Looking to arc together sections of bicycle chain...

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Anyone have experience with this, or know of a shop that could help me with this? Basically, I am looking to create designs out of bicycle chain, and then instead of trying to weld each link ( huge pita/time consuming!) I am hoping that there is an arc process or plating type process that can fuse them all together to retain those shapes for decorative purposes. Think between 12-24 links at a time, in a jig, and then 'zap', or what have you, and then they would be fused, and ready to finish. I am looking to do commercial volume on these if I can get the per piece cost to a reasonable price. also hoping this same process (or processor) can also handle chemical cleaning of chains with varied dirty lubricants on them. Anyone have any ideas for a good contact to try this process? I am looking to do hundreds to thousands of these this summer if the per piece is competitive. Thoughts?Last edited by rideit; 05-27-2012 at 12:37 PM.
Reply:Cleaning will be a big issue if welding. Residual grease/oil will cause problems welding unless it can be completely removed. Maybe you could get non lubricated chain in large quantities direct from the manufacturer. It's common to pre-lube chain before shipping to prevent rusting. If you will be making a large quantity of the same shape, a jig could be built to quickly position the chain in  the desired shapes. Then a CNC welder (MIG, TIG, or Laser) could be programmed to quickly step around the shape to spot weld it together.  For higher volume, automated loading and unloading of the chain could be implemented. Even more automation could cut the chain to the correct lengths.I'm a retired automation engineer  Sorry, but I cannot help with any contacts for this. My work was mostly in integrated circuit manufacturing.CharleyMiller MM252Miller Bobcat 225NTMiller DialArc HF / DIY Cooler2 Victor O/A TorchsetsMilwaukee 8" Metal SawMilwaukee Dry Cut "Chop" Saw 5 Ton Wallace Gantry Various Grinders, Benders, etc.
Reply:Thanks, Charley, I appreciate any suggestions. Part of what I sell is repurposed (used) bicycle components, as that has a very strong appeal for the bicycle crowd. I am trying to find info on chemical cleaning, as well as unplumbed bulk direct from manufacturer, but it is not easy to get through to the right folks, (but I have only really just begun). I will be subbing these out to a manufacturer that can either handle the chem clean, or source the unlubed stock chain, so ANY commercial contacts or suggestions will certainly be helpful!
Reply:Oh, Fwiw, this is my little business, if it helps to contextualize.https://www.facebook.com/pages/Bicyc...27621407276660
Reply:Buy a 5 gallon pail of chemdip or other high quality solvent and a parts washer. Cleaning bicycle chain should be a few minute ordeal including soaking time. Sent from my Galaxy Nexus using Tapatalk 2Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:Seeing as I owned a bicycle shop for 15 years, and worked in them for ten years before that, I do not concur. Especially if you are wanting to clean a few hundred at a time.
Reply:What about sandblasting them?  We'd sandblast every greasy car part that came in the shop, spray some rubbing alcohol on it, and powdercoat it without a problem. If we could powder over it without any problems you can definitely weld itEdit: After degreasing with Simple Green and a tire brush.Last edited by Ludasmith; 05-27-2012 at 06:34 PM.
Reply:Again, I am looking to find a supplier that will handle this step, as well as the fusing/welding or wht have you.
Reply:could they be oven heated and dipped in to a liquid flux and then dipped in molten solder, zinc, tin etc some what like making of circuit board, that is dipped soldered.I do not know but possibly there is a substance that could be applied on cool and oven heated or the ends touched and Resistance convection or induction heated to hold in a shape,if cleaned in a tumbler with the proper cleaning agent,  (aka cement mixer with degrease type cleaner)  and dip in a clear epoxy and left to set up,or something that is UV cured,  (when I was in the dentist he remade some teeth sections for me out of some type of UV curing product). ,Last edited by Farmerboy; 05-27-2012 at 09:03 PM.
Reply:I gotta tell you.. I keep getting lightweight spam emails from one of the bicycle parts supply warehouses.  They always advertise % discount over retail pricing.  Generally each month there is one or two items that offer 93 or 94% discount.  When you go to find out what item that is, its generally a piece of jewelry made from bicycle parts.  I think its performance bike, but not positive.  ooooo... just found it... Its pricepoint... www.pricepoint.com   Chrome-Link-BraceletGood luck, but do tread carefully.zip.
Reply:Originally Posted by zipzitI gotta tell you.. I keep getting lightweight spam emails from one of the bicycle parts supply warehouses.  They always advertise % discount over retail pricing.  Generally each month there is one or two items that offer 93 or 94% discount.  When you go to find out what item that is, its generally a piece of jewelry made from bicycle parts.  I think its performance bike, but not positive.  ooooo... just found it... Its pricepoint... www.pricepoint.com   Chrome-Link-BraceletGood luck, but do tread carefully.zip.
Reply:No offense intended.  From your first posting, i just assumed you were working on jewelry.  You weren't all that specific before.  You said "designs".  All i'm saying is based on one small snapshot at that bracelet pricing, bicycle chain jewelry design projects are probably doomed.As now described, the project sounds intriguing.   Good luck.
Reply:Can any of you recommend a fab shop that might be able to bid on a job like this? I am happy to call anyone anywhere that might be able to help me find a solution. Rather stay in the US if I can!
Reply:Originally Posted by rideitCan any of you recommend a fab shop that might be able to bid on a job like this? I am happy to call anyone anywhere that might be able to help me find a solution. Rather stay in the US if I can!
Reply:Thanks for the plating insight.  I started this thread topic specifically with this title because that is what I am looking for...a mechanical/ electric process for fusing that introduces little if no additional cost per piece. I am thinking the hydraulic pressing of the forms in order to deform the link pins is getting on target, but I will have to devise over 45 jigs that would likely need to be less than 4mm each in order to do this, I would think. Bottom line: these are a commodity project, that I will source and sub to a fabricator that can do it for me. My own time is better spent on pieces that I am working on that retail for up to 5,000, and I have a few hundred to make for the summer art shows here in JH, which go for $75-$350.These pieces will retail for $10-$25, at most, and I am hoping for wholesale distribution eventually (think thousands).Any welding or brazing technique would have to automated.
Reply:How big are your pieces? There are companies out there that have cnc welders. Fixture your parts and start the cycle.Something like this:http://www.centroidcnc.com/cnc_welder.htmHonestly a good welder can likely do this an still be competitive... your talking about tacking links. Remember that a human is much more adaptive than a machine which makes bringing new designs faster to market. Hundreds is still in the realm of hand work/cottage industry. Do you know how long each part takes to tack up?As for cleaning... SuperArc nailed it. Another option may be ultrasonic cleaning.