The ramp’s substantial size—31½ inches long and 54 pounds—was a key factor in the customer selecting Ultra as their supplier. Our 800-ton Minster stamping press, combined with in-house secondary operations, demonstrated that Ultra could manage the entire production process at one facility.
The ramp is made using a progressive stamping die with a single forming station. We engineered this station to perform five operations in one hit, forming the edges, top, sides, and lips, along with coining on the top surface. This forming station is made of bronze material to better protect the cosmetic integrity of the ramp.
The edge quality of the ramp is of critical importance for it to correctly operate on the elliptical equipment; and it can also be clearly seen by the end-user. A detailed finishing process is followed to ensure the edges are smooth and meet cosmetic standards.
- Deburring of sharp edges.
- Polishing of edges with hand sander.
- Washing the ramp in hot, soapy water and drying with microfiber cloth.
- Removing the protective coating for final assembly.
