Establishing Production Consistency and Minimizing Downtimes

This metal part was having quality issues and its production costs were increasing. A new locking feature corrected the quality issues and building a more efficient progressive stamping die reduced costs.

High Volume Metal Stamping

A crimping operation was added to the metal stamping process to lower costs for this product line. And utilizing only two progressive stamping dies to produce five parts was another cost-savings.

Delivering Quality with Innovation

This metal part was having quality issues and its production costs were increasing. A new locking feature corrected the quality issues and building a more efficient progressive stamping die reduced costs.

Producing a Robust and Precision Metal Part

This metal part was having quality issues and its production costs were increasing. A new locking feature corrected the quality issues and building a more efficient progressive stamping die reduced costs.

Streamlining Production and Improving Quality

This metal part was having quality issues and its production costs were increasing. A new locking feature corrected the quality issues and building a more efficient progressive stamping die reduced costs.

Meeting Design Challenges

The tabs on this lock washer were not forming correctly leading to production delays. Prototyping established a feasible manufacturing process that could metal stamp this part and its tabs to the design print.

Prototyping to Production

A successful transition from a two-piece welded assembly to one-piece aluminum frame with 21 hardware insertions required the manufacturing expertise of our Die Designers and Toolmakers.

Reducing Costs with a Progressive Stamping Die

Production costs were increasing because a splash guard and (6) drainage slots were added to the part’s design to meet safety requirements. The part’s length changed with these newly added features and made the existing die unusable.

Lower production costs for the fuel filler by utilizing a more efficient production process. Ensure the new features maintain the overall functionality of the fuel filler cup.

Improving the Production Process

The (6) bends and (8) holes require a detailed and customized fabrication process to match the design print. Hardware insertion and final inspection complete this production process.

Achieving Manufacturing Cosmetic Standards

This stainless steel part is metal stamped in our 800-ton press using a 144-inch progressive stamping die that successfully removes sharp edges and cleans the surface areas.

Quality Controlled Manufacturing Process

With a manufacturing process like this that utilizes our in-house services and outside suppliers, continuous AQL inspections are required to verify the metal part is defect-free.

Delivering Cost-Savings for a Metal Stamped Part

This involved adopting a new way to manufacture the shaft component of this part. And providing assembly of the final part in the stamping press with a progressive die.

Achieving Tight Tolerances Metal Stamping

Collaborative discussions with the customer helped Ultra fully understand the functionality and features of the thrust ring. It was identified that the part’s tabs required a tight tolerance of no more than .062” to achieve correct alignment with threads during the multi-assembly process.

Robotic Welding a Stamped Metal Part

Improvements were needed to the welding process to maintain a high-quality and functional metal part. And a more efficient method needed to be implemented to reach acceptable cost levels.

Metal Part with Weight Requirements

The total weight of this part and the positioning of its legs are critical to its performance. An automated inspection system was created to verify both of these features are met after metal stamping has been completed.

High Volume Metal Stampings

A crimping operation was added to the metal stamping process to lower costs for this product line. And utilizing only two progressive stamping dies to produce five parts was another cost-savings.

Precision Metal Fabrication Components

Established a metal bending and metal cutting process to produce components for a fan assembly requiring a precision fit to operate as designed.

Customizing Parts with Metal Fabrication

Providing high-quality and durable metal components for the manufacturer to customize assemblies as needed at their production facility.

Providing Innovative Tooling Dies

This project focused on improving the performance and quality of the cutting operation located in this production tooling. This also included an effort to increase accessibility of this cutting component.

Comprehensive Die Maintenance Services

This was leading to a decline in the precision and quality of work being performed. Concern was growing that this inconsistent service would negatively impact the quality of their products.
The customer’s plan of action was to establish a tool & die shop that could successfully handle the quantity and diversity of their dies for regular preventative maintenance and unexpected service issues.
Ultra was able to deliver a customized service plan to fit the needs of the customer.

Forming a Metal Part With the 800-Ton Press

This ramp is manufactured on a progressive die that includes only ONE forming station to complete that stage of production. A detailed finishing process includes deburring and polishing.

Outdoor Power Equipment Metal Stamping Case Study

Manufacturer of Rotary Lawn Mower Blade Sharpeners and Balancers for the Outdoor Power Equipment Industry

A recommendation from their previous supplier brought Outdoor Power Equipment Manufacturer’s leaders, Gerd & Erik Bauer, to Ultra’s front doors to continue production of their lawn mower blade sharpener.