Motorcycle Manufacturer
Fuel Filler Cup

Manufacturing Issue

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

Customer’s Goal

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.

Redesign Process

It was determined that utilizing a progressive die to produce this part would cost less per part and require less labor than choosing to use a hand-fed option. A new progressive die was designed and built with numerous stations to produce the various features of this part. In fact, it required two separate stations to accurately form the threads into the cup. The six drainage slots were pierced from the inside to eliminate burrs and meet the customer’s cosmetic standards. With our 800- ton press and its 168” bed we were able to design this die to perform most of the operations during stamping, thus reducing time spent on secondary operations and significantly reducing part cost.

The final operation was the installation of the splash guard that was critical for safety purposes. Our smaller, hydraulic press accurately placed and secured the splash guard with very little labor required.

Customer Outcome

Ultra’s customized manufacturing process reduced costs as requested by the customer and even increased production rates. Our high-quality progressive die produced a fuel filler cup that matched the customer’s safety requirements. Appearance wasn’t overlooked during manufacturing and cosmetic standards were maintained.

Other Case studies

Thrust Ring

Collaborative sessions with the customer helped Ultra fully understand the functionality and features of the thrust ring and established a productive setting for die designing and building. 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.

Read more

Automotive Manufacturer

Ultra conducted an in-depth analysis of the customer’s current manufacturing process for the shaft piece. It was being produced as a sintered metal piece to attain the shaft’s form. This was time consuming and expensive.

Read more

Controlled & Precise Operations

The manufacturing of this part, Inner Cone and Contact Spring, was a detailed process that required 100% inspection throughout to deliver high-quality and precision.  Perfection was needed to guarantee the part performed as designed in the final product.  A progressive die draws the inner cone and contact spring utilizing beryllium copper which is only .0150 thick. […]

Read more

Major Appliance Manufacturer

The sheer size to stamp this part was causing production issues at the customer’s own manufacturing facility.
An unacceptable amount of resources were allocated to produce this side table at the required quantities.
Serious concerns that an outside supplier would be unable to meet their strict cosmetic standards was…

Read more

Recreational Vehicle Manufacturer

The (6) bends and (8) holes required a manufacturing process that produced no variance to achieve successful placement on the recreational vehicle.

Find a supplier that could provide an efficient and cost-saving process to produce the part with 100% accuracy while meeting output demands in a timely manner.

Read more