CUSTOM CAPABILITIES ACROSS MULTIPLE INDUSTRIES

Our metal forming technologies and processes are second to none – we are the custom manufacturer to beat.

APPLIANCE

APPLIANCE METALFORMING

AUTOMOTIVE

AUTOMOTIVE METALFORMING

INDUSTRIAL

ELECTRICAL METALFORMING

MANUFACTURING PROCESSES

Stamping- Progressive, Transfer, Robotic set-in and transfer, manual set-in and transfer with “In-Die Tapping and Fastener insertion”
Stamping tonnage 100-1100
33 presses
Welding- Robotic Mig, Manual and Robotic Resistance, Robotic Plasma, Tig,
Machining- Full capabilities utilizing CNC Milling and Wire EDM cutting machine, Standard Vertical Mills, Grinding
Powder Coating (Class A)
Assembly – Orbital Form, Staking, Riveting,
Tumbling (Deburr)
Quality- Tensile tester, CMM and VCMM
Custom in-house built, dedicated processing equipment
Stamping plant and corporate offices 150,000 square feet
Powder Coat and assembly plant 150,000 square feet

Manufacturability

Our product engineering and quoting processeses emphasize close consultations with our customers to assure the manufacturability of their parts and assemblies. The Metallurgy and Tool Engineering Departments evaluate each and every part print at the quoting phase for part geometry, challenging tooling conditions & tolerancing against the material’s properties and continue the dialog with the customer through a formal APQP process. Some of our resources include:

  • Solid Edge
  • AutoCAD
  • 3-D Forming Simulations
  • Pareto Charts
  • Empirical Data
  • Metallurgical analysis

The Right Process – every time.

Utilizing a wide cross-section of skills & experiences, our company takes a fully integrated approach to production. At the core lies our unwavering commitment to the Toyota Production System (TPS). This methodology is further augmented with mistake-proofing technologies and the best Lean practices throughout our metalforming and value added processes. Our extensive production experience with automotive and appliance parts includes welding & robotics, Tox-Lock, In-Die Progressive Stamping & Assembly including Tapping, Staking, Hardware Insertion of Bolts & Pins and automatic self adjusting dies and tooling for raw material fluctuations.

A Wide Variety of Stamping Capabilities

Encompassing a total of 36 stamping presses, our metalforming capabilities include:

  • 2 transfer presses with 240” x 84” beds, up to 40” pitch, up to 60” wide and 1,100 tons of force.
  • 22 coil fed presses with up to 240” x 84” beds, up to 60” wide and 100 to 1100 tons with speeds of up to 130 strokes per minute.
  • 12 manual presses up to 192” x 48”, up to 700 tons

Assembly Technologies:

IN-HOUSE CAPABILITIES INCLUDING ROBOTICS

  • Welding:
    • Resistance (more than 14,000,000 functional welds sold in 2008)
    • MIG/TIG
    • Cosmetic (Corner finishing of brushed stainless steel & cold rolled steel cosmetic parts)
  • Tapping:
    • In-die
    • Rotary
  • Orbital Riveting: (more than 6,000,000 orbital rivets sold in 2008)
  • Mechanical Metal Joining:
    • Tox-lock (more than 8,000,000 tox-lock sold in 2008)
    • Tog-l-lock
  • PEM & Weld nut installation
  • General Assembly:
    • Installing sub-assemblies to metal stampings with screws, snap fits, & press fits:
      • Wheels
      • Stand offs
      • Plastic components
      • Metal brackets
      • Decorative plates
      • Kitting/Bagging

EXTERNAL CAPABILITIES:

  • E-coat
  • Plating
  • Heat Treat
  • Passivation
  • Plastic Injection Over-molding

Powder Coating:

2 fully automated powder coating lines

Allmond Plant:

  • 7 stage pre-treatment system with iron phosphate & De-ionized rinse
  • 2 “in-line” spray booths in two separate rooms for quick color change over
  • Paints 5 colors & capable of many new colors
  • World class cosmetic finishes
  • Capable of achieving 750 hours salt spray when painting over e-coat base.
  • Capable of achieving 500 hours salt spray when painting over raw cold rolled steel.
  • (Currently) Largest part painted: 384 square inches
  • Process window: 44” tall by 30” wide
  • Painting polyurethane powders
  • Painting as many as 2,000 pcs/hour

Preston Plant:

  • 5 stage pre-treatment with iron phosphate
  • Paints in 3 colors
  • FDA approved powder
  • Capable of achieving 500 hours salt spray when painting over raw cold rolled steel
  • (Currently) Largest part painted: 270 square inches
  • Process window: 64” tall by 30” wide
  • Painting Polyester & Hybrid powders
  • Painting as many as 7,000 pcs/hour

Our process is entirely enclosed from beginning to end. It is common to see in other companies, a part to be painted being exposed to the general plant environment from the exit of the pretreatment area to the time it enters the paint room. In our process, the part is never exposed to the outside environment thus reducing the opportunity for contamination to the product or the overall process.

Graphics:

Pad printing and Screen printing capabilities gives nth/works the ability to print 3-dimensional and 2-dimensional surfaces/parts along with capability to print multiple color graphics.

Pad Printing:

  • 3 automated pad print machines
  • Pad printing system has the ability to use various colors and ink cup sizes (provides broad graphics capability to customer)
  • Multi color printing, equipment has the ability to print 5 different colors currently, but the equipment can easily be modified to support 6 different colors.
  • Image size: As small as 1 square inch. On the large size…the sky can be the limit in some respects because we can print multiple images on one part (single image on the large size is around 6.5”…limited by the size of pad).
  • Capable of printing on 2-D & 3-D surfaces.

Screen Printing:

  • 2 stand alone screen printers with UV flash curing units and convection curing oven.
  • Ability to print solvent and UV hybrid inks
  • Printing capabilities up to 2 colors
  • This process is more of a manual process when compared to our pad printing process (pad printers make use of servo to select different colors, screen printing requires one screen printer/color).
  • Image size: As small as 1 square inch. On the large size we can print approximately 10” x 30”
  • Capable of printing on 2-D surfaces

Error-Proofing: Realtime Process Monitoring With Electronic Sensors

When Statistical Process Monitoring (SPC) is not enough to guarantee 100% good parts on critical dimensions, only a real-time electronic sensor based set of technologies can assure our customers of our quality. From stamping on through assembly and finishing, we use digital and analog electronic sensors to patrol the manufacturing processes. This technology supplements our certified quality procedures and ensures that the manufacturing processes are robust and at maximum performance levels while maintaining the highest levels of quality.

Die Protection & Process Automation

  • Six full time staff dedicated to die protection and process automation activities
  • Ongoing effort to upgrade automation controls on all presses to Wintriss SmartPAC 2
  • Ongoing effort to redesign die protection sensing scheme on all tooling in house- roughly 200 dies
  • Some dies in our plant have up to 48 sensors
  • Work with tool designers to integrate appropriate sensors into new tool designs
  • 300 sq. ft. sensing and automation development lab for in house sensor testing, design, and programming
  • Recently addition of LabVIEW programming software and expanded testing capability in the lab to begin building dimensional check fixtures and to automatically check part dimensions and record the data.
  • Working to develop in die measurement capability and automatic die adjustments on the fly based on those measurements