Superior tool and die services

Discover how we build and maintain innovative tools and dies that reduce your costs, increase repeatability and deliver high-quality, defect-free parts.

Technology and craftsmanship drive our die building capabilities that continuously improve die functionality and longevity for OEM customers and in-house stamping jobs. Working side-by-side with Design Assistance ensures dies are built to specification utilizing the most cost-effective methods.

Our Capabilities

We have the technology and hands-on expertise to manufacture everything from simple tooling projects to complex progressive dies that are up to 168 inches long.

  • Design-and-build production tooling for OEM’s and in-house stamping jobs
  • Incorporate in-die sensor technology to improve production methods and protect dies
  • Utilize VISI-Design 3D technology
  • Custom-build tooling for in-house prototyping work completed by Fabrication
  • Perform die try-outs and first-run production to prove functionality before final production
  • Implement capability studies and PPAP to meet inspection requirements
  • Perform comprehensive die maintenance to prolong die longevity and functionality

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

Technology we use

In-die Sensor Application

We incorporate sensors into every die utilized in our stamping presses. Ultra’s sensor technology provides critical information throughout production and provides immediate alerts when issues arise during stamping. Customized sensor strategies combined with our press control system allow for immediate shutdowns when a problem is detected in the die. The lost time and money that can occur from a mishit needs to be avoided on every production run.

Ultra’s sensor application team is focused on precision and innovation and continues to lead with improvements in the following areas.

  • Reduced die maintenance costs
  • Reduction in mishits
  • Less time sorting
  • Consistent, high-quality parts
  • Improved on-time delivery

3D Design Software

We use state-of-the-art software by VISI-Design to create complete and accurate die, gauge and fixture designs in 3D. This design technology delivers precise instructions to all those on the tooling floor. The die design and building process is all encompassing and no detail can be overlooked. And that is why we have a pre-build meeting to establish a cooperative approach with all facets of the tooling department: CNC operators, Wire EDM operators, programmers, designers and toolmakers. This process communicates design changes easily and ensures 100% consistency and precision throughout a project.

Precision CNC Machining

Programming begins the CNC process and is critical to delivering quality and precision components for each project. A 2D or 3D CAM model is created utilizing our VISI software for a continuous transition from the design to the actual building process. This provides step-by-step instructions for the operator as they build each die component; including the precise tools to use with set dimensions. And the flexibility of CNC programming allows for easy modifications as needed.

A dedicated space in the Tool Room with specific temperature and sanitary regulations maintains a consistent, high-quality manufacturing environment that houses three Wire EDM machines . The technology of this equipment delivers higher accuracy and has less impact on the material when producing specific shapes compared to standard CNC machines.

We continue to make our tool shop modern with additional state-of-the-art CNC equipment ranging in size, power and variety of applications. The table size of our recently added Double Column Bridge Mill Feeler (55” x 85”) accepts larger projects and is loader-friendly; a big time-saver! We guarantee quick turnarounds for prototypes to intricate components with our equipment, experienced operators and advanced programming.

Capabilities

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

Advantages

  • 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 human capabilities
  • Handle a variety of materials including bronze, gold and silver. Polymers such as ABS, polycarbonate and PTFE can also be used.

Die Maintenance

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

Standard and customized checklists guide each die that is serviced in our department to ensure precision work is completed and that no die component is overlooked. Customized criteria are determined by die complexity and the type of production job. Stamping hits for each job are maintained in our cloud-based ERP system and our die maintenance manager 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

Progressive Die Redesign Case Study

Collaborative sessions with the customer helped Ultra fully understand the functionality and features of the thrust ring and established a productive setting for die designing and building. 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.

Motorcycle Progressive Die Redesign Case Study

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.