The need to reduce vehicle weight has spawned myriad new technologies for assembling aluminum, high-strength steel and other materials. These new technologies include self-piercing rivets, flow-drilling screws and friction-stir spot welding.

Lean manufacturing was not a concern for Mark DeWys in 1977 when he founded DeWys Manufacturing Inc. in Grand Rapids, MI. The focus of his one-man shop back then was the fabrication of fireplace inserts, racks and various small metal parts.

Manufacturers increasingly need to join multiple sheets of lightweight materials. Clinching can do it quickly, consistently and cost-effectively.

With specialty tack fasteners, manufacturers can quickly attach nameplates, install microelectronic components, and join thin and thick sheets of different metals.

MARNE, MI—Metal fabrication shop DeWys Manufacturing Inc. has developed a robotic cell that automatically installs up to eight self-clinching fasteners in sheet metal.

Automakers are increasingly using hydroformed metal tubing in vehicular structures. Compared with stamped and welded metal parts, hydroformed parts weigh less, cost less, and have a higher stiffness-to-weight ratio.

As household appliance manufacturers continue using thinner sheets of material, engineers must address new challenges and explore alternative joining solutions.

Steel is not about to disappear anytime soon as the dominant material used in the home appliance industry. Unlike automakers, which are turning to aluminum, carbon-fiber composites, magnesium, plastic and other lightweight materials, steel still rules in the world of refrigerators, dishwashers and dryers.