Delivering cost-savings and repeatability

We partner the hands-on manufacturing experiences of our die designers with VISI-Design 3D software to improve the overall design and production process of a part. Balancing cost-reduction strategies with quality expectations is our focus for each customer.

The NPI (New Product Introduction) Process begins with our design team establishing a solid foundation to meet cost, quality and delivery goals throughout production.

  1. Develop or modify design plans
  2. Build the tooling
  3. Simulate a full production run
  4. Evaluate and adjust as needed
  5. Move forward with full production

Our 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.

Technology we use

VISI-Design 3D software

VISI-Design 3D software provides a step-by-step process to successfully launch the manufacturing of a part. Continuous customer input assists in a cohesive plan for cost, quality and delivery time for each project.

Benefits of Software

  • Optimizes designs and processes to improve profitability
  • Detailed building plans improve tool room productivity
  • Easy to share plans and updates across workstations

3D Measurement

This measurement equipment gives us the ability to perform reverse engineering on dies with insufficient design plans. With a scan rate of 560,000 points per second this process can deliver 3D building plans to the tool room quickly. The technology of the Faro Arm accurately captures the physical dimensions and features of a die to better assist our design team in modifying the existing die or creating a new one depending on your cost goals and desired lead times.

Case studies

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.

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.

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.

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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 […]

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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…

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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.

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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.

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