Case Study: Forming a Metal Part with the 800-ton press

31 ½ inches, 54 pounds Ramp

The sheer length, 31 ½ inches, and weight, 54 pounds, were key factors in the customer selecting Ultra as the supplier of their ramp.  Our 800-ton Minster metal stamping press combined with our secondary operations proved Ultra could handle the ramp’s production all at ONE facility.
The ramp is produced utilizing a progressive stamping die that includes only ONE forming station to complete that stage of production. We designed this forming station to include five different operations to be performed in ONE hit. The edges, top, sides, lips are being formed along with coining on the top of the ramp. 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.


Deburring a metal stamped part

Watch the 800-ton press stamp this heavy-duty metal part.

Other Case studies

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.

Read more   →

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.

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   →

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.

Read more   →

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.

Read more   →