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Waterjet

  • DIMENSIONS 7'x13'
The Metal Shop uses a Mitsubishi Suprema Waterjet with Mitsubishi controls. We think the fact that the control is not some re-hashed windows computer makes it a much more reliable and accurate machine. Our table is 7'x13' which can handle a 5'x12' sheet. The machine is equipped with a Mitsubishi Intelligent Taper Control control head. Why this is important is that we can program a part to run at normal speed and still maintain our accuracy and limit taper. On machines without Intelligent Taper Control, you control taper by reducing the speed which means it takes longer to cut the part and increases your cost.
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3D Printer

  • DIMENSIONS 355 x 254 x 254 mm (14 x 10 x 10 in.)
  • Thicknesses 0.330 mm (0.013 in.)
The Fortus 400mc 3D production system produces accurate, durable, repeatable 3D parts with superior throughput. It comes in two configurations: the basic system, which builds parts as large as 355 x 254 x 254 mm (14 x 10 x 10 in.); or an optionally upgraded system, which builds parts as large as 406 x 355 x 406 mm (16 x 14 x 16 in.) and features two material bays for maximum uninterrupted production. The 400mc builds in nine materials, including high-performance thermoplastics for biocompatibility, static dissipation and resistance to heat and chemicals. With four layer thicknesses to choose from, you can fine-tune your desired balance between FDMs finest possible feature detail and the fastest build. Fortus 400mc throughput is twice that of the Fortus 250mc.
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Sheet Metal Shear

  • width 12
  • DIMENSIONS 0.375" thick mild steel, 0.25" aluminum, and 0.25" stainless steel.
Shearing is most often used in conjunction with another process such as laser cutting or turret punching. This is the most effective way for our steel fabricators and aluminum fabricators to make long straight cuts up to 12' wide, for up to 0.375" thick mild steel, 0.25" aluminum, and 0.25" stainless steel.
The machine used is called a squaring shear, power shear, or guillotine. The machine may be foot powered (or less commonly hand powered), or mechanically powered. It works by first clamping the material with a ram. A moving blade then comes down across a fixed blade to shear the material. For larger shears the moving blade may be set on an angle or "rocked" in order to shear the material progressively from one side to the other; this angle is referred to as the shear angle. This decreases the amount of force required, but increases the stroke. A 5 degree shear angle decreases the force by about 20%. The amount of energy used is still the same. The moving blade may also be inclined 0.5 to 2.5, this angle is called the rake angle, to keep the material from becoming wedged between the blades, however it compromises the squareness of the edge.
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Laser

  • DIMENSIONS 5'x10'
  • Range 20mm
Our machine is a Mitsubishi 3015 LVPLUS II Laser with a 5'x10' Table that can cut 0.125" steel @ 115" per minute. The Mitsubishi LVP 3015 LVPLUS II Laser provides precision, flexibility, low cost and speed for our customers. Plus zero set-up time is perfect for one piece or long runs. In addition the laser we have an 8 shelf auto loader which allows the machine to run unattended for longer run jobs. This helps keeps handling cost to a minimum and helps reduce scrap.
The effects on the work piece materials are rather minimal due to the small zone of metal affected by the laser beam. However, the effects are due to the high temperature of the laser that change the hardness and the creation of a narrow heat-affected zone.
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CNC VERTICAL MILLS

  • DIMENSIONS 40" x 20" x 30"
CNC VERTICAL MILLS
We have two Fadal 4020 3 axis vertical machining centers with bed sizes up to 40" x 20" x 30" and 21 tools per machine to provide you with quality machining for small to large parts. We also have Mazak VTC 200 Vertical Mill 120 x 20 x 20 which is ideal for long parts.
The Fadal 4020 has a 2215 HP Motor with 10, 000 RPM Spindle that accepts CAT-40 tooling. The machine travels: X-axis - 40"; Y-axis - 20"; Z-axis (extended) - 28". 20" x 48" T-slotted table; Table load capacity is 1, 500 Lbs.; 900 IPM XY Rapid traverse rates. Programable 21 Position ATC. Machine also includes pallet changing system and COOL POWER refrigerated coolant system.
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Manual Bending Machine

Manual Bending Machine
For smaller jobs we have an assortment of hand bending machines for specific applications. Our selection of tubing and pipe benders, ranging from simple manual benders to full production mandrel machines. These tools are excellent for building roll cages, handrails, furniture, gates, sculptures, or automotive exhaust.
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Cnc Lathe

  • Diameter 14" for 30"
CNC LATHE For your precision turning requirements our Bridgeport EZPATH lathe offers a cutting diameter up to 14" for 30" long parts.
The EZ Path machine features EZPATH IIIS is constructed on a rigid cast-iron frame, with induction hardened and ground ways. The Turcite-coated carriage and cross-slide move on solid cast iron bed and saddle guideways for high rigidity, accuracy and durability. AC brushless servo motors and drives provide feed rates up to 394 ipm on the Z-axis and 295 ipm on the X-axis. Dual electronic handwheels are provided for manual or semi-automatic operation.
To provide control flexibility and enhanced operator safety, the handwheel unit remains stationary during automatic operation, or travels on an independent track outside the front sliding door for manual operation. A rigid one-piece tailstock, with two clamps instead of one, provides rigidity for heavy turning and manual drilling. The tailstock includes a large, manually operated quill with tang stop and tool knock-out features.
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Press Brakes

  • Size ± 0.00039 inches
We use three electric Toyokoki press brakes, 12, 6 and 10 with forming pressure up to 60 tons paired with our MetaCAM and SolidEdge software for precision forming within 0.00039 inches (That's 1 micron!)
Our 100% electric Toyokoki APB-5620Wu press brake was purchased to increase the shops productivity and accuracy .The press brake supplements our 10 - 100 ton Accurpress press brake.
Toyokoki company pioneered the development of the world's first 100% electric press brake. With over 30 years experience designing brakes, Toyokoki recognized the need for a new machine to meet the growing demand for shorter lot runs with greater accuracy and repeatability.
Since the repeatability of dead bottom center was dependent on oil temperature and viscosity, they developed a new machine called the APB Series which for the first time controlled the ram movement directly with heavy-duty ball screws.
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Miller TIG Welders

  • Power 700
TIG welding is our primary type of welding. TIG welding is a slower process than MIG, but it produces a more precise weld and can be used at lower amperages for thinner metal and can even be used on exotic metals. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required. We have four TIG welders, a Miller Dynasty 700, a Miller Dynasty DX, and two Miller Syncrowave 250 DX machines.
The Dynasty 700 is a powerful, compact power source capable of welding up to 1" aluminum. Total arc control provides maximum productivity and weld quality while conserving energy compared to traditional welding machines.
The Miller Syncrowave 250 DX has proven itself time and time again in the most demanding applications. Its industrial design and construction ensure reliable operation for years to come. Squarewave technology was developed by Miller Electric in 1976 to improve your weld quality and make TIG welding easier. Miller Squarewave technology provides arc stability when welding aluminum, prevents arc rectification and eliminates tungsten erosion.
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Saws

  • Capacity 3.54" Tubing / 2.3" Solid Rounds
We also offer a full line of sawing capabilities including a variety of band saws and chop saws. Our saws are effective for cutting various types of tube, rod, or extrusions. Many of these are automated and programmable for repeatable quality and increased throughput.
Our automatic sawing machine is a MEP Condor 90 CNC electropneumatic saw, is a non ferrous saw which can cut nearly perfect flat ends with very little scrap and great applicative flexibility. The machine makes easy work of doing large amounts of small piece cutting. We also have a variety of smaller saws and cut-offs that we use for small runs and detail work.
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Mig

  • Power 350 MPa
MIG welding can be used on all thicknesses of steels, on aluminum, nickel, and even on stainless steel, etc. However, it is most typically utilized in manufacturing and in commercial fabrication settings. MIG welding is versatile and can be used with a wide variety of metals and alloys. We have four MIG welders, a Miller Alumapower 350 MPa for welding aluminum and a Miller Millermatic 350P and Millermatic 250 for welding steel. Our fourth welder is a high end Fronius CMT. The CMT process gives mig welds the tig like look with a dramatic increase in speed.
The Metal Shop's variety of MiG machines make it possible for us to accept any job and know it will be done right. We pride ourselves in staying on top of the machine trends and updates which make our shop more capable of the tasks, you the client expect from us.
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CNC Bender

  • Size 3" O.D.
Tube bending is accomplished by an Eaton Leonard CNC mandrel tube bender. This machine can accommodate steel and aluminum tubing, with sizes ranging up to 3" O.D. The CNC control allows us to achieve multiple bends on the same piece of tubing (Example is the Serta Mattress Dolly Cart shown elsewhere on the site.) Tubing from 1" to 3" can be bent on this machine. Please call us with any questions on material thickness and radius needed for your project.
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Fronius MIG Robotic Welder

ABB Fronius MIG Robotic Welder
We also have an ABB Robot with a Fronius MIG welder. This machine can be changed over to various metals from aluminum to stainless and carbon steel.
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Finn-Power P32 VS23 Swaging Machine

  • Weight 178 kg, its 2000 kN
  • Series P20 and P32
  • Size 1.5".
This process is done mostly with aluminum, copper or thin wall steel. We take tubing and reduce the outside diameter down to a specific diameter. Cold swaging is relatively quick, inexpensive and chip less. We use a Finn-Power P32 VS23 swaging machine that handles 4mm-87mm tube.
Finn-Power's P20 and P32 series of crimping machines are mid-range in terms of power, but compact from the point of view of space requirements.
Finn Power's successful P20 crimping machine ensures maximum operator ease and productivity, whatever the nature of the crimping task. Max. hose size is 1.5".
Althougth the Finn Power P32 weighs only 178 kg, its 2000 kN force produces high-quality crimping power for years and years of manufacturing. Maximum hose size is 2".
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Manual Mills

  • DIMENSIONS 36"x12"x16".
We have four Bridgeport Series I Standard Mills that can manually machine parts up to 36"x12"x16".
For more than 60 years, the Bridgeport Series I Standard Mill - the original, all-purpose mill - has been the "real thing" in milling, drilling, and boring for metalworking shops throughout the world. Today, the Series I Standard continues to fulfill the industry's need for an accurate, reliable, and versatile mill.

The Series I Standard features an innovative airflow cooling design that uses no external fans to prolong bearing life and prevent expansion from heat build-up. A full range of accessories are available, including optional chrome-plated ways and gibs to ensure that the machine will last a lifetime.
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CNC ROLLER

  • Size 4” round and 6” square
These machines are used for bending tube, angle, or shapes into coils, circles or large arcs using a wide variety of materials. We have two Arkus CNC Roll Benders from Switzerland. These are the best machines on the market and are highly accurate. We can roll square, rectangular, round, obround and angle material with these machines. These machines allow us to do many difficult projects such as ellipses and compound radius rolling. Between the two machines we are capable of rolling round tubing up to 4 round and 6 square.
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Fronius MIG Welder

Fronius MIG Welder
Fronius power sources are in a class of their own. Each system has been developed and produced by Fronius using state-of-the-art technology.
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Miller Welding Cell

Panasonic Miller Welding Cell
We have Panasonic (Miller) Welding Cell. This fully functional cell is used for production jobs where it can out put parts in an accurate and quick fashion.
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  • (The Metal Shop, LLC)
  • Pleasant Prairie, WI 53158 map, United States
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