Case Study: Precision Metal Fabrication Components
This Wisconsin-based manufacturer of Outdoor Power Equipment was striving to select a local supplier for better responsiveness, lower shipping costs and more personalized customer service.
It was key to correctly manufacture the specific design of each metal component for this four-piece assembly to achieve a quality and consistent fit during operation.
Blade Production
The customer designed the fan blades with four individual bends to better draw in the air during operation and to utilize standardized tooling on the press brake versus more costly customized tooling.
The blades present two key challenges to manufacture as designed.
1. Managing the overbends and underbends that naturally occur in materials during metal forming.
2. The exact placement and size of the four tabs on each blade. These tabs are critical to successfully align with the slots on the disk.
Utilizing the capabilities of the CNC press brake, our Fabrication Technicians consistently apply their material knowledge and manufacturing experience to match the blade's design print.
Disk Production
The most critical feature in laser cutting these disks is the slots. Their placement needs to be exact and within a tight tolerance to ensure correct alignment with the blade’s four tabs.
With Ultra's prototyping standards, we were able to establish the correct programming for the fiber laser prior to final production. We also ensure the blades are being laser cut to their design prints with regular quality checks. This includes a set-up check and in-process checks during laser production.
Customer Outcome
Ultra's high-quality, precision metal fabricated parts continue to meet the customer's design for complete assembly at their manufacturing facility.
The customer is also utilizing our services to manufacture 14 different metal components for their blade sharpening assembly.
Other Case studies
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.
Read more →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.
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.
Read more →Customizing Parts with Metal Fabrication
Providing high-quality and durable metal components for the manufacturer to customize assemblies as needed at their production facility.
Read more →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.
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