Tool and Die Making powered by CNC technology and experience

Our Toolmakers build and maintain innovative metal stamping dies that reduce costs, increase repeatability and deliver high-quality, defect-free parts.

Our Machinists utilize their extensive tooling knowledge and technical skills to operate CNC and Wire EDM equipment that delivers precision die components. The Tooling Department continuously works with Die Design and Metal Stamping to ensure metal stamping dies produce parts to print consistently and without problems.

Tool and Die Capabilities

  • Design-and-build progressive stamping dies for OEM’s and in-house metal stamping jobs
  • Apply in-die sensor technology to improve production methods and protect metal stamping dies
  • CNC Machining delivers precision die components and die blocks with greater speed
  • Achieve tighter tolerances, greater accuracy and more complex shapes for tooling die components with Wire EDM equipment
  • Attain production tolerances within  .001" with the ability to achieve .0002" as needed
  • Perform die try-outs and first-run production in (13) metal stamping presses with 45 to 800 ton capabilities
  • Custom-build tooling for metal fabrication prototyping and production
  • Design and build gauges and metal fixtures for inspection, production and assembly purposes
  • Perform preventative die maintenance to prolong die longevity and performance

Our tool and die services

  • Blanking
  • Cut off
  • Forming
  • Shaving
  • Compound Operations
  • Pancake die
  • Side-cam die
  • Curling
  • Drawing
  • Honing
  • Trimming
  • Progressive die
  • Transfer die
  • Compound die

Tool and Die Technology We Use

In-die technology establishes high-quality and reliable production

In-die Sensor Application

We apply sensors into every progressive stamping die utilized in our presses. Sensors ensure the progressive die is operating correctly from set-up in the stamping press to die strip removal.  Overall, sensors are protecting the most critical and most costly asset in the production of  stamped metal parts.

Establishing controlled stamping & CNC operations with VISI Design Software

KEY BENEFITS OF SENSOR TECHNOLOGY IN PROGRESSIVE STAMPING DIES

  • Reduces die maintenance costs
  • Lessens the probability of mishits
  • Delivers more consistent, high-quality parts
  • Improves turnaround times
Designing tooling dies in 3D

3D Design Software

We use state-of-the-art software by VISI-Design to create detailed design prints for metal stamping dies, production tooling, measuring gauges, and fixtures utilized on the manufacturing floor. This advanced design software allows our Die Designers to simulate production and verify what is and isn't feasible. It also more easily identifies potential issues in the design stage when changes are easier to perform and are less costly. Our pre-build meetings establish a cooperative approach with CNC machinists, Wire EDM operators, CNC Programmers, Designers and Toolmakers. This helps ensures stamping dies will consistently deliver metal stamped parts that match the design print.

Precision CNC Machining

Detailed 3D computerized prints guide our CNC Machinists as they build precision die components and made-to-order fixtures and gauges. The print outlines the CNC tools to use to match specific tolerances, hole sizes, and other dimensioned features.

We utilize 3-axis CNC equipment like the Double Column Bridge Mill Feeler

We utilize 3-axis CNC equipment like the Double Column Bridge Mill Feeler with a larger table size (55" x 85") that can handle larger die blocks and metal components. It's also more loader-friendly which improves turnaround times.

Greater precision and tighter tolerances delivered with Wire EDM

A dedicated space in the Tool Room with specific temperature and sanitary regulations maintains a consistent, high-quality manufacturing environment that houses our THREE Wire EDM machines . This CNC technology delivers less impact on the material when producing specific shapes compared to standard CNC machines and its turnaround is quicker with greater accuracy.

 

Capabilities

  • Drilling
  • Tapping
  • Grinding
  • Milling
  • Boring
  • (17) pre-set tools for standard operations
  • (7) open tools for customized operations

Advantages of CNC Equipment

  • Multi-tool changers manufacture complex parts quickly
  • Repeat a detailed manufacturing process with 100% accuracy
  • Achieve tighter tolerances
  • Perform customized operations
  • Quality of work superior to manual equipment
  • Handle a variety of materials including bronze, gold and silver.
Toolmakers performing die maintenance services on tooling dies

Die Maintenance

Our TOP priority in the Die Maintenance area is protecting your tooling investment. Regular preventive services are critical to longevity and performance. We can handle the most complex tooling dies and even pinpoint the source of a problem on tooling dies that weren't originally built at Ultra. Even with our 100% commitment to preventive die maintenance; crashes and mishits still do occur. And this is where our experienced Toolmakers can review a situation quickly, identify the issue and fix the tooling die in a timely manner.

Scheduled evaluations on tooling dies prevent issues

Standard and customized checklists guide each tooling die that is serviced to ensure precision work is completed and that no component is overlooked. Customized criteria are determined by the tooling die's complexity and the type of production job. Stamping hits for each metal stamping job are maintained in our cloud-based ERP system and the Tool Room is alerted when service is required.

  • Sharpen punches
  • Polish
  • Strip the coating and recoat
  • Check tapping units
  • Check sensors
  • Regrease cams
  • Cleaning
  • Remove shavings
  • Tighten screws

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.

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.