Our E-book "The Definitive Guide to Custom Hinge Manufacturing" was created to give customers a close up look at what custom industrial hinges are, how they are made, what equipment is used in the process as well as some practical advice about what to look for in terms of craftsmanship as well as important topics such as tolerances. You can find out more by visiting our website http://www.midlake.com/.

1. Copyright 2012 Midlake Products & Manufacturing. May not be re-produced without permission.

2. Table of Contents
Introduction ................................................................................................................... 3
Customizing Your Work ........................................................................................................4
Ways of Building Custom Hinges .........................................................................................5
Using Traditional Technology ....................................................................................................... 5
CNC Turret Presses ..................................................................................................................... 6
Incorporating Skill and Craftsmanship .......................................................................................... 7
The Most Popular Types of Custom Hinges .........................................................................8
ATM Hinges ................................................................................................................................. 8
Butt Hinges .................................................................................................................................. 9
Concealed Hinges...................................................................................................................... 10
Continuous/ Piano Hinges .......................................................................................................... 10
H- Hinges................................................................................................................................... 10
Inset Hinges ............................................................................................................................... 11
Latch Hinges .............................................................................................................................. 11
Lift Off Hinges ............................................................................................................................ 11
Marine Hinges............................................................................................................................ 12
Non-Mortise Hinges ................................................................................................................... 12
Off-Set Hinges ........................................................................................................................... 13
Removable and Slip Joint Hinges ............................................................................................... 13
Security Hinges .......................................................................................................................... 13
Spring Hinges ............................................................................................................................ 14
Staked Hinges ........................................................................................................................... 15
Strap Hinges .............................................................................................................................. 15
Hinge Finishes ........................................................................................................................... 15
A Few Words About Tolerances.........................................................................................17
The Impact of Lead Time ...................................................................................................17
Quality Manufacturing ........................................................................................................18
About Midlake Products .....................................................................................................18
Conclusion ................................................................................................................... 19
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3. An Introduction to Custom Hinges
Hinges – for some companies, hinges might be the last thing you think about when
constructing a new product or trying to improve an existing one, but if you ignore these
little pieces of metal it can make life quite difficult! The goal of a custom hinge is to
integrate a separate hinge application into two components of the finished product while
maintaining functionality of the moving part(s). Custom hinges allow for the elimination
of a hardware hinge and often can reduce the overall manufacturability of the parts
while significantly improving performance and reliability. What you will find in this book
is that hinges are not merely parts for functionality; they are also closely related to
design.
People who are building a specific product must pay close attention to design. The
quality of the design is just as dependent on good craftsmanship as it is on choosing the
decoration of the product. Although custom hinges are generally used in an industrial or
commercial setting, the process for designing and building one is not that different from
any type of hinge. For instance, a good carpenter is not going to grab a bunch of shelf
product hinges from a hardware store to fit your doors, cabinets, windows and
cupboards. He is going to discuss with you exactly what you want, how you wish your
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4. partitions and accessories to function, whether the hinges should be decorative or
unobtrusive, and even considerations to the type of building material you wish used,
such as steel, stainless steel or aluminum.
With all the different types of products, doors, machinery and industrial products
available, there is a great need to find the right specialty hinges for particular design
layouts and functions that you just can’t find by visiting your local hardware store, or
ordering generalized mass-produced hinges from a factory. For these purposes, you
need custom manufactured hinges.
There are a number of specialty hinges. In this short eBook, we will take a closer look
at the most popular types of custom hinges, as well as the fundamentals of using them
in manufacturing. So let’s get started with the first section!
Customizing Your Work
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5. Specialty hinges need to be sized to exact specifications in order to produce their
highest degree of effectiveness. Whether you are doing the manufacturing phase of
your project on your own, or have hired an outside contractor, consult a sales engineer
who has the technical background necessary to understand the requisites for each
product, and its expected performance.
There are many considerations involved in choosing the materials and design of a
specialized hinge, such as weight, durability and thickness. Once a sales engineer
understands your expectations, and how the product is expected to perform once it’s
attached to the other parts, he can work with you and give you recommendations and
suggestions based on past experiences.
Other considerations include configuration, design features, types of materials used,
welded pins or machined pins and caps, and use of the product. The hinges used for a
steel safe are not going to fit the same requirements used for an automatic door in a
doctor’s office.
Ways of Building Custom Hinges
Using Traditional Technology
The punch press is a wonderfully efficient piece of technology, making it possible to
perform many secondary operations on the turret press as well as standardized
punching, saving time and reducing machine downtime. In many cases, the use of a
punch press will eliminate some of the additional equipment and part handling often
needed for a customizing a hinge product.
Secondary operations for fashioning a custom hinge include using special applications
handling with a turret press. A special punch tool can produce self-locking, spring-
loaded tabs that snap securely into pre punched holes, eliminating the need for welding
connecting parts.
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6. The technology used in the punch press application has come a long way since first
introduced, but the initial machinery was only able to produce single shapes, with holes
punched in the exact same place with each application. Today’s machines are more
sophisticated and able to accurately and consistently produce goods to specific
requirements, especially in the hands of a skilled craftsman.
CNC Turret Presses
In keeping with the advanced technology inherent to the punch press, is the
development in versatility for the turret press. Turret presses are used to cut holes in
strong, dense materials, such as brass or steel. Turret presses are used for high
volume production because of the ability to process large workloads without losing
accuracy.
Traditional presses are operated manually, which made them time consuming to
operate, as well as somewhat limited in the type of manufacturing performed. The term
“CNC” stands for “Computer Numerically Controlled” and it refers to the way the turret
press is operated. CNC turret presses operate according to pre-programmed
specifications, creating a product that is both accurate and uniform, according to
specifications.
A CNC turret press is far more versatile than a standardized punch press. With its
advanced, computerized machinery it is capable of creating a number of products
including:
 Embossed holes
 Forming
 Extruded holes
 Tapped holes
Whether a manual or a CNC turret press is used is largely dependent on the type of
work that needs to be done.
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7. Incorporating Skill and Craftsmanship
Precision products demand a great deal of skill no matter what type of machinery or
equipment is being used. And while machinery automates much of the labor,
craftsmanship is defined by the ability to produce quality design and flawless
engineering.
The devotion of a good craftsman is one of pride and integrity. Skills involve not only
knowing how to run machinery efficiently, but also knowing which type of technology is
appropriate for getting the job done right. There are times when high-end machinery is
necessary for optimum performance, and times when only the craftsmanship of manual
operation will produce the type of product that caters to your specific needs. This
personal basis of manufacturing is what makes the production of custom-made products
so valuable. When you want only the best and precision is your goal, then look for a
quality craftsman with the skills to do the job right and the integrity to produce with
maximum efficiency and minimal lead-time.
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8. The Most Popular Types of Custom Hinges
Construction and manufacturing depends on hinges. Look around at your everyday
objects, and you will see the number of hinges involved, from your laptop computer to
the thick metal plates on the doors, trunk and hood of heavy machinery. Each type of
hinge takes a special consideration as to the weight of the object, distribution of weight,
strength, durability, materials, use and design. The hinges you choose in your
construction and manufacturing can be the deciding point in the quality of your product.
ATM Hinges
These incredibly sturdy hinges are built specifically for the banking industry for use in
ATM kiosks or built-in ATM machines. The unique feature of this maximum strength
hinge is that it runs the entire length of the door. One of the leaves and knuckles are
integrated into the door, and the other into the stationary machine, creating a fixed,
nearly seamless component for high-security use. This type of hinge design is
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9. particularly beneficial for ATM machines and other structures that need to maintain high
security levels and cannot afford any gaps or potential forced entry points in their
construction.
Because of its strength and resistance to corrosion, stainless steel is the most common
material used for this type of hinge. American steel and aluminum, however, are also
sometimes used depending on the type of project.
There are many types of finishes used to complete the look, feel or aesthetic quality of
an ATM hinge. Options include powder coating, passivating, mass media blasting and
tumbling, plating, E-coating and anodizing.
Butt Hinges
Butt hinges are the most typical
choice for mounting the doors in a
house, building or other non-
specific needs structure. Butt
hinges are generally six inches or
shorter in length and are used in
multiples for installation. They are
usually comprised of two matching
leaves; one attached to the moving
element or door, the other mounted to the fixed structure. When the door is shut, the
two leaves are flush, exposing the “knuckle”, which is the curved barrel of the hinge.
Butt hinges made from stainless steel are able to withstand marine abuse or harsh
environment and are routinely used by marine industries. Additionally, they are
generally the choice of fittings for cabinets, internal doors, fire doors, external doors, lids
and many other products. Along with stainless steel, the materials offered in the
manufacturing of butt hinges include cold rolled steel, hot rolled steel, aluminum,
galvanized steel and galvanized steel. Preferences for finish include powder coating,
passivating, anodizing, plating and E-coating.
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10. Concealed Hinges
The practicality of concealed hinges is their use within closed or confined spaces.
These hinges are not visible when the door is shut, which is why they are referred to as
concealed hinges. Their configuration allows the door to swing out and clear of the
frame when it is opened.
Concealed hinges are most commonly used when the design calls for a smooth,
unbroken surface, such as metal cabinets, storage lockers, ATM machines, office and
marine applications, the overhead compartments of airplanes and for automobiles. You
can customize your concealed hinges from steel, stainless steel and aluminum,
selecting a finish in a variety of colors and textures.
Continuous/ Piano Hinges
Continuous hinges are popular due in large part to the technology of how they are
designed and built in a manner which distributes weight and stress in a uniform fashion
across a long distance and are very easy to install. One of the main reasons they are
also called piano hinges is because you will most commonly see them used hinging
piano door covers into place. The weight distribution allows the heavy lid to be opened
with ease, without straining the perfect and delicate construction of the piano. They are
the ideal choice for simple applications with cost restraints. Other applications where
you might find this type of hinge used is in barn doors, warehouse doors, blast doors,
electrical doors and toolboxes. The most common materials for continuous hinges
include steel, stainless steel, and aluminum. All three materials can come with the
metal finishing of your choice. Secondary operations i.e. cut to length, add holes to the
leaves, stake the pin, or add forms to the leaves, can be applied to the continuous hinge
to further customize the desired final part.
H- Hinges
Manufacturers often forget to include the specifics of the amount of weight involved
when creating a product. The end result may be using hinges that are too light for the
specific application – a sure fire recipe for product failure. H-hinges are designed to
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11. hold up to several hundred pounds when correctly installed. In order to receive
maximum weight properties, your project may require more than one for more even
weight distribution, however H-hinges are very easy to install, are versatile and can be
used in a number of applications. This type of hinge is identified by a strap that forms
the letter, “H”, which is attached to the joint over the crossbar, reinforcing the ability of
the hinge to support heavy weight. H-hinges come in steel, stainless steel, aluminum
and your choice of metal finish.
Inset Hinges
Inset hinges are very much like concealed hinges, in that both sides of the hinge are
mounted on a single side of the frame, giving a seamless appearance. However, inset
hinges have an additional advantage. Depending on the requisites of the project, an
inset hinge can be used to move both horizontally and vertically. Materials used for
these hinges are usually steel, stainless steel or aluminum. The finishes are
customized to suit the environment where the hinge will be used.
Latch Hinges
Latch hinges do exactly what the name implies. It is a hinge with an in-built latch
mechanism which allows it to function as a single piece of hardware. Generally, latch
hinges have a spring release, but they can also be built without them. When combined
with a spring hinge, it will have a single handle or set of handles that are loaded with the
springs. This set of springs will release the door when pulling it toward the center.
When produced without the spring hinge, the latch will normally have a simple slot that
can be easily installed with screws or rivets, although it’s recommended that for best
efficiency, the latch is welded. Custom made latches are offered with a variety of
finishes according to the most appropriate for your application.
Lift Off Hinges
For a product that receives a lot of wear and tear and requires frequent maintenance,
there is nothing more convenient than lift-off hinges. Lift off hinges are especially
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12. designed for easy removal of doors that suffer routine damage. You just lift it from the
hinge and repair it. Lift off hinges are incredibly versatile in the style and type offered to
suit your product needs. They include loose joint butt hinges, stainless steel lift-off
hinges, flag lift-off hinges, take apart hinges, drive in hinges and hatch hinges.
Marine Hinges
The harshest condition for any metal equipment is constant exposure to moisture and
salt water. For this reason, marine hinges must be manufactured to the tightest
tolerance and highest-grade materials for withstanding the corrosive conditions that
invite rust, salt and grit, and hampers the ability of hatches, doors and openings to
function correctly. Primary safety concerns dictate that this cannot afford to happen.
Marine hinges will also be found in use for lights and electronic mountings, seating, boat
boxes and windshield attachments. Only state of the art technology is acceptable in
manufacturing hinges for this - the most demanding of all environments.
Non-Mortise Hinges
When would you use a non-mortised hinge? It’s most practical use is in the application
of bi-fold doors, wrap-arounds, shutters, screens and cabinets, and as a lift-off non-
mortise hinge. Its great advantage is that it does not require the additional work and
precision of a mortised hinge. It sits on the surface of the face or jamb of the door and
can be easily adjusted if out of line by simply re-drilling the mounting holes.
Furthermore, it leaves only a small gap between the door and the frame; however a
poorly mounted non-mortise hinge might require filing, sanding and a re-cut to make the
hinge fit correctly.
Some types of non-mortise hinges include a hinge with a finial tip, flag style hinges,
tipped, non-mortise, steeple tipped, bell tipped, shutter hinge, lid hinge and locking bi-
fold hinge.
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13. Off-Set Hinges
Offset hinges change the swinging pattern of the unit as the two components attached
to the hinge open and close. The most common places you will see offset hinges are
on the lead-lined doors in hospitals and clinics, on the bathroom doors of airplanes and
for medical equipment. In an offset hinge, either one or both of the leaves are formed
away from the pin. This allows for a decrease of leaf width as well as a decrease of
opening width. This makes the hinge useful when space is limited. It also insures that
the hinge does not corrode or become damaged by the knuckles rubbing against the
hinge. Common types of offset hinges include offset butt hinges, offset pivot hinges and
offset strap hinges.
Removable and Slip Joint Hinges
Removable, slip joint or take apart hinges as
they are also known, are very similar to lift-off
hinges in their application; that is doors can be
removed easily for repairs and maintenance.
Only the technique is different. Instead of
sliding the door off its hinges, the hinges
themselves are removable. This allows for
speedy and efficient door removal and re-installation without compromising the integrity
of its motion and path.
While removable hinges are generally built from steel, stainless steel or aluminum, there
is a great deal of variety in your choice of finish. These choices include silk screening,
passivating, anodizing, E-coat, powder coating, mass media blasting or tumbling and
zinc plating.
Security Hinges
Security has become a highlight on everybody’s list; especially for banks, high-end
industries, technology companies and office buildings. Security hinges are built to
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14. prevent doors from being opened from the hinged side. They are especially resistant to
breaking and can be designed to prevent or discourage removal.
Security hinges come in a wide assortment of sizes, materials and functions based on
the application for which they were designed. Examples of security hinges are those
designed to allow electricity to a door in a hidden manner, or the ability to self-close.
Others may feature a non-removable pin, which incorporates a screw in the barrel that
is accessible only when the door is open. Other types of security hinges include an
interlocking security stud pin, a secured hinge pin, or a hinge pin set screw type.
Various types of continuous hinges can provide extra strength to a weakened area and
do not allow a gap between the door and the jamb.
Spring Hinges
The unique feature presented
by spring hinges is that they
use the energy of a spring to
return an opened door to its
original position. Spring
hinges can also be used to
keep a door locked into an
open position without the
necessity of doorstops or
props. Spring hinges reduce
the costs of installing door-closing devices on industrial, commercial, institutional and
residential applications. They are used in hotels, apartments, dormitories and other
public service construction where doors are required to be self-closing.
Typically, the materials used for spring hinges include cold rolled steel, stainless steel,
or aluminum, with choices in anodized, plated or passivated finish. Other
considerations involved in choosing the spring hinges for your project are the amount of
torque required, whether the spring will be normally closed or open, the spring’s life
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15. cycle and the operating arc. You may also wish to know if the spring can be replaced if
it fails to give the maximum performance required.
Staked Hinges
Staked hinges have a fixed or staked pin. This is a cost effective way of ensuring that
the pin stays in place and will not be affected during the course of normal use. Either
staked or loose pins spun on both ends are particularly useful in very unstable or high
vibration environments such as in the use of industrial machinery. Staked pins are often
used in many products and applications where the hinge pin needs to stay in place and
where removing it is not advantageous. You will often find staked hinges in vertically
mounted equipment where the critical the pin does not fall out.
Strap Hinges
Strap hinges are a very traditional type of hinge but remain popular for a number of
reasons. A typical strap hinge is made up of two unequal hinge parts, where one is
longer than the other. The larger part, called a leaf, creates a mounting surface for the
smaller leaf, which is used as the opening mechanism. Strap hinges are advantageous
because they can be used for full surface mounting to wood, metal or structural steel,
and the design can be industrial or more ornate, lending aesthetic appeal. Strap hinges
are often used for gates or enclosures, as they are able to support a great deal of
weight. Heavy-duty strap hinges are able to stand up to a great deal of use and with
their versatility can be fashioned into many attractive designs.
Hinge Finishes
Take some time to consider the finish you wish to add to the hinges you have chosen as
this final touch can increase the value of your product in a number of ways. It can add
an attractive touch, protect the hinges from corrosion or tarnish, create chemical
resistance, modify electrical conductivity, remove burrs and other surface flaws and
control surface friction. Protect your investment and add the personal touch by
choosing a compatible finish for the hinges you will be using.
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16. Types of Metal Finishing Available for Custom Hinges:
Powder Coating is applied using a free-flowing dry powder and does not require a
solvent for keeping the binders and fillings in a liquid suspension form. Applied
electrostatically, powder coating creates a very hard finish that is tougher than
conventional paint.
Silk Screening is a decorative finish and is used to add graphics to metal parts. It
transfers artwork, directions, and images, such as logos, directly into the completed
product.
Aluminum Anodizing protects your product with an electrolyte process used to
increase the thickness of the natural oxide layer on the surface of metal parts.
Anodizing increases corrosion and wear resistance and is most commonly used but not
limited to, aluminum alloys. While clear anodizing is the general choice, it can also be
used in your choice of paint colors.
Passivating removes the iron particles from a stainless steel component. The
additional use of citric acid in the passivating process improves the corrosion resistance
of the stainless steel part.
Plating comes in two types - electro plating and zinc plating are typical requirements for
steel and stainless steel. Electro plating is used on steel parts to clean, brighten, polish,
and add to the corrosion resistance of stainless steel. Zinc plate finishes are offered in
clear, olive drab, yellow and black chromate coatings. Environmentally friendly Trivalent
clear chromate finish can meet or exceed your salt spray requirements.
E-Coating (or electro-coat) is an electrically applied paint that provides good coverage,
corrosion resistance, and adhesion. It can be used on any metal that conducts
electricity, such as aluminum and steel. E-coating can be used as a base paint, topcoat
or single coat cover.
Mass Media Blasting removes metal, strips paint, de-burrs or provides a satin coat to
your finish. This process also improves the coating adhesive prior to painting.
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17. Mass Media Tumbling is a different technique from mass media blasting, but the effect
is the same. Mass media tumbling is used to de-burr, burnish, descale, polish or clean
parts during the finishing process.
A Few Words About Tolerances
The tolerance level of your hinge is highly dependent on the strength of the pin used. A
weak material can warp and deform a pin during a pull test. The deformation of the pin
serves to concentrate the loading at the very edges of each hinge segment. If the hinge
material is not able to withstand the stress of external forces, or local use, the pin will
begin to deform. Precision hinges with high load bearing capacity are dependent on all
metal construction and the use of thicker pins for heavy load bearing capacity.
Also, oftentimes companies may set their tolerance limits too tight simply for the sake of
a tight tolerance and under the idea that tighter must be better. Remember that the
tighter the tolerance, the more difficult the manufacturing becomes and this can
potentially slow down the process or make it more expensive. Our recommendation is
to speak with a sales engineer that can help you evaluate what the most effective
tolerance would be for your particular product or application.
The Impact of Lead Time
Lead time is the delay between the initiation and the execution of a process, and
includes the time required to ship the parts from the supplier. The manufacturing
company needs to know when the parts will be available for material requirements time
and planning. Sometimes, the lead time also includes the time it takes for a company to
process and have the product ready for manufacturing once the materials have been
received. It is important to get a good understanding of what the lead time will be for
any given order. At Midlake, we measure lead-time in days not weeks.
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18. Look for Quality In Manufacturing
With the advent of globalization and instant communications, the
manufacturing industry has become much more competitive in recent
years. Manufacturers have found it necessary to stay focused on
finding new ways to design, produce, sell and deliver their products.
For a manufacturing company to have true success, it must integrate the qualities of
craftsmanship with an intimate knowledge of state of the arts technology and
machinery. It must ensure quality products at every level, and maintain sensitive and
knowledgeable understanding of customer needs.
Leaders in manufacturing provide an active support group of
technicians and sales representatives to guarantee customer
satisfaction with their products. One of the ways top manufacturers
accomplish this is by committing to the principles of “lean
manufacturing” as established by the guidelines of Six Sigma.
Additionally, ISO Certification is another strong indicator that an
organization is committed to quality. Look for a manufacturing partner
that can provide you with details about the impact of Six Sigma on their operations as
well as a copy of their current ISO Certificates.
About Midlake Products
Established in 1987, Midlake Products first developed our
reputation in the manufacturing of products that found their way
into boats; no small feat as our company started in a one-car
garage, and marine parts are the most challenging of all
manufactured parts, due to the strenuous environmental
factors of constant exposure to moisture. Despite its humble beginnings, Midlake now
operates around the clock in a 55,000 square foot manufacturing facility in Louisville,
Ohio which is approximately one hour south of Cleveland. We continue to do business
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19. within the marine industry, but now focus heavily on medical, transportation, security,
storage, alternative energy and self service industries.
We attribute much of our success to showing sensitivity towards customer needs, with
quality custom made parts to assure the flawless integrity of a planned project. We are
ISO certified and follow the principals of Six Sigma.
Beyond the work of skilled technicians and implementation of quality control processes,
Midlake takes tremendous pride in our commitment to community. With a strong focus
on the local Community Cupboard, we also support local youth by providing
opportunities to participate in team sports like baseball, football, soccer and track. We
also support education with monetary donations, new computers and equipment for
local schools, preschools and after school programs.
A good business acknowledges that its success is due to the satisfied customers that
support it. Midlake Manufacturing gives back to the community that has engineered its
success, and that’s just good business.
Conclusion
We hope you have enjoyed reading “The Definitive Guide to Hinges.” If you have any
questions feel free to visit our website at http://www.Midlake.com where you will find our
contact information as well as a free, custom request quote form. Thanks for reading
and good luck on your next commercial or industrial project!
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