Active Manufacturing

United States

• Length1”
• Thickness0.006”
• Weightless Than 1 lb.
• Tightest Tolerances± 0.001”
• Width11.250”

A customer in the medical industry required a custom-made test tube holder. This holder was challenging to make for several reasons. There were difficult conditions to overcome including handling coils that were .006” thick and 11.250” wide forming difficulties due to spring back. We employed extra high yield stainless steel as required by our customer’s specifications and used our 60 ton Komatsu Press to stamp and form this test tube holder. Our highly trained personnel utilized hand fed processes, worked with die cut blanks, and pick & place forming to produce prototypes for examination by our customer. After approval, we fabricated a short run order of test tubes with part dimensions that included a length of 11-14”, a width of 1”, a thickness of 0.006”, a weight of less than 1 lb. each, and tightest tolerances of ±0.001”. This project was completed in its entirety and delivered to our Michigan client within a timeframe of just three weeks. Our customer was pleased with the results. We have established a long-term relationship with this client, and now produce 5, 000 to 10, 000 of these test tube holders per monthly release as directed by our customer.

• Weightless Than 1 lb.
• Thickness0.025”
• Width3”
• Tightest Tolerances± .005”
• Length7-¼”

We were pleased to take on this complex project, which required wire EDM machining and a total of 26 different forming operations. Using Beryllium Copper C17200, we employed our wire EDM machine and Pro Active Servo Press to machine and form this intricate frame, which required every bend to be formed individually. The finished part had overall dimensions of 7-14” in length, 3” in width, 0.025” in thickness, and weighed less than 1 lb. With our experienced personnel and advanced equipment, we were able to hold tolerances on this project to ±0.005”. Thorough dimensional and visual inspections were performed throughout the process to ensure that we met all of our customer’s specifications and that our work was of the highest quality. We were able to create and deliver this prototype to our Michigan client within just three weeks. Our customer was pleased with every aspect of our work, and has enlisted us for numerous additional project partnerships since.

• Tightest Tolerances± 0.010”
• Width7”
• Length21”
• WeightLess Than 1 lb.
• Thickness0.019”

We specialize in prototype and short-run production for many different areas of business, including extensive work in the automotive industry. In this project a customer needed a window accent trim for an aftermarket automotive application, and we were pleased to take the contract. Using 430 Bright Stainless Steel, we employed our state-of-the-art equipment, including Mazak laser and a 220 Ton Komatsu Press, to form and trim this product. Our customer’s previous supplier could not produce parts with consistent quality; we were able to form this trim with a class A surface and provide handling that prevented scratches and protected its polished finish. The completed trim measured 21” in length, 7” in width, had a thickness of 0.019”, and weighed less than 1 lb. Our highly accurate equipment enabled us to keep tightest tolerances to ±0.010”, with dimensional and visual inspections performed throughout the process to ensure the highest quality. Our client was very pleased with our work, making us the sole supplier for this type of part and consulting with us for additional project partnerships. We were able to complete this project in its entirety and deliver it to our Indiana client within 3 to 4 weeks. This customer now requests 300 to 500 of these steel window trims per order.

• Height5”
• Weight2 lbs.
• Length12”

In the project detailed here, we were contracted by a client in the automotive industry to fabricate a prototype of a steel battery tray with brackets. This project included 5 gusseted brackets and required complex alignment, including 7 critical alignment holes. We employed a range of our advanced equipment, including our Mazak Laser, 150 ton Komatsu, 60 ton Amanda presses, and our Single Point Spot Welder. Forming, welding, e-coating, and assembly processes were performed to create a prototype that measured 12” in length, 11” in width, 5” in height, and weighed 2 lbs. We held tightest tolerances to ±0.020”, and performed dimensional and visual inspections throughout the manufacturing process to ensure our work was of the highest quality. When completed, this prototype was made exactly to spec and met all relevant industry standards. We were able to complete this battery tray in its entirety and deliver it to our Toledo, OH customer within a timeframe of 3 weeks.

• Length1-¼”
• WeightLess Than 1 lb.
• Thickness.021”
• Tightest Tolerances± .005”
• Width1”

We were approached by a client in the automotive industry to manufacture a formed spring steel wire protector bracket, and we were pleased to take on the project. Our client needed a prototype and initial production support within a fast timeframe. Using annealed high carbon spring steel, our team of experts employed our Mazak Laser and our Pro Active Servo Press to laser cut, form, heat treat, and finish with zinc plating for the prototype. A great deal of care was required during machining, as the wire protector bracket had two complex parts that needed to be precisely aligned. The completed bracket featured dimensions of 1-14” in length, 1” in width, .021” in thickness, and weighed less than 1 lb. The bracket was produced with uncompromising accuracy as well, with tolerances that were held to ±0.005”. Quality assurance was made with dimensional and visual inspections performed throughout the manufacturing process. We were able to meet all of our customer’s specifications and requirements for a fast turnaround time, with lead times of just one week for the prototype and three weeks for the initial production support, including delivery to our client in Michigan.