- Design single-hit and progressive dies
- Design customized fixtures and gauges for in-house processes.
- Provide comprehensive assistance from estimation to design
- Design customized tooling for prototypes.
- Evaluate production operations and identify methods to improve functionality.
- Reverse engineering utilizes design software and Faro Arm technology
Designing is a highly technical process that requires patience and attention to detail. It is our hands-on manufacturing knowledge and emphasis on innovation that sets our design team above the others. A die is a valued investment and our goal is to design a robust die that consistently produces high-quality parts.
Metal Stamping for Lawn and Garden Equipment Manufacturer Case Study
Tabs on a lock washer were not forming correctly, causing continuous frustration and part assembly delays. The tabs needed to be redesigned to deliver the correct force and maintain the washer’s locking feature.Read more
Streamlining Production and Improving Quality Case Study
A box lug was both mis-performing and slow to produce. A collaborative redesign introduced a new locking feature, correcting thread alignment and improving overall part quality. Plus a switch to a progressive die combined a number of operations into a single, fast production process.Read more
Fitness Industry Metal Stamping Case Study
Our 800-ton stamping press combined with our secondary, high-quality services proved Ultra could completely handle the ramp’s production all at ONE facility.
The ramp is manufactured on a progressive die that includes only ONE forming station to complete that stage of production.
Tool and Die Design Assistance Case Study
Tool and Die Design Assistance Case Study This customer needed a different design intent for the filter cutting component of a die utilized in an existing assembly machine. The current design was causing cutting and maintenance issues; leading to a decrease in the quality and consistency of their final product. Our design team reengineered this […]
Outdoor Power Equipment Metal Fabrication Case Study
The most critical feature in laser cutting the disks was the slots. Their placement needed to be exact along with a tight tolerance to ensure correct alignment with the blade’s tabs. Our quality system establishes the programming of the laser is correct with a set-up check; and then in-process checks…
Increasing Output and Precision with Robotics Case Study
There was increasing variability when welding the hinges onto the footboards and this was risking the quality and functionality of the part.
Manufacturing costs were growing to an unacceptable level as production quantities continued to increase.
Prototyping Establishes Manufacturing Success
This Manufacturer was encountering increasing costs and difficulty in maintaining accuracy with a two-piece welded aluminum assembly frame with inserted hardware. The company tasked Ultra to develop an inexpensive one-piece design that improved part accuracy and eliminated assembly.