Our Die Design Capabilities
- 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
Die Design Commitment
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.
Meeting Equipment 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
Forming a Metal Part With the 800-Ton Press
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.
Providing Innovative Tooling Dies
Case Study: Providing Innovative Tooling Dies 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 die […]
Precision Metal Fabrication Components
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…
Robotic Welding a Stamped Metal Part
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 to Production
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.