable to .50" and .625" (1.125" total).
   
   
5. Use the same thickness hinge leaf as the door or base material. Exceptions are recommended when the width of the door is more than twice the height, or if a device mounted on the door doubles the moment of the door.
   
   
6. A 2:1 ratio of pin diameter to leaf thickness usually provides optimum strength. For example, a .120" diameter pin with a .060" leaf.
   
   
7. Most stock hinges are supplied with the pins not staked in place. Let us know if you require staking or another type of pin retention. (Those stock hinges which are staked are so noted.)
   
   
8. Standard tolerances for hinges made with secondary finishing operations are shown in the diagrams below. If you require tighter tolerances for your application, we may be able to meet your requirements with special fixtures or tooling.
   
   

   Tolerances for .025 to .062 thick material
   Tolerances for .074 and thicker material