Prototyping Leads to a Feasible Design & Manufacturing Process Case Study

A two-piece aluminum frame requiring welded assembly and containing multiple pieces of inserted hardware was brought to Ultra to redesign. The list of concerns with the current design was growing and it needed to be addressed before costs increased further and quality continued to suffer.

Manufacturing Issues

  1. Increasing production costs.
  2. The welded assembly wasn’t strong enough to stop leakage problems from occurring.
  3. Inconsistency in the frame was making hardware insertion difficult and timely.
  4. Forming the aluminum frame was challenging because of its inherent softness.

Customer’s Goal

Reduce production costs with an iproved manufacturing process.

Remove the need for welding in the frame and increase the part's strength.

Develop a consistent and accurate method for hardware insertion.


Redesign Process

The original two-piece aluminum frame, 27" long x 12" wide, required welded assembly and contained multiple pieces of hardware.  First, the redesign process began with a form analysis to establish the manufacturability of the proposed one-piece design. Then various grades of aluminum were tested to identify the specific aluminum that would be strong enough for the new design. This included shock and vibe tests on the different types of aluminum until the results met the customer’s standards. This entire prototyping process ensured the frame could meet its performance requirements in an industrial environment.

Second, we designed and built a progressive die to support this new one-piece design. Throughout the prototyping we utilized our fiber laser to cut different strip configurations and fine tune the die design to eliminate wrinkles.

Third, to improve accuracy and productivity during hardware insertion we utilized our Pemserter. This equipment has the capability to insert all the required hardware including three different types within one-set up.

Customer Outcome

This redesign created a more efficient manufacturing process that lowered costs and improved the frame's quality.

Prototyping provided 100% assurance that the frame would function hassle-free.

The customer selected Ultra to redesign their even larger frame – 35” long x 17” with a similar shape and hardware insertions.

Other Case studies

Precision Manufacturing Process Case Study

Precision Manufacturing Process Case Study 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 […]

Read more

Delivering Production and Cosmetic Standards Case Study

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

Increasing Production Rates & Precision Case Study

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

Reducing Costs with a Progressive Die Case Study

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.

Read more

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.

Read more