The Fabricator - December 2020 - PMI LLC

An o� icial publication ofDECEMBER 2020 / VOL. 50 NO. 12

www.thefabricator.comThe o� icial publication

of the Fabricators & Manufacturers Association

50 Fine-tuned information fl ow streamlines bending performance

54 Discovering opportunities in laser welding

56 What a shop needs to know before jumping into plate rolling

Also inside:

Cutting fast with

ultrahighlaser powerPennsylvania shop fi nds successwith 15- and 20-kW machines

Dec20FAB_Cover.indd 1Dec20FAB_Cover.indd 1 11/19/20 2:05 PM11/19/20 2:05 PM

http://www.thefabricator.com

DecFAB20FAB_FrontAds.indd 2DecFAB20FAB_FrontAds.indd 2 11/18/20 11:39 AM11/18/20 11:39 AM

http://mazakoptonics.com


http://fairmontmachinery.com

mailto:[email protected]



http://metalforming-usa.com

FEATURES50 Avoid the bending speed bumps

Many hang-ups in the bending department can be avoided not with special tools or equipment, but by asking the right questions.

54 Essential considerations for laser welding Laser welding involves a plethora of process variables. But with creative thinking, it also o� ers significant opportunity.

56 Getting ready for plate rolling If shops thought finding a skilled welder or press brake operator was hard, they shouldn’t bother trying to find a plate rolling expert. They might be better o� trying to grow their own expert.

58 How gemba reduces sta� turnoverGemba walks help employees perceive their

bosses di� erently. For employee retention, employee perception can make all the di� erence.

60 Cracking the (weld) nut of operational excellence Tired of dealing with excessive downtime in welding automation? To improve things requires taking a long-term view and, not least, a di� erent mindset.

62 The punch at the center of it all Metal fabricating lives under a big tent. In many ways, the tooling is the common denominator in all the di� erent types of manufacturing applications. In this tale, a punch connects three di� erent fabricators.

MANAGEMENT34 BIZ TALK 2021 forecast: The road to recovery continues 2020 will be a year we’ll be happy to forget. 2021 is shaping up to be much better— unless a worsening pandemic chokes the recovery.

35 AROUND WASHINGTON Labor Department recognizes industry-organized metalworking apprenticeship

Raytheon is first out of the gate with an industry-organized apprenticeship program that avoids the paperwork and frustrations associated with traditional apprenticeships organized through state and federal authorities.

CONTENTS DECEMBER 2020 / Vol. 50 No. 12

6 The FABRICATOR DECEMBER 2020

COVER STORY

46Cutting with more kilowattsOne Pennsylvania shop has two laser cutting

machines—nothing out of the ordinary, until you realize they have 15 and 20 kW of cutting power, respectively.

Cover photo courtesy of Fairmont Machinery.

36 STEEL NEWS Steel prices defy predictions of a peak Most observers thought the mills couldn’t maintain their discipline in the face of increasing demand for steel. Well, they have, and they have no immediate plans to increase steel supplies.

38 CHIEF CONCERNS Di� erent ages, one goal Thanks to a generation that doesn’t want to leave the manufacturing world just yet and an abundance of opportunities for younger workers, metal fabricators might have five di� erent generations working under one roof.

EXPERTISE40 PRECISION MATTERS 3D models need to be more than pretty CAD jockey Gerald Davis reviews modeling and documentation for threaded features in an exported model.

42 CONTINUOUS IMPROVEMENT Weave lean thinking into decision-making You make countless decisions to weather a crisis. Remember that lean thinking will enhance, not hinder, your response.

44 BENDING BASICS How about a little quiz? Bending guru Steve Benson gives readers a quick quiz covering everything from k- factors to springback.

[GET SOCIAL]Connect with The FABRICATOR

The FABRICATOR

@TheFabricator_Magazine

@Fabricating

The FABRICATOR Magazine

Dec20FAB_Contents.indd 6Dec20FAB_Contents.indd 6 11/18/20 12:21 PM11/18/20 12:21 PM

AMADA AMERICA, INC. 180 Amada Court | Schaumburg, IL 60173 | 877-262-3287 | www.amada.com/america

Nest. Cut. Profi t.On-Demand.

SendCutSend is a thriving shop that specializes in low-volume, quick-turn, custom laser cutting. This unique Reno, Nevada-based company’s success powerfully refl ects the fol-lowing: when given the right training and technology, entrepreneurs with fresh ideas can uncover new mar-kets with incredible potential. In this case, industry-leading technology came in the form of an ENSIS 3015 fi ber laser, backed by AMADA’s unmatched customer support. SendCutSend’s founder and CEO,

Jim Belosic, summed up his company’s partnership with AMADA. “One of our engineers who had experience at another fabrication shop told us early on, ‘Feel free to look at other brands, but AMADA is the Cadillac of sheet metal equipment, and their service is second to none.’”Belosic recalled his fi rst meeting with the AMADA team. They discussed customers’ increasing demands for quick delivery on low-volume orders.

During the meeting, Belosic said, “We want to be able to produce and ship a single part in as little as 12 hours.” After listening to Belosic

and discussing his specifi c manufacturing goals, AMADA provided the ideal solution.

ENSIS 3015 Fiber Laser Cutting System: AMADA’s ENSIS fi ber laser technology automatically changes the beam mode to accom-modate the unique attributes of each material and thickness being processed. As a result, ENSIS processes a wide range of materials and thicknesses without requiring a lens change or additional setup. The systems’ high-speed AMNC 3i control ensures fast, effi cient results from operator to operator, and programming complex nests has never been easier. Consequently, an expanded nest of small parts can literally include work from more than 100 different customers — enabling SendCutSend to cost-effectively produce high-quality custom parts with maximum effi ciency, speed, and fl exibility.

“We chose AMADA becausewe wanted the abilityto cut and ship custom partsin as little as 12 hours.”— Jim Belosic, CEOSendCutSend

June_2020_Fabricator_ads.indd 1June_2020_Fabricator_ads.indd 1 5/7/20 1:12 PM5/7/20 1:12 PMDec20FAB_Contents.indd 7Dec20FAB_Contents.indd 7 11/18/20 12:21 PM11/18/20 12:21 PM

http://www.amada.com/america


BUYERS’ GUIDE64 FORMING & FABRICATING® 2020 Press Brake Buyers’ Guide©

CONTENTS DECEMBER 2020 / Vol. 50 No. 12

COMING IN JANUARYHow do you hire for attitude? As one fabricator’s hiring strategy shows, listening carefully during a job interview does a world of good.

Need a special press brake tool? Does a job call for an offset? A few louvers? Special brake tools can help, but they can’t solve every problem.

A fabricator could have derailed but didn’t. A railroad component manufacturer experienced a crisis five years ago. But the business didn’t derail. It instead shifted into high gear. WHAT’S

ONLINE?THEFABRICATOR.COMThe COVID crazies.North Carolina job shop Barnes MetalCrafters has been handling what Manager Nick Martin calls the “COVID crazies” better than expected. And stainless steel projects have helped.

Lesson learned in shop safety. The devastating blast at a Beirut port in early August raised some alarming concerns about workplace safety, especially in welding and other industrial settings, writes Detroit metal fabricator Josh Welton.

Sustaining strong growth. Manufacturing expansion in October hit a two-year high, according to data from the Institute for Supply Management. Digital Editor Gareth Sleger writes how metal fabrication benefited as one of the strongest sectors.

TECHNOLOGY24 APPLICATIONS n Digital work instructions keep quality up, footprint down

n Modular fixturing shortens lead times

26 PRODUCT HIGHLIGHTS n Ultrasonic polisher reaches complex corners n Press brake offered in electric, hybrid versions

28 TECHNOLOGY SPOTLIGHT Fiber laser cutting assist gas tech evolves Fabricators now have more laser cutting assist gas options than ever. And as fiber laser powers increase, so will the assist gas possibilities.

30 PRODUCT NEWS

DEPARTMENTS 10 FROM THE EDITOR-IN-CHIEF Could the 2020s turn out like the 2010s for metal fabricators? Even though the 2010s started out with the Great Recession, the decade turned out OK for metal fabricators. The 2020s have gotten off to a rotten start, but fabricators might end up making this coming decade one to remember. 11 CALENDAR

12 READERS’ FORUM

13 INDUSTRY NEWS

72 CLASSIFIED ADS

72 ADVERTISERS INDEX

74 BACK PAGE Artist brings a stunning sense of realism to sculptures After learning to weld at a young age, sculptor David Madero focused his artistic skill and obsession with detail on his work, establishing an international reputation.

26

74


http://THEFABRICATOR.COM

http://fmamfg.org/annualmeeting



FROM THE EDITOR-IN-CHIEF

Read more from Dan Davis at www.thefabricator.com/author/dan-davis

Could the 2020s turn out like the 2010s for metal fabricators?This year is one to forget, but it could lay the foundation for an exciting decade of new opportunities and technology adoption

The FABRICATOR and Fabricators & Manufac-turers Association celebrated their 50th an-niversaries this year, and needless to say,

our timing stinks. It’s hard to be joyous about the occasion when the very act of blowing out some candles on a cake can be viewed as a threat to someone’s health. Such is life in the pandemic era.

But we also learned about the phrase “essen-tial personnel” this year, and for the most part, it’s hard to argue that metal fabricators don’t fall into that category. When the world needed ventilators, beds for temporary hospitals, and hand sanitiza-tion stations at the very beginning of the COVID-19 crisis, metal fabricators stepped up and worked their wizardry to deliver their parts and assem-blies in record times. Even as we cope with life in the midst of this pandemic, metal fabricators are making it easier by building the racking systems that support the servers that act as the backbone of virtual work environments, fabricating the tubes used in home exercise equipment because the gyms are closed, and supplying that shelf at the local sandwich shop where patrons pick up their to-go orders. Metal fabricators are making a differ-ence when they are needed most.

In early November the Institute for Supply Man-agement reported that its index of national factory activity increased to a reading of 59.3 for October. That was the highest mark since November 2018 and improved the September reading of 55.4. (Anything above 50 indicates expansion in manufacturing.)

Economists suggest that results were a reflection of manufacturers ramping up production for goods that are needed as a result of more people working and schooling at home, and even though it may be difficult to sustain the same level of manufacturing exuberance in the coming months, companies still have plenty of opportunities awaiting them.

So much like the 2010s, which began in the wake of the Great Recession but ultimately had the lon-gest economic expansion on record, the 2020s may yet be another golden decade for metal fabrica-tors. The hints are hard to ignore.

Life will forever be altered post-pandemic. Embarrassingly enough, I thought about this when I saw some of the new fast-food restaurant concepts being floated now. These restaurants of the future will have little to no seating, focusing rather on drive-thru lanes. People, whether ordering a Whop-per or the week’s groceries, are using apps and then picking up their order. That turns the world of cus-tomer interaction on its head and likely calls for a new infrastructure to support it. Metal fabricators will deliver that new reality.

Advanced manufacturing technology will give fabricators new opportunities much more rapidly. Collaborative robots will become more common sights as they sit in front of press brakes and in welding cells. They can be programmed and deployed quickly for tasks deemed too mundane or too repetitious for humans, allowing employers to assign their more talented personnel to more

important projects. The lack of skilled labor becomes less important because automation can fill the gap in some instances.

Manufacturing will become more of a desti-nation job than a fallback. Parents are skeptical of paying top dollar for a college education with no real job prospects to follow, and young people have less of a desire to pile up huge college debt. Manufacturing offers the chance to learn a skill and get paid while doing it. In the right situation, a person can actually get reimbursed for his or her college courses while working. Manufacturers just need to do a better job of letting the public know about career opportunities. There’s a receptive au-dience waiting.

Of course, we all have to work our way through the current crisis that we face. Large numbers of people remain unemployed, and entire economic segments, such as the travel and restaurant indus-tries, can’t return to full vibrancy until a vaccine has been widely administered and that most are willing to take. But when life returns to some sort of normal, which it will, manufacturing is poised to take off as the U.S. embarks on another economic expansion.

Metal fabricators will help us to get to that point and beyond. It’s going to be an exciting decade. Let’s just hope the 60th anniversary year is an en-joyable one.

FMA OFFICERS CHAIRMAN OF THE BOARD William Isaac MC Machinery Systems/Mitsubishi LaserFIRST VICE CHAIRMAN Carlos Mendizabal-Perez Industrias Selbor SA de CVSECOND VICE CHAIRMAN James Rogowski TRUMPF Inc.SECRETARY/TREASURER Jason Hillenbrand Amada America Inc.

IMMEDIATE PAST CHAIRMAN Gregg Simpson Ohio Laser LLC

FMA DIRECTORSMichael Barnett Grand Steel & Products Inc.

Stephen Ford Lapham-Hickey Steel Corp.Brian Havlovic Kawasaki Motors Mfg. Corp. USA

Vanessa Heim Brenco Industries Ltd.

Phil Kooima Kooima Co.

Rakesh Kumar Cincinnati Inc.

Scott Myran Mississippi Welders Supply

Rick Olson Roll Machining Technologies & Solutions Inc.

Jay Phillips Valley Iron Inc.

Sarah Richards Jones Metal Inc.Jason Stadler John Deere Power ProductsLori Tapani Wyoming Machine Inc.

Lisa Wertzbaugher Wertzbaugher Services Wertzbaugher Consulting

Roger Wilson

PRESIDENT & CEO Edward Youdell Fabricators & Manufacturers Association Internationa

FMA’S CERTIFIED EDUCATION CENTERS FMA Certified Education Centers (CEC) are community and technical colleges, trade schools, and universities that specialize in training adults for careers in the metal forming, fabricating, processing, and machining sectors. They offer coursework for local students year-round and serve as host locations for many types of FMA professional development programs as requested. A council of members convene six times a year to plan and execute special programs on worker training for educators and human resource managers from companies of all sizes.

To learn more about FMA’s CEC program and view a list of the current member schools, visit https://www.fmamfg.org/membership/schools.

To discover how your local community or technical college can become a member, call 888-394-4362 or send an email to [email protected].

Dec20FAB_Editor.indd 10Dec20FAB_Editor.indd 10 11/18/20 12:25 PM11/18/20 12:25 PM

http://www.thefabricator.com/author/dan-davis

https://www.fmamfg.org/membership/schools


https://www.fmamfg.org/membership/schools

DECEMBER 2020 The FABRICATOR 11

CALENDAR OF EVENTSEvent information may be out-of-date due to the coronavirus (COVID-19). Please check with the event organizer for cancellations or date changes.

Design2Part Show Feb. 16-17—Grapevine, TexasJob Shop Co.800-225-4535www.d2p.com

Qualification of Welding Procedures—Best Practices Feb. 17-18—ClevelandAmerican Welding Society305-443-9353www.aws.org

HOUSTEX Feb. 23-25—HoustonSME800-733-4763www.sme.org

Powder Coating Week Feb. 23-26—Orlando, Fla.Powder Coating Institute800-988-2628www.powdercoating.org

Virtual FMA Annual Meeting March 2-4Fabricators & Manufacturers Assn.888-394-4362www.fmamfg.org

TMS 2021 Annual Meeting & Exhibition March 14-18—Orlando, Fla.The Minerals, Metals & Materials Society800-759-4867www.tms.org

GOLF4MFG South April 26—Charlotte, N.C.Fabricators & Manufacturers Assn.888-394-4362www.fmamfg.org

The FABRICATOR’s Technology Summit May 11-12—Elgin, Ill.Fabricators & Manufacturers Assn.888-394-4362www.fmamfg.org

Stamping in an EV World June 1—Plymouth, Mich.Fabricators & Manufacturers Assn.888-394-4362www.fmamfg.org

FABTECH Mexico June 8-10—Monterrey, MexicoFABTECH Event Partners888-394-4362mexico.fabtechexpo.com

Coil Processing Workshop & Tours June 9-10—Michigan City, Ind.Fabricators & Manufacturers Assn.888-394-4362www.fmamfg.org

PowderMet 2021 June 20-23—Orlando, Fla.Metal Powder Industries Federation609-452-7700www.mpif.org

MD&M West Aug. 10-12—Anaheim, Calif.Informa Markets310-445-4273www.mdmwest.com

Submit your industry event information for future publication to Editor-in-Chief Dan Davis at [email protected].

December20FAB_Calendar.indd 11December20FAB_Calendar.indd 11 11/18/20 12:37 PM11/18/20 12:37 PM

http://www.d2p.com

http://www.aws.org

http://www.sme.org

http://www.powdercoating.org

http://www.fmamfg.org

http://www.tms.org




http://mexico.fabtechexpo.com


http://www.mpif.org

http://www.mdmwest.com



http://radan.com


http://coletuve.com

Keep Manufacturing Moving Forward

Editor’s Note: With the U.S. dealing with another wave of COVID-19 cases and municipalities gearing up for the possible reality that their medical facilities may be swamped with virus-stricken patients, we thought we’d share these thoughts from the board leadership of the National Association of Manufac-turers. They are issuing a call to all Americans to observe COVID-19 safety protocols so manufacturers can continue to work to rebuild the economy.

As manufacturers for America’s goods and essential products, we have a strong message for our team members and the country. All Americans must do everything in our power to keep our workers, our communities, and our fellow citizens safe from COVID-19.

Our industry will continue manufacturing per-sonal protective equipment, medical supplies, and therapeutics; racing to develop a safe and effec-tive vaccine; and keeping consumer goods and the food supply plentiful. We have been able to do this throughout the pandemic and keep our workers safe because we follow the science.

We will continue to set the right example by practicing the guidance outlined by the CDC and other medical experts. That’s why we encourage

all Americans to wear a mask, social distance, avoid large gatherings, use contact tracing, and quaran-tine for 14 days if there is direct exposure to the vi-rus, especially when one is tested positive. We are on the front lines of rebuilding our economy, but we cannot do so until we defeat COVID-19, and we can-not defeat COVID-19 if we fail to protect each other.

COVID-19 has already taken more than 210,000 American lives, and each week that number grows by the thousands. The economic toll has resulted in millions of jobs lost—some permanently. Among those who survive, many will endure lifelong dis-abilities. It doesn’t have to be this way. We know the science, and we have the tools. We all must follow best practices and look out for each other so we can keep the country open, supply the world, and de-feat this invisible enemy.

Mike Lamach Chairman/CEO and NAM Board Chair

Trane Technologies Davidson, N.C.

Jim Fitterling Chairman/CEO and

NAM Board Vice Chair Dow

Midland, Mich.

Chuck Wetherington President and NAM Small and Medium Manufacturers Chair

BTE Technologies Centennial, Colo.

Vicki Holt President/CEO and NAM Small and

Medium Manufacturers Vice Chair Protolabs

Maple Plain, Minn.

Looking for Insurance HelpI have contacted you previously about schedul-ing software vendors for the metal fabricating in-dustry. Again, thanks for the information that was provided.

Today I am researching for my client possible re-sources for insurance companies that might have industry-tailored or specialized policies for welding-

related businesses. Do you have any recommenda-tions for such resources?

Lew Blakeney Certified Business Advisor

Small Business Development Center Okanogan County, Wash.

Editor’s Note: Unfortunately, we don’t have a lot of knowledge in this area. As our Forming & Fabricating Industry Directory reveals, we don’t have a lot of con-tacts in this area: https://www.thefabricator.com/directory/category/250/business-services-insurance-workers-compensation

Having said that, CNA has been a longtime spon-sor of many FMA-related activities and conferences. They have a targeted metal fabrication practice. You might find some help there. They can be contacted at 800-362-2000 or [email protected].

Walls Sometimes Make for Successful Companies

Editor’s Note: In an Oct. 5 blog post to thefabrica-tor.com (“In defense of the wall between sales and production in metal fabrication”), Senior Editor Tim Heston wrote that sometimes the goal of seamless integration between sales, design, and manufactur-ing is just not possible. Sometimes the sales staff is only interested in closing the deal and simply doesn’t have any room to suggest design for manufactur-ability options. In other instances, manufacturing doesn’t have the time, and maybe the experience, to be pulled into these conversations. The blog, when shared on Facebook, elicited this response.

There definitely is a tug of war between production and sales. I think a good sales team needs to know the limits of the shop’s capabilities and know when to test capacity and when not to.

There is a big difference between “Hey, this is a potential big client. If we can dig deep and pull this off, it’s beneficial for everybody” and “Hey, we just gave the production team an impossible feat, and everybody is pulling their hair out and wanting to jump ship.”

Brian Ryden Dallas

Publication StaffPresident & CEO, FMA Communications Inc.: Edward Youdell

Vice President of Publishing and Events: Andy Flando

Editor-in-Chief: Dan Davis, [email protected]

Senior Editor: Tim Heston, [email protected]

The Tube & Pipe Journal Editor: Eric Lundin, [email protected]

STAMPING Journal Editor: Kate Bachman, [email protected]

The WELDER Editor: Amanda Carlson, [email protected]

Contributing Editor: Amy Nickel, [email protected]

Digital Editor: Gareth Sleger, [email protected]

Senior Copy Editor: Teresa ChartosGraphic Designers: Mary Mincemoyer, Janell Drolsum, Margaret Clark, Jennifer PaulsonMedia Coordinator: Rose MerlinoDirector of Circulation: Kim BottomleyCirculation Manager: Brenda WilsonData Processing Specialist: Kelly PalmerData Verification Specialist: Rhonda FletcherSenior Fulfillment Specialist: Anna PeacockWeb Designer: Sherry YoungSenior Web Developer: Mike Kunzelman

Advertising SalesAssociate Publisher: Jim Gorzek [email protected] 815-227-8269

Senior Account Representatives: Sean Smith [email protected] 815-227-8265

Mike Lacny [email protected] 815-227-8264

Amy Hudson [email protected] 815-227-8237

Michael Scott [email protected] 815-227-8271

Classified Advertising Jerry Gunderson [email protected] 815-227-8257

Published by: FMA Communications Inc., 2135 Point Blvd., Elgin, IL 60123 815-399-8700 | www.thefabricator.com

Statement of PolicyAs the official publication of The FABRICATORs & Manu fac turers Associa tion, International, The FABRICA-TOR recognizes the need and importance of dis seminating information about modern metal forming and fab ricating techni ques, machinery, tooling and man age ment concepts for the metal fabricator. The policy of the publisher and this journal is to be non partisan, favoring no one product or com pany. The repre-sentations of fact and opinions expressed in the articles are those of the author and are not necessarily endorsed by the publisher and this journal. By including information on new products, new literature, news of the industry, articles, etc., this impartiality is strived for and extends to the mention of trade names. Unless product ident ification makes the reference unavoidable, the generic name is used. We acknowledge that on occasion there may be oversights and errors; the editors regret such oversights and re-emphasize their policy to be impartial at all times. The publisher reserves the right to refuse advertis-ing deemed in appropriate for publication in The FABRICATOR, in cluding ads for classes of products and services not considered of significant interest to the readership. “The FABRICATOR” is a service mark and a trade mark of The FABRICATORs & Manufacturers Association, International, and is used, under license, by FMA Communi cations Inc. Standard Rate & Data Service lists our advertising rates in Section 88. Consult SRDS or our current rate card for full rates and data. Publications of FMA Communications Inc. main-tain a policy of keeping editorial and advertising separate to ensure editorial integrity that most ben-efits our readership. Editorial content, including feature articles and press releases, is determined solely by the publisher. Editorial content cannot be purchased, nor can it be used as a benefit of advertising dollars spent. Editorial is free-of-charge, subject to space availability, and open to all interested parties that submit items meeting our editorial style and format as determined by the publisher. Note: Some photographs printed in this publication may be taken with safety equipment removed for photo graphic purposes. However, in actual operation, it is recommended that correct safety procedures and equipment be utilized.


READERS’ FORUM

Dec20Fab_Readers.indd 12Dec20Fab_Readers.indd 12 11/18/20 12:53 PM11/18/20 12:53 PM

https://www.thefabricator.com/


http://thefabricator.com















http://thefabricator.com


INDUSTRY NEWSFinnco Fabricating acquired by investor groupAn investor group comprising Milwaukee-based Newel Capital LLC and Optimus Capital Partners has acquired Finnco Fabricating LLC. The 30,000-sq.-ft. shop offers plate rolling, bending and forming, angle rolling, burning, shear-ing, punching, welding, and assembly.

Business executives Buddy Robinson and Kevin Seiberlich will lead the business. Former owner and op-erator Steve Parnitzke will remain involved.

Solar Atmospheres of California forms strategic partnership with KittyhawkSolar Atmospheres of California, a provider of vacuum heat-treating services, has announced a strategic partner-ship with Kittyhawk, a provider of hot isostatic pressing (HIP) services.

Both companies are certified to Nadcap, ISO 9001, and AS9100 and maintain source approvals for major aero-space primes.

BTD Mfg. adds fiber laser to Minnesota facilityMetal fabricator BTD Mfg. has added a TRUMPF TruLaser 5030 fiber laser to its Lakeville, Minn., facility. According to the company, the machine’s High-speed Eco cutting process allows it to double its rate of production when processing medium sheet thickness-es. In addition, the machine monitors the cutting process and automatically adapts parameters to maintain cut-ting efficiency.

The laser is equipped with a Cool-Line nozzle that mists water around the laser as it operates to mitigate heat from the surrounding material. This allows for cleaner and shorter sheet head entry to the part profiles and enables the machine to cut small contours.

AT&F installs 5-axis cutting system Cleveland-based AT&F has added a heavy-duty gantry shape cutting ma-chine that includes 5-axis and dual plate capabilities, as well as next-gen-eration software.

The system can oxyfuel-cut steel up to 6 in. thick and has laser mark-ing capabilities. A three-torch sys-tem can create a double bevel in one pass. It also can plasma-cut up to 2-in.-thick carbon steel, stainless, and aluminum.

The company can handle plates up to 15 ft. wide and 150 ft. long.

Laser Mechanisms marks 40 years in businessFounded in 1980 by industrial laser processing pioneer William G. Fred-rick, Laser Mechanisms marked its 40th anniversary on July 17, 2020.

The manufacturer of beam deliv-ery components and laser process-ing heads is based in Novi, Mich., with sales offices located worldwide.

East Coast Steel Fabrication to expand in North CarolinaChesapeake, Va.-based East Coast Steel Fabrication Inc., a provider of heavy steel fabrication for barges and marine structures, has announced plans to expand its production facility in Hertford, N.C. The $480,000 invest-ment is expected to create 28 jobs.

The six-employee operation in Hertford opened in 2019.

Dec20FAB_IndustryNews.indd 13Dec20FAB_IndustryNews.indd 13 11/18/20 3:17 PM11/18/20 3:17 PM

http://wilausa.com/grow-through-it

14 The FABRICATOR DECEMBER 2020 The FABRICATOR 15

INDUSTRY NEWSMazak Optonics expands North American headquarters

Mazak Optonics is expanding its North American headquarters in Elgin, Ill., by more than 20,000 sq. ft. This ad-dition to the Elgin Technology Cen-ter will include a new auditorium, increased capacity for parts and cus-tomer service support, a new R&D center for laser cutting and automa-tion systems, and additional machine tool technology areas.

The project is scheduled for com-pletion in spring 2021.

TAB Industries adds laser cutter to Pennsylvania facilityMetalworking manufacturer TAB In-dustries LLC has added a 3300 Bescut-ter fiber-optic laser cutting system to its 44,000-sq.-ft. manufacturing cen-ter in Reading, Pa.

The machine expands the metal shop’s in-house capabilities, which include metal fabrication; CNC and traditional machining; GMAW; GTAW; stamping; deburring; powder coat-ing; and a variety of engineering, finishing, assembly, packaging, and supply chain services.

Williams Intl. to expand in UtahJet engine manufacturer Williams Intl. has announced plans to expand its gas turbine production facility in Ogden, Utah. The project is expected to create up to 300 jobs over the next seven years. The facility currently employs 500 people.

Huntington Ingalls Industries to open unmanned systems facility in VirginiaMilitary shipbuilder Huntington In-galls Industries has begun construc-tion of its Unmanned Systems Center of Excellence in Hampton, Va. Com-prising two buildings to be complet-ed by the end of 2020 and late 2021, respectively, the facility will provide prototyping, production, and testing of unmanned systems.

Expected to create more than 250 jobs, the plant’s capabilities will in-clude precision machining, surface finishing, and welding.

Sharpe Products adds 3D robotic laser cutting equipmentNew Berlin, Wis.-based Sharpe Products, a provider of pipe and tube bending, laser cutting, and custom fabrica-tion services, has purchased a BLM GROUP LT-Free laser cutting system. Built for complex, 3D part profiles, the 5-axis, 3-kW fiber-optic laser has additional features such as robotic part manipulation and dual-access part loading capabilities.

“With our current capacity, we are able to laser-cut holes, or features, in tubes prior to the bending process,” said Paul Krickeberg, president/CEO. “There are instances where, because of tolerances required or the location of the cutouts on the tube, parts require additional, more costly postbending operations such as machining or punching. This technology can reduce or eliminate these types of additional steps and cut the cost of consumable tooling.”


http://www.ati-ia.com

The FABRICATOR 15

INDUSTRY NEWSU.S. DOL recognizes FANUC America, Rockwell Automation, and industry partners for apprenticeship programs FANUC, a supplier of CNCs and robotics, has been named a Standards Recognition Entity (SRE) by the Department of Labor (DOL). The company shares this achievement in collaboration with industry partners including Rockwell Automation, APT Manufacturing Solutions, and the Na-tional Occupational Competency Testing Institute.

The FANUC America-Rockwell Automation coalition was recognized for its focus on robotics and advanced automation, specifically the integration of these tech-nologies into systems and the future workforce needed to support them.

DeWys Mfg. acquires ReFabDeWys Mfg. Inc. has announced the acquisition of ReFab LLC, a metal fabricator located in Grand Haven, Mich. This addition expands DeWys’ core capabilities in cutting, form-

ing, and welding while allowing for quicker turnaround times.

“Growth of DeWys Manufacturing with expansion of our offerings and capabilities has been on our one-page strategic plan for a few years now,” said Jon DeWys, CEO. “The ac-quisition of ReFab will allow for this to happen.”

Ready Robotics launches Ready Academy online platform to teach automation deploymentColumbus, Ohio-based Ready Robot-ics has launched the Ready Academy, an online educational platform that helps manufacturing professionals learn how to design, deploy, manage, and scale automation.

The platform launches with more than 40 hours of educational videos with curriculum developed by robot-ics PhDs Kel Guerin and Jake Hucka-by. Building on more than four years of the company’s experience en-abling manufacturers to deploy auto-mation on their own, the curriculum covers automation topics including project assessment, end-of-arm tool-ing, parts presentation, robot safety, no-code robot programming, and building machine-tending tasks.

Key to the rapid learning enabled by the platform is the use of the com-pany’s Forge/OS enterprise-grade operating system and Task Canvas for robot programming. In the same time it typically takes to learn how to program simple movements in a ro-bot’s native programming language, students can achieve lights-out automation. This is accomplished through Task Canvas’ intuitive pro-gramming interface. Robot program-ming is condensed into a matter of days so that more attention can be given to all the other equally critical components of automation.

(From left) Jon DeWys, CEO of DeWys Mfg.; Josh Vink of ReFab LLC; and Mark Schoen-born, president of DeWys Mfg.

(continued on page 16)


http://fststeelfab.com

http://coldworksedquipment.com

The FABRICATOR 17

INDUSTRY NEWSschool and postsecondary FANUC-certified training organizations and more than 150 university and career technical training partners associ-ated with this industry team.

As an SRE, FANUC and its coalition will work with customers to align them with schools in FANUC’s Educa-tion Network that are local to their manufacturing facilities. The team will guide each company to develop an IRAP that helps them build a pipe-line of skilled workers by upscaling current employees and filling open positions with high school and col-lege students.

Forest River announces expansion in IndianaElkhart, Ind.-based Forest River, a manufacturer of recreational vehi-cles, has announced plans for a $3.5 million project involving expanding a facility in Butler, Ind., and construct-ing and equipping a new building there. The project, expected to create 120 jobs, is scheduled for completion in February 2021.

The company also will invest an-other $3.5 million on a new building in LaGrange, Ind. That project is ex-pected to create 249 jobs.

IMH Products acquires Mainstay Mfg. SolutionsIMH Products Inc., a provider of high-volume metal fabrication, laser cutting, stamping, machining, and welding services in Indianapolis, has announced its acquisition of Mainstay Mfg. Solutions Inc., Brownsburg, Ind.

Mainstay offers high-mix/low-vol-ume and prototype metal fabrication and machining. Its operations will move to IMH’s Indianapolis facili-ties. IMH operates another facility in Prophetstown, Ill.

Mountain Top to begin production in AlabamaDenmark-based Mountain Top In-dustries, a producer of pickup truck bed parts and accessories, has an-nounced plans to enter the U.S. mar-ket with a $13.3 million facility in Montgomery, Ala.

The company expects to hire 90 people at the facility, which will sup-ply OEMs and aftermarket opera-tions. Operations are scheduled to begin in late 2020 or early 2021.

Effective May 11, 2020, the U.S. DOL issued a Final Rule that establishes a system for advancing the development of high-quality Industry-recognized Apprenticeship Pro-grams (IRAPs). IRAPs provide individuals with opportu-nities to obtain workplace-relevant knowledge and pro-gressively advancing skills. IRAPs include a paid-work and an educational component and result in industry-recog-nized certifications.

The intent is to address America’s skills gap and rapidly increase the availability of high-quality apprenticeship programs in sectors where apprenticeship opportunities are not widespread. SREs have the authority to oversee the development of high-quality IRAPs.

FANUC and Rockwell have worked together over the past decade developing training, certifications, and an education and training delivery network. This network of educational partners includes more than 1,200 high


(continued from page 15)


http://ivecsystems.com


The FABRICATOR 17

INDUSTRY NEWSArch Global Precision acquires Morsch MachineBloomfield Hills, Mich.-based Arch Global Precision has acquired Morsch Machine, a manufacturer of precision-machined parts, electronic mechanical support com-ponents, enclosures, chassis, and modules for the com-mercial aviation, defense, and space industries located in Chandler, Ariz.

Morsch joins the Arch Precision Components Segment, offering a variety of capabilities in 3-, 4-, and 5-axis pre-

cision machining, structural adhesive bonded assembly, mechanical assembly, 3D printing, and engineering CAD/CAM design support.

Arch manufactures cutting tools, medical instruments and implants, and precision-machined components for the medical, aerospace, defense, energy, semiconductor, surgical robotics, and progressive industrial markets.

Miller Metal Fabrication to expand in DelawareMiller Metal Fabrication has an-nounced plans to expand its current warehouse in Bridgeville, Md., and build a new, 60,000-sq.-ft. warehouse. The $4 million facility will double the company’s existing space.

The company provides CAD, laser cutting, bending, machining, weld-ing, and assembly services.

TRUMPF, Munich Re plan new pay-per-part modelThe TRUMPF Group and the Munich Re Group are entering into a strate-gic partnership for a service offering of laser cutting machines. The jointly developed pay-per-part model en-ables customers to use a full-service laser machine without having to buy or lease any equipment. Instead, cus-tomers pay a previously agreed price for each cut sheet metal part, paying only for what they need.

Initially the partnership will com-mence as a project with a learning phase, the length of which is to be agreed upon by the contractual part-ners. Munich Re acts as a business enabler of this model, financing the machine and bearing the resulting investment risk. The IoT service pro-vider relayr, a subsidiary of Munich Re, provides the data analysis for the financing model. TRUMPF sup-plies customers with the required production components, namely the machines for their factory lines and the corresponding software and ser-vices for manufacturing sheet metal parts. Steel producer and distributor Klöckner & Co. will be a development partner of the business model.

As a part of the service offering, the production process is tailored to the customers’ requirements. It includes access to a fully automatic laser cutting machine, a storage sys-tem, TRUMPF’s production know-how, and the necessary service components, as well as equipment maintenance and the required raw materials. Customers gain access to automated laser cutting technolo-gies without the need for massive investment, and the production vol-ume is easily adjustable based on demand.


http://comeq.com


18 The FABRICATOR DECEMBER 2020 The FABRICATOR 19

INDUSTRY NEWSfacility. It houses 13 machines—the previous lab had six—and four in-dustrial dust collectors have been installed outside the building.

The new lab’s sample processing capabilities allow it to simulate a vari-ety of industrial blasting applications. After a customer sends samples of parts to be blasted, along with details about the end results desired and its current process, the lab replicates the conditions of the customer’s facil-ity and researches solutions. The lab then uses the data it has collected to recommend the best equipment, me-dia, and process required to serve the customer’s blasting needs.

The facility also conducts R&D by exploring methods for enhanc-ing dust collector, reclaimer, and blast system efficiency; researching how to develop better equipment components and safety equipment; developing more productive blast machines, cabinets, and rooms; and discovering how best to use media, equipment, and new procedures.

Brookfield, Wis.-based Exact Me-trology, a 3D metrology service pro-vider and hardware sales company, recently celebrated the opening of its newest location in Moline, Ill., with a ribbon-cutting ceremony. Members of the Quad Cities Chamber joined the company for the ceremony.

Arc welding products manufac-turer Lincoln Electric, Cleveland, has introduced an app that helps take the guesswork out of preventive maintenance to maintain optimal performance from the company’s Ranger welder generator.

The NEXTime app connects to most Ranger welder generators from 15 ft. away or more to provide real-time data and alerts. It monitors battery and fuel status, creates main-

Supplier NewsIndustrial saw manufacturer Behringer GmbH has announced the 100% take-over of France-based Vernet-Behringer (VB) and the integration of VB into the

Behringer-Group. Since 1996 Behringer GmbH has been the key shareholder and strategic partner of VB, in particu-lar for the supply of band saws integrated into the auto-matic drilling/sawing lines developed by VB.

VB is a manufacturer of machining lines for profiles, as well as machines for processing metal angles and sheets. It also offers shotblasting and painting systems that are integrated into its automated lines.

Clemco has opened an ex-panded Sample Processing-R&D Lab in Washington, Mo. The new facility is 4,500 sq. ft., more than double the size of the previous

The ribbon-cutting ceremony included Exact Metrology personnel (from left, in red) Dean Solberg, Patrick Wigans, and Joe Wright, along with Quad Cit-ies Chamber members (from left) Larry Makoben, Jan Mohr, Tushar Patel, Bri-an Williams, Scott Naumann, Amanda Hess, Ron Crouch (far right), and Mayor Stephanie Acri.


http://hougen.com


http://www.voortmancorp.com

The FABRICATOR 19

INDUSTRY NEWSinteractive web page at www.aec.org/autosolutions provides information on the effective use of aluminum extrusions in various vehicle components, systems, and subsystems and highlights technical details such as alloys, fabrication methods, and performance characteristics.

As visitors scroll over an image of a vehicle, a pop-up box appears to provide information on the selected sys-tem or component, offering a link to explore deeper into that particular application. Currently the site features

detailed information on roof headers, battery boxes, sub-frames, rockers, and cross members.

The website features aluminum extrusion technical details, applications, and case examples for automotive industry professionals.

Bosch Rexroth has launched a new e-commerce portal at buyrexroth.com, designed to streamline the purchase of a variety of the company’s components,

tenance logs, provides maintenance instructions and locates service and distribution facilities, and manages an unlimited number of machines.

Master Fluid Solutions, Perrys-burg, Ohio, a provider of fluids for cutting, grinding, forming, cleaning, and corrosion control, has launched the WEDOLiT brand in North America for corrosion control, cold forming, and tube and pipe manufacturing markets.

The company acquired the Düs-seldorf, Germany-based brand in October 2019. It includes short- and long-term corrosion inhibitors, de-watering products, and VOC-free products.

Waltham, Mass.-based Olympus, a manufacturer of NDT systems, has supplied Hellier NDT’s Houston lo-cation with an OmniScan X3 phased array flaw detector and other instru-ments for use in training new inspec-tors in ultrasonic testing.

Hellier NDT is a provider of NDT training and Level III services at loca-tions throughout the U.S.

Students receive phased array ultra-sonic testing training at the Hellier NDT facility in Houston.

Website NewsChicago-based Aluminum Extruders Council has unveiled a new, interac-tive resource tool on its website for automotive design engineers. The

(continued on page 20)


http://www.aec.org/autosolutions

http://buyrexroth.com

http://trilogymachinery.com


INDUSTRY NEWSand Jessica Gerlich; and added tech-nical service support with new service technicians Didier Decoopman and Eduardo Calzada.

Along with using the new center and staff for customer service and support under one roof, the compa-ny has made the facility a centralized hub for rapidly deploying technical service and engineering support to the field. It includes warehousing of spare machine parts and plasma consumables and serves as a training center for customers and staff with on-site profile-cutting demo machin-ery showcasing the company’s latest software.

People NewsBumax Sweden AB, a manufacturer of stain-less steel fasteners, has named Lars Holm as business unit man-ager/managing direc-

tor. He has extensive sales and man-agement experience in the logistics, manufacturing, adhesive, and tool-ing industries.

Holm served most recently as re-gional manager of Linde Material Handling. Before that he was a re-gional sales manager at Ahlsell and worked for Akzo Nobel.

Jenoptik, a pro-vider of equipment for industrial metrology and optical inspec-tion, laser-based ma-terial processing, and

robot-based automation, has named Steve Green as president of Jenop-tik Automotive North America, Roch-ester Hills, Mich. He has more than 25 years of manufacturing, automation, and specialty tooling experience, supporting North American energy and automotive markets.

Green previously worked in several roles at Kuka Robotics, including op-erations and customer services man-ager, president of Kuka Canada, and president of Kuka Robotics USA.

Wausau, Wis.-based Linetec, a paint and anodize finisher and independent archi-tectural finisher, has hired Jason Morrey

as a safety manager. He has 24 years

including industrial and mobile hydraulics, linear motion

technology, electric drives, and controls.

The site’s features include quick access to find available

products for immediate purchase; real-time information

on pricing, availability, and shipping terms; and a site lay-

out that includes homepage callouts promoting featured

products, bestsellers, and new products.

HGG Profiling Equipment continues growth in North AmericaSince opening its new 6,500-sq.-ft. facility in Houston in spring 2020, HGG Profiling Equipment has announced the addition of six staff members. The company has ex-panded its North American sales coverage by hiring Todd Wellens as area manager for eastern and midwestern U.S. and Canada; increased its customer service and support capabilities by adding Carlos Rodriquez, Michelle Cooper,

(continued from page 19)


http://donaldson.com


INDUSTRY NEWSheld a variety of manufacturing management positions, serving most recently as fabrication manager for a belt-ing manufacturer for the automotive, textile, packaging, food, and printing industries. Before that he held roles as plant manager for a trailer axle and brake manufacturer and a metal exhaust manufacturer.

Webb holds a degree in mechanical engineering from The University of Texas at Arlington.

Wildeck Inc., a manufacturer of structural steel mez-zanine platforms and material handling equipment in

Waukesha, Wis., has hired Steve Holland as vice president of operations. He has more than 20 years of operations, engi-neering, and continuous improvement leadership experience.

Holland holds a bachelor’s degree in mechanical engineering from Arkansas State and an MBA from the University of Texas at Dallas.

of manufacturing experience and more than a decade in safety, health, security, and property protection programs.

Morrey previously served as the corporate safety and health manager for Verso Corp. and as a safety advo-cate for NewPage Corp. He studied occupational health and safety at Co-lumbia Southern University.

Providence, R.I.-based Mahr Inc., a manufacturer of pre-cision measurement equipment used for dimensional metrol-ogy, has named Josh Howlett as Northeast regional sales manag-er and Celina Ortiz as

manager of quality assurance. Howlett has held sales manage-

ment positions at Zeiss Industrial Me-trology and HGH Infrared Systems, serving most recently as regional sales manager for Koma Precision. His educational background includes studies in business management and marketing at Assumption College.

Ortiz most recently held the posi-tion of quality assurance manager at Freeport-McMoRan. She has a bach-elor’s degree in metallurgical and materials engineering from the Uni-versity of Texas.

MC Machinery Sys-tems, a manufacturer of metalworking and metal fabrication ma-chines in Elk Grove

Village, Ill., has named Mary Bopp as marketing coordinator. She has several years of experience working in marketing and communications, most recently at a software company in Glendale, Wis.

Bopp holds a bachelor’s degree in public relations, advertising, and ap-plied communications from the Uni-versity of Wisconsin-Whitewater.

Southern Alumi-num Finishing (SAF), a global metals dis-tributor, fabricator, anodizer, and finisher,

has appointed Matthew Webb as general manager for its original lo-cation in Atlanta. Webb has more than 20 years of professional experi-ence. Before joining the company, he


http://www.mcmachinery.com


INDUSTRY NEWS• Akai Longo, Taos, N.M.—MMI

(Motorcycle Mechanical School)—motorcycle mechanics/ metal fabrication

• Heather Holler, Incline Village, Nev.—Mitchell Community College—mechanical engineering (focus in motorsports)

• Sarah McConkie, Bountiful, Utah—Davis Tech College—rope access welding and pipefitting

The mission of the foundation (comprising Combs’ industry friends, family, colleagues, and loved ones) is to educate, inspire, and empower the next generation of trailblazing and stereotype-breaking women.

MC Machinery Systems survey reveals drivers for increased automationWhile 37% of manufacturers say the pandemic is a catalyst for increasing automation, the primary drivers for adding and expanding automation in-clude the need for increased produc-tivity and a shortage of skilled work-ers, according to a new survey from metal fabrication equipment manu-facturer MC Machinery Systems, Elk Grove Village, Ill.

More than 160 manufacturers par-ticipated in the online survey between Oct. 7 and Oct. 16. The respondents represented job shops, automotive, food, mold and die, aerospace, medi-cal, and energy. Nearly 85% work for or own manufacturing companies with less than 200 employees.

About 72% of survey respondents said they are using automation, with 45% using it minimally and 27% ex-tensively. The automation or digital technologies most used in the pro-duction process are computer-con-trolled devices (85%), robotics (45%), IoT (10%), AI (3%), and AR/VR (2%.)

Almost 30% of respondents said they are planning to add or expand au-tomation capabilities to the produc-tion process in the next few months.

The manufacturers cited the fol-lowing main reasons for adding or ex-panding automation:

• Need for increased productivity (74%)

• Lack of skilled workers (67%)• Business continuity (58%)• Safety (33%)• Social distancing requirements

(12%)

The Jessi Combs Foundation announces scholarship winnersThe Jessi Combs Foundation, Mitchell, S.D., has an-nounced the winners of The Jessi Combs Foundation Scholarship program for 2020. In addition to the two pre-viously announced scholarships for $10,000 each, contin-ued fundraising efforts allowed the foundation to add five $2,000 scholarships. In total, $30,000 worth of scholarships have been awarded to the following women:

• Sana Anderson, Beach Park, Ill.—College of Lake County—welding program

• Hannah Stout, Sterling, Ill.—Wyotech (Laramie Campus)—custom fabrication/welding

• Melissa Jester, Huntington Beach, Calif.—Summit College—structural welding

• Erin Joseph, Lansing, Mich.—Lansing Community College—automotive mechanical/electrical


http://greinerindustries.com


http://haeusler.com

http://www.etcna.net

http://fststeelfab.com


TECHNOLOGY » APPLICATIONSDigital work instructions keep quality up, carbon footprint down for HVAC manufacturer

SITUATIONAurora Group is a producer of HVAC systems for buses and heavy-duty ma-chinery within the agricultural, construction, and forestry industries. Its North American production and test site in Rochester, Mich., takes on projects from the early design stages to assembly, testing, and deployment, while ensuring every unit meets the company’s best-in-class quality standards. Production op-erators perform numerous inspections during and after assembly to ensure the quality of the equipment.

However, the company’s production process was being hampered and slowed down by having to print work instructions and inspection booklets on paper. Updating processes while keeping track of checkups using paper checklists was burdensome.

As a result of a global initiative to reduce its carbon footprint, Aurora identi-fied a need for leaner production that would eliminate waste and improve op-erational quality. To stay true to this vision, Aurora North America decided to shift to a paperless production method that would streamline daily inspections and floor data capture.

RESOLUTIONVKS helped Aurora analyze its need for a visual, user-friendly tool and suggested VKS Pro manufacturing software. Now the facility has a consolidated shop floor with monitors and tablets that display digital guidebooks. Capable of capturing data in real time, tablets help enhance the internal audits performed daily by making them effortless and centralized.

“By switching to digital work instructions, Aurora was able to eliminate paper waste and streamline the inspection process with fast mass updates of the shop floor guidebooks,” said Brian Benson, manufacturing and testing engineer.

In addition, being able to capture data throughout the assembly process has allowed the company to respond to customer requests with speed and efficien-cy, as live data is directly accessible from the shop floor. Visual instructions help workers assemble parts the right way from the first try, reducing operator errors.

Operators have a clear view of build time and quantity expectations, which has led to a 20% increase in build-time productivity on the shop floor since the implementation of digital work instructions.

The software system also helps with workforce training. The user-friendly in-terface guides employees through digital training checklists to facilitate the pro-cess. A combination of pictures and job assembly directions serve as training guides for every work process on the shop floor. New employees can use them to get familiar with a building process, and veterans can refresh their memory.

Shop floor managers can restrict untrained personnel from accessing specific guidebooks through a certification feature. Along with increasing control on the shop floor, this feature helps to decrease the assembly line’s defect rate.

A critical step to ensuring full compliance with customer requirements is the ability to pull data in relation to specific product builds. The North American fa-cility uses scanners to record bar codes and input torque values into the digital instructions. This helps Aurora report quality data to customers quickly while building an internal record on the tools and parts used during each assembly job. With visual, real-time KPIs accessible to all decision-makers anywhere in the world, the company can trace efficiency with specific work orders.

By switching to digital work instructions, Aurora has tapped into lean man-ufacturing principles by standardizing best practices, reducing waste, and in-creasing efficiency. Going digital has allowed the company to reduce its carbon footprint while maintaining high quality standards.VKS vksapp.com

Being able to capture data throughout the assembly process has allowed the company to respond to customer requests with speed and efficiency, as live data is directly accessible from the shop floor.

Dec20FAB_Applications.indd 24Dec20FAB_Applications.indd 24 11/18/20 3:44 PM11/18/20 3:44 PM

http://vksapp.com

http://www.peddinghaus.com



SITUATIONTom Onsrud, CEO and owner of CNC machinery manufacturer C.R. On-srud, and Eric McAllister, his fabrica-tion manager, were getting tired of waiting. Their standard practice had always been to have the frames for their 70 CNC machine models welded by an outside shop, but that process

had them waiting up to 12 weeks for initial delivery. And that was a best-case scenario. If the part didn’t pass quality control once it got back to McAllister’s shop, it would have to be shipped back and they’d have to wait another month.

“When a salesman says ‘I can get a half-million-dollar order for a machine if we can deliver it in x number of weeks,’ well, then we had to get in line with the outside vendor, where a good delivery was six weeks,” said Onsrud.

He knew that the lost time was costing money, he knew exactly what the heart of the problem was, and he knew how to fix it.

“They were a good shop, but nobody cares about your stuff the way you care about it,” said Onsrud. It was that simple. The company would have to bring the welding process in-house.

RESOLUTION“I ran into [sales engineer] Josh Hill at the Bluco booth at IMTS. Afterwards I sent him prints to see how he’d handle our parts,” explained Onsrud.

Hill came back with a plan for modular weld fixturing—five custom tables on a floor rail system that would allow McAllister’s crew to slide them back and forth to accommodate every frame size. The plan looked promising, so Onsrud sent a base frame kit to Bluco and brought his team to test the system at the Valida-tion Center.

“Our welders tacked it up, welded it out, changed it over to weld the bridges, and shipped it back,” Onsrud said. “When it came back to us, we machined it on our big mill, and the machinists were very impressed by how accurate it was.”

Bluco installed the system at Onsrud’s Troutman, N.C., plant, giving the company control of its own timeline.

TECHNOLOGY » APPLICATIONSModular fixturing system for in-house welding eliminates manufacturer’s long lead times

“Now we can rearrange things and build a frame in a week. We get to pri-oritize, and we don’t have to worry about other customers in front of us any-more. It just makes everything run a lot smoother,” said Onsrud. It’s helping his company move toward the ultimate goal of bringing the entire manufacturing process in-house.

“We’re getting better product off the Bluco, so it’s cut way down on machining time, which is something we hadn’t thought about or anticipated,” he explained. “I’m getting reports back from machinists that they’re saving one to two hours on each base because of the accuracy we can achieve on the Bluco tables,” McAl-lister added. On machines that cost $400 an hour to run, those savings add up.

With so many different parts to make, McAllister’s team is constantly chang-ing over the fixturing, and the modular components help speed that process. “When we do runs of three to six at a time, once we set up, it’s so much easier to loosen the angles, slide them back, remove the part, put a new one in and boom—we’re back together again instead of breaking down the fixture every time,” he explained.

The company has since installed a second floor rail system to minimize downtime further.

“We got into this because of the frustration of long lead times,” Onsrud said, “but we ended up getting a better product faster.”Bluco Corp. bluco.com

Dec20FAB_Applications.indd 25Dec20FAB_Applications.indd 25 11/18/20 3:44 PM11/18/20 3:44 PM

http://bluco.com

http://www.mitusaproducts.com

http://hypertherm.com/yesplasma3d


TECHNOLOGY » PRODUCT HIGHLIGHTSPress brake offered in electric, hybrid versions

BLM GROUP has introduced ProBend press brakes in the patented all-electric E-series and hybrid H-series versions. All systems come with a 21.5-in. touchscreen console for graphical or direct-mode pro-gramming directly on the ma-chine or offline.

The all-electric machine is available in sizes from 44 to 276 tons. It handles bending

lengths of 4 to 17 ft. Its direct-drive design has the ball screw directly con-nected to the torque motor, eliminating gearboxes and belts. This Y1/Y2 press brake offers positioning and repeatability of ±0.0001 in.

The hybrid unit is available in sizes from 44 to 660 tons, handling bending lengths of 4 to 20 ft. According to the company, the machine reduces energy demand by 35% while providing greater ram speed performance and an Y1/Y2 accuracy of ±-0.0004 in. It can be equipped with up to a 6-axis backgauge.

BLM GROUP USA www.blmgroup.com

Horizontal band saws feature EVS control, oversized chip catch basin

The new JET 9- by 16-in. and 10- by 18-in. horizontal band saws are designed to make consistent straight cuts and occasional angled cuts in ferrous and nonferrous solid and tube stock. They are suitable for use in welding and fab-rication shops, job shops, plant maintenance, and agricultural facilities.

The saws feature electronic variable speed (EVS) control, an extra-large chip catch basin, quick-positioning vise, carbide blade guides, large hand wheel, and built-in gauge. The two models weigh 726 lbs. and 805 lbs., respectively, and are constructed of cast iron and heavy-gauge steel throughout to dampen vibration and prevent deflection.

The saws are driven by 1½- and 2-HP, TEFC, three-phase motors, which in-put power of 115 V. A frequency inverter enables the band saws to operate on 115-V, single-phase input and provides blade speeds from 82 to 330 SFPM. EVS control boosts production speed and efficiency by enabling operators to change blade speed quickly at the turn of a dial, the manufacturer reports. No downtime is needed to change speeds for cutting workpieces of different materials and shapes.

JET Tools www.jettools.com

Cutter/welder offers patented functions for improved results

Koike Aronson Ransome has released the portable IK-12 Next system, which offers plasma and oxyfuel cutting as well as general welding and pendulum weave welding. The machine’s patented heat emis-sion mechanism is designed to displace up to 45% of all heat. Its patented creep control but-ton slows down the machine at the beginning and end of a cut to help improve thick plate cutting.

The unit comes standard with a multifunction digital control panel that enables the operator to set a variety of pa-

rameters. Its powertrain allows for specific positioning and helps ensure con-tinuous drive speed and pulling force regardless of power fluctuations and varying load weight.

Koike Aronson Ransome www.koike.com

Dec20FAB_ProductHighlights.indd 26Dec20FAB_ProductHighlights.indd 26 11/18/20 3:51 PM11/18/20 3:51 PM

http://www.blmgroup.com

http://www.jettools.com

http://www.koike.com

http://bluco.com

As a fab shop, you rely on your buyer relationships. You want more business, and new buyers are where you are going to find it. Keeping buyers satisfied is key to success. Trends show that the buyer profile is changing, and their expectations also have evolved. Paperless Parts surveyed 350+ parts buyers, to understand their expectations, so that fabricators are better equipped to meet them. Join Paperless Parts as they reveal the survey results and give you insight into what your buyers expect from you. They will discuss the profile of the buyers today and:

• How/when/where buyers look for new manufacturing partners

• What characteristics a buyer looks for in a fabricator

• What expectations buyers have of their supply chain partners

• How to gauge price sensitivity and upsell where appropriate

What Buyers Expect From Fabricators:

2020 Survey Results

This webcast was recorded on

October 20, 2020

YOU’LL HEAR FROM:Jason RayCo-Founder and CEOPaperless Parts

This free webinar is brought to you by:

Register today atwww.thefabricator.com/webcast

Jason Ray is the Co-Founder and CEO of Paperless Parts, the platform

for manufacturing that enables machine shops to streamline communications, quote

faster and more accurately, improve customer experience, and grow their business. Jason found his passion for manufacturing while serving at the Pentagon in the United States Navy as a supply and logistics officer, where he led advanced manufacturing implementation. Seeing the negative impacts associated with ineffective sourcing of short-run production components, Jason was determined to solve this critical problem that plagues manufacturing. Jason has a B.A. from Trinity College and MBA from Babson College.


TECHNOLOGY » PRODUCT HIGHLIGHTS

Hand-held laser welding system processes thick, thin, reflective metals

IPG Photonics Corp. has launched the Light-WELD hand-held laser welding system.

Designed and built with patented and patent-pending fiber laser technologies, the small, lightweight system enables fast welding and high-quality results in a variety of materials and thicknesses, with low heat

input and little or no filler wire, according to the manufacturer. Simple controls, including 74 stored preset and user-defined process pa-

rameters, help novice welders learn the system in a matter of hours. The sys-tem welds thick, thin, and reflective metals with minimal distortion, deforma-tion, undercut, or burn-through, the company reports.

Welding fixtures are simplified or unnecessary, and metals do not need to be prebrushed or ground completely clean. The system handles materials with dissimilar thicknesses and high/low electrical conductivity. The HAZ is minimized, as is the need for traditional postprocessing grinding or polishing.

IPG Photonics Corp.handheldlaserwelder.com

Ultrasonic polisher reaches complex corners, ribs

NSK America Corp. has intro-duced the Sheenus Zero ultra-sonic polisher. It removes hard layers of EDM deposits and polishes di� icult areas such as complex corners and ribs. It can be used for deburring, grinding, and polishing on fer-rous and nonferrous materials.

The polisher provides variable amplitude between 19 and 29 kHz/sec. and produces minimal hand vibration. It features a lightweight, resin-body hand-piece and a heat protection function that detects abnormally high heat and automatically suppresses output to prevent temperatures from rising.

The digital LED display indicates operation function and has an illuminated handpiece. Additional features include maximum output power of 45 W, LED display switchable between amplitude and watt, and a built-in cradle for the handpiece.

NSK America Corp. www.nskamericacorp.com

Wire wheel brush has each steel wire locked in place

Felton has introduced the No Throw encapsulated wire wheel brush for weld and rust cleaning. This en-capsulated technology locks each steel wire firmly in place so that pieces of wire do not fly o� during use, allowing for more aggression, greater balance, and safer use at high RPMs, the company states.

Unlike common polyurethane encapsulation, the wheel’s plastic material does not bind up or leave any residue behind on hot welds. Built with 0.30-mm steel wire, the brush can be used in applications such as automotive, pipeline, metal fabricating, aerospace, and construction. It’s available in 5-, 6-, and 7-in. dia. for compatibility with most grinders.

Felton Brushes www.feltonbrushes.com

Dec20FAB_ProductHighlights.indd 27Dec20FAB_ProductHighlights.indd 27 11/18/20 3:51 PM11/18/20 3:51 PM

http://www.thefabricator.com/webcast

http://handheldlaserwelder.com

http://www.nskamericacorp.com

http://www.feltonbrushes.com


By Tim Heston

The past few years have been a period of transition for laser cutting assist gas. Con-ventional wisdom is being questioned, and

because of that, in fact, the market now has more options than ever. Bulk and bottled nitrogen and oxygen are still popular, but other options are mov-ing quickly into the fray. These include using a ni-trogen-oxygen blend, nitrogen generation, as well as dried-air systems.

According to Steve Albrecht, president of Hart-land, Wis.-based Liberty Systems, the industry’s as-sist gas usage has evolved significantly over the past few years, a trend implied by the company’s sales record. Liberty, best known for its nitrogen-genera-tion systems, is now selling more high-performance air systems.

“Of the systems we’ve sold this year, between 20% and 30% are nitrogen-generation systems,” he said, adding that another 10% consists of blended nitrogen-oxygen systems. “The rest is almost entire-ly high-performance air.”

The traditional assist gas options like bulk nitro-gen aren’t going anywhere. Still, Albrecht said he wouldn’t be surprised that, with the rise of fiber la-sers and, especially, laser power, high-performance air might eventually become, if not the most popu-lar, at least a major form of laser cutting assist gas that the industry uses.

How exactly? First, it helps to define some terms. When you talk with Albrecht about cutting with high-performance air, don’t call it “shop air.”

“If you’re talking about regular shop air, you’re talking about relatively wet air that you might be able to use in material up to 1/8 in. thick,” he said. “But cut thicker than that and it’s not going to look pretty.”

As it stands today, lasers use one of about three types of assist gas that come from ambient air, all

of them filtered for cleanliness (minimizing particu-lates) but each with a different level of dryness. One is refrigerant dry air that Albrecht considers “wet.” This can work fine on thin stock, depending on what a job’s edge requirements are, but might present challenges for thicker cutting. The midlevel com-prises dry-air systems that use desiccant.

“Then you get to the extremely dry, high-perfor-mance air systems,” Albrecht said. “This is very dry air and, in many cases, gives the performance and speed you need.”

Between 2005 and 2008 the first higher-end nitro-gen-generation systems, both the membrane and pressure swing absorption (PSA) varieties, began appearing in the market. Also in the late 2000s came, of course, the emergence of the fiber laser and with it the need for greater assist gas pressure. Early on the fiber laser’s nitrogen consumption was a rude awakening for some. This in turn gave a boost to nitrogen generation, a technology that has become increasingly accepted by more laser machine OEMs.

Still, as Albrecht explained, although assist gas usage has increased, it hasn’t gone through the roof as the fiber laser has taken over the industry. The story’s a bit more nuanced than that.

On most early fiber laser machines, operators used the same straight nozzles—with hole diam-eters of 2, 2.5, 3, or 4 mm—that they used on their CO2 laser cutting machines. “With these nozzles, the machines consumed so much more assist gas be-cause the required pressure was much higher than what CO2 lasers required,” Albrecht explained. “It’s simple physics. If you have a certain size hole and you elevate pressure, you have more gas flow and more gas consumption.”

To combat this the industry has seen innovations in nozzle technology and refined beam parameters.

Fiber laser cutting assist gas tech evolvesThe rise of high-performance air

TECHNOLOGY » TECHNOLOGY SPOTLIGHTBeyond this, the continual increase in fiber laser power is starting to have an effect on assist gas us-age. “The assist gas pressures have been able to be reduced as lasers have become more powerful,” Al-brecht said.

Over recent years Liberty has been developing and refining its nitrogen-oxygen blended-gas systems, which continued to find popularity in challenging cutting applications, especially those involving alu-minum. “In these systems, you typically have a bulk supply of nitrogen combined with a bank of oxygen cylinders,” Albrecht explained. “When cutting alu-minum, the oxygen content helps. In fact, it’s very similar to high-performance air cutting.”

That’s not a coincidence. When developing their mixed-gas systems, Liberty Systems technicians kept reducing the amount of nitrogen in the mix, eventually to the point where it was very similar to the mix found in the air we breathe. If that air could be filtered, cleaned of particulate, and dried to the extreme, could air cutting work for edge-critical ap-plications, even in thicker material?

As it turned out, yes. The first high-performance air systems were installed in 6-kW fiber lasers. These systems cut with air for anything 0.25 in. and less. As power increased, though, so did the capa-bilities of cutting with air. “When the 8-kW systems came out, the rule of thumb was 5/16-in. material,” Albrecht said. “Now, for 10-kW systems, that rule has changed to between 3/8 in. and ½ in. So as fiber laser powers continue to increase, you’re going to see additional thicknesses being cut with high-per-formance air.”

He added that these thicknesses are only rules of thumb; air cutting’s efficacy depends on the mix of materials a shop processes, the lasers it has on the floor, the cutting parameters the shop uses, and the edge quality customers require.

Regardless, Albrecht said the assist gas market share might shift in the coming years. Oxygen cut-ting relies on that exothermic reaction and, hence, can occur only so quickly. A decade ago this wasn’t an issue, considering how the fiber laser crawled as it cut thick plate. But as fiber laser powers reach 12, 15, even 20 kW and beyond, the story is changing.

“Oxygen is fairly inexpensive, but high-perfor-mance air cutting is really taking over,” Albrecht said. “For many applications, air might displace oxygen cutting.”

He added that oxygen cutting won’t go the way of the dodo and neither will conventional nitrogen cutting. It’s hard to imagine an effective laser cut-ting operation with 1.25-in.-thick carbon steel being cut by a laser beam surrounded not by purified oxy-gen but by a jet of air.

That said, never say never. “I’ve seen 1-in.-thick stainless steel cut with high-performance air,” Al-brecht said. “The edge didn’t look pretty but none-theless it was done.”

Senior Editor Tim Heston can be reached at [email protected].

Liberty Systems Inc., www.lsn2.com

Dec20FAB_TechSpotlight.indd 28Dec20FAB_TechSpotlight.indd 28 11/18/20 4:01 PM11/18/20 4:01 PM


http://www.lsn2.com


Dec20FAB_TechSpotlight.indd 29Dec20FAB_TechSpotlight.indd 29 11/18/20 4:01 PM11/18/20 4:01 PM

http://mgsrl.com

http://www.vmstyle.it

TECHNOLOGY » PRODUCT NEWS


Punch/laser combination completes multiple processes on one machineLVD Strippit has introduced the Strippit PL punch/laser combination, a machine that combines the punching and forming of the Strippit PX or V series punch press with the speed and versatil-

ity of fiber laser cutting to complete multiple processes on a single machine. Three punch/laser models are available: the single-head style Strippit PX 1530-L and Strippit V 1530-L in thick- and thin-turret configurations.

Combination technology offers complete part process-ing. The punch press handles high-speed punching and forming operations. The fiber laser delivers high-quality

cutting of outer contours and intri-cate inner contours, as well as mate-rial etching.

The system can laser-cut intricate shapes and process materials up to 3/8 in., punch holes up to 0.250 in., and produce forms and bends up to 3.543 in. long and 3 in. high on the PX 1530-L version.LVD Strippit www.lvdgroup.com

Leveling rollers are reversible for increased service life

Kohler has developed reversible level-ing rollers for part leveling machines. Operators often use the area close to the operator panel when leveling narrow parts. Reversing the leveling rollers during routine maintenance moves the narrow-parts contact point on the rollers to a different location in the leveling roller cassette.

Roller reversal is recommended during routine maintenance (clean-ing) of the rollers for increased roller life expectancy.Kohler www.kohler-leveling.com

Blast cabinets offer height-adjustable legs

Clemco has created the ZERO brand Pulsar Plus line of blast cabinets. Six models are avail-able offering various suction and pressure.

A detached power module allows for flexible blast system configurations in awkward or tight workspaces.

Features include height-adjustable lift legs; quick-change glove ports with integrated armrests; 50-W LED lights; centralized operator control panel; electric control circuit; 1-HP exhauster motor; timed auto pulse; differential pressure gauge; side-access filter cartridge door and twist-lock filter cartridge; and 6-gal. dust container on wheels with interlock.Clemco clemcoindustries.com


Dec20Fab_ProductNews.indd 30Dec20Fab_ProductNews.indd 30 11/18/20 2:47 PM11/18/20 2:47 PM

http://www.lvdgroup.com

http://www.kohler-leveling.com

http://clemcoindustries.com


http://www.betenbender.com

http://www.carellcorp.com

mailto;[email protected]

http://www.eaglebendingmachines.com



http://www.tenexincorporated.com


TECHNOLOGY » PRODUCT NEWSIIoT system offers simple connection to edge-source data

Quantum Automation has an-nounced the availability of its QCloudServer Industrial Internet of Things (QCS IIoT) system for remote monitoring and control applications.

It allows end users and systems integrators to connect to edge-source data, transmit it on-site or to the cloud, aggre-gate and log the data, perform calculations and analysis as

needed, and deliver mobile/web visualization.The system has been developed as a configurable soft-

ware as a service (SaaS). End users can define their needs via a spreadsheet and can create a complete IIoT installa-tion—either directly or by engaging an SI—with a system that can be up and running in hours, the company reports.Quantum Automation www.quantumautomation.com

Pulse function added to welding machines

Fronius has upgraded its TransSteel 3000 compact and TransSteel 4000 and 5000 welding machines with the addition of a pulse function. The pulse mode makes it possible to bypass the intermediate arc to reduce spatter, and the pulsed arc allows faster weld-ing speeds.

The machines include a variety of supportive functions. The spot func-tion helps produce even, consistent welding spots for tacking workpieces. Interval welding produces a rippled seam appearance, and the lower heat input helps reduce material distor-tion on light-gauge sheets.

Special characteristics ensure the user has the most suitable arc prop-erties available. Steel Root has been developed for root welding and also provides a soft, stable dip transfer arc for good gap-bridging ability over wide gaps. The Steel Dynamic welding program, on the other hand, produces a particularly hard and concentrated arc for high welding speeds and deep penetration.Fronius www.fronius.com

Rockwell hardness tester available

Buehler offers the Wilson RH2150 Rockwell hard-ness tester in two sizes with vertical capacity of 10 or 14 in. The machine performs hardness test-ing according to the cur-

rent Rockwell standards, as well as plastics and carbon testing scales and Brinell depth testing scales, within the load range from 1 to 187.5 kgf.

The autostop clamping device holds down the sample and secures it during the testing. Adjustable LED workspace illumination highlights the test location. Indenter extensions are available in several sizes to enable testing in hard-to-reach locations. Buehler www.buehler.com


800-886-5418Fax 810-632-6640www.heckind.net

BEVEL-MILL®

HAND OPERATEDPLATE BEVELERSBevel up to 13/16”

WELD BEADSHAVERMachines weld beads flushto work piece.

BENCH TOPDEBURRINGPrecision finish chamfers.

POWER FEEDBEVELERS

Model9000

World’sLargest

ModelPRO21-G

Up to 10feet perminute

ModelBB27

ModelWS625

HeckBM_3.375x4.875_Heck_BM_3.375x4.875 2/15/17 4:01 PM Page 1


http://www.quantumautomation.com

http://www.fronius.com

http://www.buehler.com

http://www.heckind.net

http://diamondground.com


http://www.tjsnow.com



TECHNOLOGY » PRODUCT NEWSSheet separator features spring-actuated off position

Goudsmit Magnetics has developed a fail-safe sheet separator that provides automatic separation of steel sheets up to about 4 mm thick. The machine is equipped with neodymium mag-nets and can be switched on and off pneumatically via magnet rotation.

According to the company, the sep-arator is the only one of its kind with a spring-actuated off position. It auto-matically switches to the off position even if the compressed air supply is interrupted. The magnet cannot ac-cidentally remain switched on during maintenance.

The switchable sheet separator also allows interim changeover of products during a set process. It sepa-rates steel sheets of almost any shape, length, or width, including round and asymmetrical shapes. Goudsmit Magnetic Systems BV www.goudsmitmagnets.com

Cobot helps increase shop capacity

Acieta has intro-duced the Fast-Load CX1000 col laborative expandable ro-botic cell. It is mounted on a

mobile platform that one worker can move, so it can be set up quickly at different machines around the shop.

The small-footprint system is equipped with a FANUC 10-kg, 120-V collaborative robotic arm for material handling tasks. It can be outfitted with up to three modular carts to handle a variety of parts or allow more parts in the queue.

Operators work beside the cobot to load and unload parts while it works continuously on up to two machines. Force sensors stop the robot when pressure is applied for operator safety.Acieta www.acieta.com

CNC press brake handles complicated bending jobsKaast Machine Tools Inc. has intro-duced the HPB CNC series of press brakes, suitable for complicated, sensitive, and single or multiple bends at high speed. Standard fea-

tures include sliding front support arms for simple height adjustment, Promecam-type top clamps for simple load-ing, and Delem touchscreen control.

The manufacturer recommends the AKAS Pressbrake Safety System to meet the safety requirements of Category 4 according to EN 954 and prEN 61496 and the most recent requirements of prEN 12622. The safety integrity level is SIL 3 (IEC 61508), performance level PL e (ISO 13849-1), and safety category Kat 4 (EN 954-1). Kaast Machine Tools Inc. www.kaast-usa.com

4 R O L L H Y D R A U L I C D O U B L E P I N C H P L A T E B E N D I N G M A C H I N E S

Waldemar Design & Machine LLC900 Highland Drive

Spencer, TN 38585931-946-8474, or

606-787-8474

• The 403 Series from WDM.

• Over 40 years of experience with3 generations working in the business.

• Built in USA with American components.

• 30 gauge to 3” thick, 1’ to 26’ wide.

• Custom and built to order options available.


http://www.goudsmitmagnets.com

http://www.acieta.com

http://www.kaast-usa.com



TECHNOLOGY » PRODUCT NEWSWelding fume extraction unit adjusts to individual torches

Kemper’s VacuFil welding fume extraction unit combines simple handling with needs-based extraction capacity. The 125i, 150i, and 250i digital unit variants automatically and continuously adjust the required air volume flows according to the individual

torch characteristics to maintain the protective gas layer. The system works with any conventional welding torch.

When welders couple their torches with the digital extrac-tion models, those units automatically adjust their output to the torch parameters stored in the software. The inte-grated extraction volume control helps ensure that the extraction systems continuously adjust their performance during the welding process. Kemper GmbH www.kemper.eu

Filters remove viruses, bacteria from indoor air

The Mann+Hummel Group offers a new HEPA H13 air filter in accordance with EN 1822, which

the company says filters more than 99.95% of viruses, bacteria, and mi-croorganisms from the supply air. Throughout the winter months, the Nanoclass Cube Pro membrane en-ables a return to systems using ener-gy-efficient circulation air modes. In-fectious virus particles that can attach to aerosols, such as SARS-CoV-2, are thus filtered out.

The energy-efficient filter’s new ePTFE medium reduces the pressure drop by 50% compared to conven-tional HEPA air filters based on mi-cro glass fibers, the company states. Since it is offered in various standard dimensions, it can be used in almost any HVAC system.Mann+Hummel www.mann-hummel.com

Remote-controlled lifting magnet uses almost no energy

Industrial Magnetics Inc. has introduced the FXE line of re-mote-controlled lift-ing magnets. Com-

bining the cost efficiency and safety of a permanent magnet for load han-dling with the controlled-release ca-pability of an electromagnet, the unit uses almost no energy and does not require a battery backup system, the company states.

The magnet is suitable for lifting ap-plications that require fast cycle times without the operator having to touch the load. The operator can pick up fer-rous metal sheets or parts and release them with the push of a button. Pick-up and release functions can be per-formed by using the wireless remote control or direct activation from the magnet’s onboard control buttons.

A built-in load sensor prevents the load from being released until it’s at rest, and the fail-safe permanent magnet design securely holds the load in the event power is lost.Industrial Magnetics Inc. www.magnetics.com


http://www.kemper.eu

http://www.mann-hummel.com

http://www.magnetics.com

http://www.kalamazooind.com


http://midwestfinishing.com


http://www.lasermech.com


MANAGEMENT » BIZ TALK

Read more from Tim Heston at www. the fabricator.com/author/tim-heston

2021 forecast: The road to recovery continuesIndustry’s capex focuses on the fiber laser

By Tim Heston

Most will welcome 2020’s end, but what does 2021 bring? Will we see a return to normalcy? Not likely, but the root cause

isn’t buried within dangerous flaws in the global financial system. The root cause is painfully obvi-ous, and at this writing we’ve seen vaccines with serious potential. Once they’re distributed, the world economies will again head in the right direc-tion—maybe not quickly or even steadily, but the light at the end of the long tunnel will be there. Gross domestic product will likely continue its re-bound going into 2021. But as ever, the pandemic’s path could change everything (and considering the significant rise in cases in mid-November, more widespread lockdowns aren’t out of the question).

“By the second or third quarter, we’ll likely be seeing GDP increases in the 3% to 4% range. We’ll be looking at a nice recovery—but that’s of course contingent on whether we have another lockdown.”

That was Chris Kuehl, economic analyst for the Fabricators & Manufacturers Association Intl. (FMA). He added that the dramatic economic rebound reported in 3Q 2020—greater than 30% year over year—doesn’t point to an economic panacea; the rebound just came from an exceptionally low place. The second quarter of 2020 might go down as metal fabrication’s most challenging in recent memory, surpassing even the challenges faced during the depths of the financial crisis.

The November presidential election nearly en-sured a divided government come 2021, and as Kuehl explained, the business community doesn’t mind. “If you’d ask the business community for a preferred result, they would have picked a divided government. As the saying goes, ‘That which gov-erns least governs best.’”

Because metal fabrication serves so many end markets, fabricators across the U.S. experienced 2020 in different ways. With the OEM shutdowns earlier this year, most fabricators had a rough first half of the year. Even so, many shops in the right markets—renewable, e-commerce, IT and communications infrastructure—never skipped a beat.

How a fabricator will perform in 2021 will depend a lot on what end markets it serves. Market behav-iors vary dramatically, but fabricators serve them all with metal fabrication equipment. This is why ex-pected equipment spending can be so telling.

Enter the “2021 Capital Spending Forecast” re-leased this month by the FMA. Total projected spending for 2021 is down, of course, but not off-the-charts down. Going into 2019 readers expected to spend nearly $2.8 billion on equipment. Going into 2021, they expect to spend more than $2.4 billion. That’s less than a 15% drop from the 2019 peak—not bad, considering.

These numbers are extrapolated from more than 400 survey respondents. So, yes, it’s just a statisti-cal sample, but the results are still telling, especially when it comes to spending trends for different types of equipment. For the first time in the history of the survey, the fiber laser has come out on top. That’s significant when you consider that not every metal fabricator adopts laser cutting.

For years welding equipment and power source spending dominated the survey, which was no sur-prise. A fabrication operation might cut and bend with different technologies—plasma, punch, water-jet, laser, press brake, folder, panel bender, plate roll, and so on—but most shops weld. The big number of

welding power source purchases also accounts for all the job shops that might offer only welding and a few other basic metalworking processes. Not every job shop can afford a laser.

Despite this, the 2021 forecast projects nearly $300 million to be spent on fiber lasers alone, and this doesn’t even include the more than $85 million expected to be spent on new and used CO2 laser cut-ting machines. Fiber laser spending surpasses weld-ing power source spending by millions of dollars.

Fiber lasers might be reaching an inflection point on the innovation curve. Machine OEMs have in-troduced new ways to manipulate the beam, new forms of material handling automation, and new levels of laser cutting power. One productive fiber laser can now serve a host of downstream forming and welding operations. It’s not as if the forming constraint has gone away; it’s just that recent inno-vations in laser cutting are changing the throughput equation, in turn driving equipment investment.

During the financial crisis, consumables led the spending categories, which seemed logical. It was a time to retrench, watch, and muddle through. 2021’s projections, however, fly in the face of con-ventional thinking. One would think that after a brutal 2020, fabricators would think twice before making a huge capital purchase. Nevertheless, large equipment investment continues.

Kuehl wasn’t surprised. He recalled a recent con-versation with a manufacturer outside the fabrica-tion industry, but one that still faces similar skilled labor challenges. 2020 was tough, but now the op-eration needs to grow again—but it’s not hiring. In-stead, it’s investing in flexible automation.

The global pandemic has thrown a wrench into the global supply chain. Reshoring trends will con-tinue, and so will customers’ demand for fabricators to respond quickly. Fabricators have two choices: They can hold more inventory (which could become obsolete or remain unsold) or they can ramp up their ability to fabricate on demand. Quite often au-tomation is the only practical way to scale up pro-duction so quickly. The complete “2021 Capital Spending Forecast” will be available soon at www.fmamfg.org/store.

2021 Capital Spending Forecast HighlightsProjected Spending by Equipment TypeFiber Laser Cutting Machines: $297,451,922

Welding Power Sources: $265,768,978

Hydraulic Press Brakes: $167,679,150

Plasma Cutting Machines: $162,657,970

Turret and Rail-type Punch Presses: $88,401,070

CO2 Laser Cutting Machines: $85,642,957

Tube and Pipe Bending Equipment: $72,276,715

Note: The complete “2021 Capital Spending Forecast” breaks spending down into more than 30 equipment categories. Total projected spending amounts to more than $2.4 billion.

Dec20FAB_BizTalk.indd 34Dec20FAB_BizTalk.indd 34 11/19/20 1:00 PM11/19/20 1:00 PM

http://www.thefabricator.com/author/tim-heston

http://www.fmamfg.org/store

http://www.thefabricator.com/author/tim-heston

By Stephen Barlas

A metalworking apprenticeship program at Raytheon is the first out of the gate in what was the Trump administration’s race to create indus-try-recognized apprenticeship programs (IRAPs). These programs are

viewed as being higher-quality and better-targeted than those established by state and local employment agencies.

The first nationally recognized metalworking apprentice credential offered by Raytheon will be supervised by the National Institute for Metalworking Skills (NIMS). Rebekah Hutton, deputy executive director of NIMS, said the organiza-tion has offered individual certifications for CNC and milling and turning for many years, but for the first time has combined them into one, overarching, comprehensive IRAP metalworking credential. With past DOL apprenticeship programs, employers had to report to state and federal officials. Here, with the IRAP, NIMS serves as an intermediary.

“We take care of some of the red tape,” stated Hutton. Raytheon had two classes finish the program, which started before the DOL

recognized the IRAP.“We were scheduled to start cohort three with five people, but due to COVID-

19, the start date was pushed to sometime in 2021,” said Allen Couture, vice president of operations at Raytheon Missiles & Defense.

Of the 11 apprentices in the first two cohorts, 10 currently work as full-time Raytheon machinists at Raytheon Technologies Precision Manufacturing, lo-cated in Dallas.

“In the past, due to production demands, new hire entry-level machinists would stay in their original assignment at the factory until there was a need to rotate them elsewhere,” Couture added. “Our tailored, competency-based pro-gram, which mixes time in the classroom at Dallas College with time at the fac-tory, gives apprentices exposure to multiple areas and the hands-on training needed to perform different skills and processes.”

Good News and Bad News on Aluminum ImportsThere was one bit of good news and another bit of bad news for U.S. manufac-turers that depend on aluminum imports.

On the positive side, the Trump administration reversed itself in October on the 10% tariff it imposed on unwrought, or P1020, aluminum from Canada. (The White House reimposed the tariff this past summer, arguing those imports had surged in the first half of 2020.) The about-face decision was made after the U.S. Office of the Trade Representative hammered out an agreement with Canada to significantly decrease those aluminum imports in the remaining months of 2020 from approximately 154,000 metric tons, the monthly average from the first seven months of the year, to a monthly average of about 77,000 tons for the rest of the year.

However, the Trump administration remains committed to protecting do-mestic suppliers of aluminum. Just as it unveiled its new deal with Canada, the Department of Commerce (DOC) announced affirmative preliminary de-terminations in the antidumping duty investigations of imports of common

alloy aluminum sheet (CAAS) from Bahrain, Brazil, Croatia, Egypt, Germany, Greece, India, Indonesia, Italy, Oman, Romania, Serbia, Slovenia, South Africa, South Korea, Spain, Taiwan, and Turkey. This follows recent preliminary affir-mative countervailing duty determinations for imports of CAAS from Bahrain, Brazil, India, and Turkey.

“The Department’s aluminum sheet investigations constitute the broadest U.S. trade enforcement action in two decades,” said Secretary of Commerce Wilbur Ross. The DOC is scheduled to announce its final determinations in these cases on or about Feb. 22.

If the DOC’s final determinations are affirmative, the U.S. International Trade Commission (ITC) will be scheduled to make its final injury determination on or about April 5. If the DOC makes affirmative final determinations of dumping and the ITC makes an affirmative final injury determination, the DOC will issue anti-dumping duty orders. If the DOC makes a negative final determination or the ITC makes a negative final determination of injury in an investigation, the investiga-tion will be terminated and no order will be issued. National Institute for Metalworking Skills, www.nims-skills.org

Office of the U.S. Trade Representative, www.ustr.gov

U.S. Department of Commerce, www.commerce.gov

U.S. Department of Labor, www.dol.gov

MANAGEMENT » AROUND WASHINGTON

Read more from Stephen Barlas at www. thefabricator.com/author/stephen-barlas

Labor Department recognizes industry-organized metalworking apprenticeshipThis approach helps to eliminate some of the state and federal red tape


Dec20FAB_AroundDC.indd 35Dec20FAB_AroundDC.indd 35 11/18/20 4:13 PM11/18/20 4:13 PM

http://www.nims-skills.org

http://www.ustr.gov

http://www.commerce.gov

http://www.dol.gov

http://www.thefabricator.com/author/stephen-barlas

http://www.thefabricator.com/author/stephen-barlas

http://www.weil-technology.com


MANAGEMENT » STEEL NEWS

For more information, visit www.steelmarketupdate.com

Steel prices defy predictions of a peakDemand rises as mills keep supply tight

By John Packard and Tim Triplett

Steel prices continued to move higher through the fourth quarter, sur-prising many steel buyers who were predicting a peak as new capacity and seasonal factors were expected to bring the uptrend to an end. But

steel supplies remain tight relative to demand, and buyers tell Steel Market Update (SMU) that negotiations with the mills have become quite contentious as steelmakers hold the line on spot and are less willing to compromise on contract tons.

In comments to SMU last month, buyers complained about the unusually ag-gressive nature of the pricing offers from the mills. Some are looking for alterna-tive sources, both domestic and foreign.

“I’m not used to such a combative relationship. The darn mills are taking an odd stance. They are telling us to take it or leave it. There are other places to purchase steel. The mills never learn their lesson,” said one manufacturing ex-ecutive.

Others reported some flexibility in contract negotiations with certain mills, mostly involving relief from add-ons such as coating extras and freight. But for the most part, the mills are narrowing the window on the volume of tons that must be ordered before they will consider discounts.

As the year winds down, a major event will take place that will impact the flat-rolled steel markets. Cleveland-Cliffs, owner of AK Steel, will finalize its pur-chase of most ArcelorMittal USA assets (except for its Calvert, Ala., joint venture mill). In comments to SMU last month, President/CEO Lourenco Goncalves said his guiding philosophy regarding mill production is creating value. (Goncalves: “I have said time and time again that I am for value, not for volume.”) SMU in-terprets this to mean the mills controlled by Cleveland-Cliffs would prefer to see the market stay tight and prices high.

As of mid-November, steel supply was limited, and steel spot buyers were having to pay higher prices on almost a weekly basis. With problems at Stelco (computer system hack), NLMK USA (Farrell, Pa., steel mill on strike), and on-time delivery issues with multiple mills keeping supplies tight, the expectation is for flat-rolled steel prices to remain strong through the balance of 2020 and into 2021.

The vast majority (86%) of the steel buyers responding to SMU’s poll in No-vember said they were expecting another round of price increases from the mills soon, and many were not happy about it:

• “I think another round of increases is inevitable, whether it’s a formal an-nouncement or not, but there is still blood in the water.”

• “They haven’t really needed to announce increases; they are able to get them by default.”

• “The mills have raised prices for January absent price increase letters.” • “Hopefully they will give the market a breather. Have they forgotten about

2018? Binge and purge mentality at the mill level.”SMU’s survey of service center and OEM executives on Nov. 9-11 revealed

an average benchmark price for hot-rolled steel of $710/ton, surpassing the

FIGURE 1Industry observers who suggested that steel mills couldn’t hold the line on announced price increases have been proven to be wrong. A majority of steel buyers reveal to Steel Market Update that they see steel prices possibly peaking in the first quarter of 2021.

FIGURE 2Even with the rising COVID-19 cases and the drama associated with the most recent presidential campaign, steel buyers remain optimistic about current business conditions.

“I’m not used to such a combative relationship. The darn mills are taking an odd stance. They are telling us to take it or leave it. There are other places to purchase steel. The mills never learn their lesson.”

—Anonymous manufacturing executive

Dec20FABSteelNews.indd 36Dec20FABSteelNews.indd 36 11/18/20 4:20 PM11/18/20 4:20 PM

http://www.steelmarketupdate.com


MANAGEMENT » STEEL NEWS

$700/ton level where many had expected it to top out. That’s up 60% from a low of $440/ton in mid-August as the economy struggled with the coronavirus, and it exceeds the $580/ton in mid-March pre-COVID-19.

In summary, the upward slope of the steel prices is as much about the tight supplies as it is about the growing demand as the economy rebounds from the pandemic shutdowns. Mills idled significant capacity in the second quarter and have taken their time about bringing production back. Lead times for delivery of spot tons from the mills have nearly doubled since early in the year as the mills scramble to keep up with orders. As of November, most mills were filling their order books for January already as buyers hurried to secure their share of the limited tons available.

How long will steel prices continue to rise? Forecasts are mixed as there is lit-tle consensus on the question. But the majority of buyers polled by SMU in No-vember see prices continuing to rise well into first-quarter 2021 (see Figure 1).

Current and Future SentimentLast month’s election had little effect on steel industry sentiment, primarily because steel buyers were already so upbeat. Every two weeks SMU asks steel buyers how they view their company’s chances for success in the current environment and three to six months in the future. SMU’s Current Sentiment Index registered +63 in the week after the contentious presidential contest (see Figure 2), little changed from the +68 in the weeks prior. The Future Sentiment Index was comparable at +62 (see Figure 3). To put that in perspective, current sentiment plummeted to -8 and future sentiment to +10 shortly after the pandemic hit.

That steel executives’ attitudes have recovered so dramatically so quickly is surprising given the ongoing political acrimony and threat from COVID-19. One can only surmise that this bullishness reflects the healthy steel demand and profitable steel prices the market is experiencing as 2020 comes to an end.

Steel Market Update EventsSMU is working in partnership with Port Tampa Bay to host the 32nd annual Tampa Steel Conference on Tuesday, Feb. 2. The 2021 event will be on a virtual platform similar to the SMU Steel Summit Conference produced earlier this year. The daylong program will include a variety of topical speakers as well as a speed networking session. Cost of the conference is $150 per person for those who do not qualify for a discount. Those who have attended the Tampa Steel Confer-ence in the past will get a 50% discount for registrations made by Dec. 31. SMU

FIGURE 3Steel buyers are almost as optimistic about business conditions in the coming months as they are now.

and CRU member companies qualify for a $25 discount. Visit www.tampasteel conference.com for more details and to register.

SMU also will be hosting a number of steel training workshops in 2021. We will be conducting the popular Steel 101: Introduction to Steel Making & Market Fun-damentals Workshop in February 2021. SMU also will be rolling out three new hedging steel price risk workshops. We will have an introductory (Hedging 101) workshop; an advanced workshop, focused on strategy and execution of trades; and a workshop dedicated to hedging galvanized steel. More information about SMU training workshops is available at www.steelmarketupdate.com.

Not a Steel Market Update Subscriber? SMU provides real-time pricing, news, and analysis of market trends affecting North American flat-rolled steel, plate, scrap, and related markets. To sign up for your free three-week premium trial, email [email protected], or call 724-720-1012.

John Packard, president/CEO of Steel Market Update, can be reached at john@steel marketupdate.com. Tim Triplett, executive editor for Steel Market Update, can be reached at [email protected].

Steel Market Update’s mission with its newsletters, website, conferences, and educational programs is to inform, educate, and motivate those in the flat-rolled steel industry. For more information, visit www.steelmarketupdate.com.

Fast, Productive, and Half

the Energy!

BENDING, CUTTING & PUNCHING MACHINERY800-354-3737 | [email protected] | youtube.com/boschertsales

New technology that cuts costs. The new Boschert Gizelis servo electric line: Electro Bend® and first-of-its-kind Electro Cut®. Increased ram/cut speeds reduce cycle times. 50% less energy consumed when compared to hydraulic models. Zero hydraulic fluid—no sourcing, filtering, disposal, or service costs. Shear capacities of 4-6 mm steel. Bend capacities of 60, 80 and 100 tons.

Groundbreaking ElectricPress Brakes and Shears!

BoschertHV_Gizelis_Jan20FAB.indd 1BoschertHV_Gizelis_Jan20FAB.indd 1 12/18/19 12:19 PM12/18/19 12:19 PM

Dec20FABSteelNews.indd 37Dec20FABSteelNews.indd 37 11/18/20 4:20 PM11/18/20 4:20 PM

http://www.tampasteelconference.com






http://www.boschertusa.com


http://youtube.com/boschertsales

http://www.tampasteelconference.com



By Dan Davis

Manufacturers in the U.S. find themselves in a challenging position as they try to find the right people to fill the job openings

within their ranks. The generational gap has never been greater in the manufacturing workforce.

Thanks to people generally living longer than they did in the early part of the 20th century and looking to work longer to pad their retirement nest eggs, manufacturing companies could have five gen-erations working under the same roof. That means folks who grew up with rotary dial telephones are working side-by-side with young people who only know of phones as texting devices that fit into their pockets. That generational gap might be more like the Grand Canyon.

But that doesn’t necessarily mean that a multi-generational workforce is destined for di� iculties. In fact, just the opposite may be true. With the right managerial approach, frustrations between the old and young can be minimized, and each generation’s positives can be accentuated. The FABRICATOR spoke with Denise Ball, workforce development specialist with Tooling U-SME, the workforce devel-opment division of SME that delivers competency-based, industry-driven learning and development solutions to the manufacturing community, to find out what can be done to get these di� erent gen-erations (Silent Generation, born 1928-1945; baby boomers, born 1946-1964; Generation X, born 1965-1980; millennials, born 1981-1996; and Generation Z, born 1997-2012) to work harmoniously toward a common goal.

The FABRICATOR: Tooling U-SME’s 2018 “Indus-try Pulse: Manufacturing Workforce Report” suggested manufacturers that don’t do a good job of establishing a culture of recruiting and fostering manufacturing talent of all ages could be a� ected by annual turnover of up to 20% or higher. Are companies getting the message that they need to be aware of the needs of the di� er-ent generations represented in their workforce?

Denise Ball: If you don’t perceive that there are dif-ferent generations with di� erent views, it’s kind of like sticking your head in the sand, and we don’t want that. We want people to acknowledge it and to almost embrace it in a good way. We want them to ask, “How can we leverage all the di� erent gen-erations and what they bring to the table so that we create an even better workplace, become even more innovative, and think of even greater oppor-tunities than what we’ve always done in the past?”

FAB: Why do you think so many generations find themselves working in manufacturing today?

Ball: Well, the older generation really did work for the gold watch. They stuck around and are still working in manufacturing. You’re not necessar-ily seeing a lot of boomers working at McDonald’s, Starbucks, or generally in hospitality, but you are seeing them in manufacturing because that really was the bedrock of our country. We were once really proud of it. We were proud to be working and mak-ing products. So I’m not surprised that there are so many generations in these companies.

Today it’s all about attitude and aptitude with the skills gap. That’s what I’m hearing from employers.

They’re hiring for attitude and aptitude. So they’ll work with whatever they’re given. I love that about manufacturing.

FAB: Tooling U-SME’s latest report, “6 Ways to Build a Cohesive Multigenerational Manufactur-ing Workforce: Prepare for the Future—Now,” highlights how a company’s culture can make people feel comfortable about what they do for a living, but also what they might be doing down the road. What can a company do to create a pos-itive culture that embraces a multigenerational workforce and puts them in a position to focus on achieving company goals?

Ball: I think no matter what the size of the company, people need to focus on family, friends, and a fun environment. That’s what people want from small companies and even the large companies.

Small companies can pivot quickly, so they are very responsive. They really tend to create family environments, and that is resonating right now with the younger generations. They’re wanting those connections and wanting to have that family feel. Some of the older generations—and I can say that coming from an older generation—we didn’t want to work with family and friends. We weren’t looking for that in the workplace.

So companies can leverage their hand and say, “Hey, we’re going to create an environment that, even though we can’t compete in the wage catego-ry, makes them love working here so that they don’t want to leave.”

As I speak across the country at di� erent virtual events right now, I see manufacturing companies are starting to understand that they always have to accentuate the positives and really drive it home.

I talked with one company recently that is holding cornhole tournaments in the middle of the produc-tion floor for 15 minutes every day. It’s creating that engagement. In the past, engagement may have been the once-per-year holiday party. Well, they want more than that.

FAB: Some company leaders just have a knack for connecting with people, and o� entimes a company’s culture evolves from those personal relationships. What can an organization do if leadership doesn’t have that natural connection to the workforce or if an organization is too large to develop those intimate relationships?

Ball: Companies really need to solicit feedback. No matter what the company size, just ask people, “How can we improve engagement? How can we support you?”

MANAGEMENT » CHIEF CONCERNS

different ages, one goalHow to get your multigenerational team to maximize its efforts

U.S. manufacturing companies might have as many as five di� erent generations working under the same roof. That multigenerational workforce can pose chal-lenges for the unprepared management team, but companies with cultures that engage workers and pro-vide clearly defined career pathways for employees can attest to the power of mixed-age manufacturing teams. Getty Images.

Dec20FAB_ChiefConcerns.indd 38Dec20FAB_ChiefConcerns.indd 38 11/18/20 4:28 PM11/18/20 4:28 PM


And this is not just with a suggestion box. A com-pany needs to do pulse surveys and engage with workers, even doing stay interviews. Why do you stay here? Why do you like our company so much? What can we be doing even better so that you want to tell everybody about the great place you’re working at?

Companies should think about giving business cards to their production employees. It’s a $10 in-vestment, but it gets the word out. Companies are branding themselves in the community as their em-ployees give the business cards out to friends and relatives. They’re proud of where they work.

FAB: Can technology be used to optimize knowl-edge sharing between experienced workers and co-workers of younger generations?

Ball: Yes, I absolutely think technology can be used to do that, but I still think it comes back to culture because all the generations want to feel like they’re being heard and valued. If they all feel that way, they’re openly communicating, no matter what the technology is. There’s going to be more collabora-tion, period.

FAB: The “6 Ways to Build a Cohesive Multigen-erational Manufacturing Workforce” report rec-ommends building a formal training program. How is this attainable by small to medium-size businesses?

Ball: I would say that a large number of compa-nies that we engage with on a daily basis are small to medium-size. They are seeing the value of hav-ing structured and clear training pathways for their employees. The younger generation wants as many experiences as possible, and you want to cross-train them. If you don’t show those young people their future, they’re going to find it somewhere else.

Even the smaller companies are starting to catch that vision. They see that they’re competing against other companies for this small pool of employees or skilled labor. They need to show the younger gen-eration that they have opportunities. These com-panies can use online training resources, which give everyone access to knowledge almost immediately. That way a company can begin to develop those pathways and offer training even if they don’t have a formal training program established. Then it starts to evolve like anything else.

FAB: Does having a human resources expert on staff help for setting up a formal training pro-gram?

Ball: A lot of people will look to HR to do the train-ing, but actually I think it’s a collaboration between HR and operations. Operations is where the knowl-edge is, as far as how the processes work. Now when they’re doing job descriptions, HR is definitely involved. But then they are getting down to the nit-ty gritty in determining what the knowledge, skills, and abilities are that feed into that job description.

FAB: What are the positives of having a workforce that spans the generations?

Ball: Like anything else in life, being unbalanced is usually not good. Legacy employees bring expe-rience, and they can tell you what occurred when something was tried and what a client preferred when they previously worked with them. That is so invaluable. They have such a wealth of knowledge.

That older generation is needed to mentor the younger ones and build relationships with them. A good company culture can cultivate those relation-ships.

Younger employees usually offer a new way to think outside of the box. They are more likely to suggest something that has never been tried before. They aren’t easily dismissed and kind of push back and challenge conventional thinking. Just having a balance of all the generations brings a balance of different perspectives, and that’s what you want.

FAB: What do you see as the biggest mistake man-ufacturing companies might make when trying to manage a multigenerational workforce?

Ball: It’s believing that they’re ok doing what they’ve always done and that it’s going to work for the future. It’s really false beliefs. It’s maybe not acknowledging that the next generation wants something different than what the older generation wanted when they started their careers.

FAB: Are manufacturing companies picking up on that lesson?

Ball: I think the companies that are training their employees on the key characteristics of the different

generations and how to leverage them are the ones that are going to benefit the most. The ones I see doing that are having the greatest success. They’re putting together the most collaborative teams. There’s more communication between the generations because they’ve been trained to appreciate what each generation brings to the team.

FAB: People have a good feel for millennials now that they make up the biggest portion of the U.S. workforce. They’re tech savvy and desire con-sistent feedback from their supervisors, for ex-ample. How do they differ from Gen X and Gen Z?

Ball: You have to remember that millennials and Gen X are next to each other, so you’re going to get some bridging between the two. Millennials really want a lot more experiences, while Gen Xers weren’t necessarily thinking about that. Millennials also want different connections. Gen Z, up to age 23, also wants the experiences and the different connections.

If you think about it, Xers thought that you had to stay at a place three years minimum. For baby boomers, it was five to 10 years. The millennials came along, and they thought 18 months is long enough. They’re like, “Oh well, I really didn’t like that place. I only stayed there for three months, and it’s ok because there was a problem.” So it is differ-ent.

Editor-in-Chief Dan Davis can be reached at [email protected].

Tooling U-SME’s latest report, “6 Ways to Build a Cohe-sive Multigenerational Manufacturing Workforce: Pre-pare for the Future—Now,” is available for download at https://ppc.toolingu.com/multigenerational.

MANAGEMENT » CHIEF CONCERNS

“Companies really need to solicit feedback. No matter what the company

size, just ask people, ‘How can we improve engagement? How can we

support you?’ And this is not just with a suggestion box. A company needs

to do pulse surveys and engage with workers, even doing stay interviews.

Why do you stay here? Why do you like our company so much?”

—Denise Ball, Tooling U-SME

Dec20FAB_ChiefConcerns.indd 39Dec20FAB_ChiefConcerns.indd 39 11/18/20 4:28 PM11/18/20 4:28 PM


https://ppc.toolingu.com/multigenerational



EXPERTISE » PRECISION MATTERS

Read more from Gerald Davis at www.thefabricator.com/author/gerald-davis

3D models need to be more than prettyImport your export file to ensure enough billet is there for the job

By Gerald Davis

The fabrication drawing shown in Figure 1 is for a modified bolt. Starting with a com-mon off-the-shelf item, the idea is to make a

tapped hole in the threaded-end ¼-28 and to drill and tap the headed end for a ¼ NPT fitting.

Several details are revealed in the drawing. Sec-tion A-A shows our desired through-hole, a zone re-moved by the ¼-28 threads; a pocket made by the pilot drill for the ¼ NPT; and the tapered section removed by the pipe threads.

CAD software helps to automate the production of such drawings. The hole callouts for the tapped holes required simple mouse clicks to add the de-tailed drilling notes to the drawing. Such informa-tion is pulled from the modeled features in the 3D part. This helps to minimize and goof-proof the typ-ing chore.

A CAD model that is excellent for making 2D draw-ings may, at the same time, be a catastrophe in fab-rication. I know because I received some parts that had threadless holes that matched the STEP file (not the PDF) perfectly.

Figure 2 shows a cross-section view of the shad-ed 3D model that was used to create Figure 1. When it comes to tapped holes, the 3D representation of

threads is a trade-off between computer speed and visual accuracy. For speed, threads are often shown as cosmetic threads—just phantom cylinders, not actual helical spirals.

The helical threads shown in Figure 3 (peek closely to see the cross section) require a few more CAD modeling steps. Helical surfaces task the com-puter’s video system with more work. An alternative modeling technique is to revolve “threads” instead of sweeping the helix. That illusion works great as a speed and time saver.

The scenario for this project requires that we pro-duce both a 2D PDF (see Figure 1) and a 3D STEP file (see Figure 3).

FIGURE 1A 2D drawing for a modified bolt is shown. Section A-A shows the areas where thread is removed. This removal is modeled by (drum roll, please) removing the threads from the billet and attaching a hole call-out—text that pretends the thread is there. The red box shows a view with threads. If perfectly modeled, such threads can be useful in fabrication.

FIGURE 2This is a cross-section view of the 3D model used to create Figure 1. The external threads will grow in later stages from an undersized shank. The internal threads will fill up oversized pockets.

FIGURE 3A cross-section view of threads added to Figure 2 is shown. The Thread feature quickly models the straight threads. A combination of Hole Wizard and helical sweep create the tapered thread. Disclaimer: If you download the example, the threads are not guaranteed to be standard profiles.

FIGURE 4The off-the-shelf bolt is modeled with a revolve, head hexing cut, grade bumps, forged taper, and 5/8-18 fully threaded 2-in. shank. The product manufacturing in-formation will be for the finished machined item. The raw material just happens to be a bolt.

FIGURE 5This is the Hole Wizard setup for drill and tap of a ¼-28 hole. A handy setting is shown in a red box: Remove Threads. This works well with the Thread feature, which will later be used to add in the helical threads.

FIGURE 6Configurations are used to change the model from Off the Shelf to Modified to Modified Without Threads. Per-haps another configuration is needed for raw billet for exporting purposes.

Dec20FAB_PrecisionMatters.indd 40Dec20FAB_PrecisionMatters.indd 40 11/30/20 8:30 AM11/30/20 8:30 AM

CALLING ALL MANUFACTURING SUPERHEROES!

Save Your Seat Now | fmamfg.org/annualmeeting

Now, more than ever, FMA is proud to honor manufacturers standing strong in the face of unparalleled challenges. RREESSIILLIIEENNCCEE RREESSIILLIIEENNCCEE RREESSIILLIIEENNCCEE RREESSIILLIIEENNCCEE

IINN AA WWOORRLLDD RREEDDEEFFIINNEEDDIINN AA WWOORRLLDD RREEDDEEFFIINNEEDDIINN AA WWOORRLLDD RREEDDEEFFIINNEEDDIINN AA WWOORRLLDD RREEDDEEFFIINNEEDD

Jump online March 3-4, 2021, from anywhere with an internet connection, to celebrate the tenacity of the industry and leave equipped with innovative ideas to make your career or business stronger than ever.

The FABRICATOR 41

EXPERTISE » PRECISION MATTERS

Our raw material—a common grade 5 bolt—is shown in Figure 4. To cre-ate this model, we used a revolve. Re-volves take slightly fewer CPU cycles than a boss-extrude. (Sure it’s a small nuance, but we do what we can.)

The wrench flats were cut with a sketched hexagon. The forged taper on the head is modeled with a re-volved cut, a small detail that adds visual credibility.

Three bumps on the head means grade 5. The grade marking has the pattern-of-three in the sketch for a single boss-extrude. An alternative is sketching for one boss-extrude and patterning it three times, but that takes slightly more CPU e� ort.

The thread feature adds the 5/8-18 thread around the shank of the bolt. The thread is not needed for the 2D drawing, but it is useful for visualization. It can also be important in the STEP file that is exported for fabrication.

Figure 5 shows the Hole Wizard setup for drilling and tapping a ¼-28 hole. Our red box has been added to emphasize a setting—Remove Thread. This works nicely in conjunc-tion with the Thread feature, which puts the threads back in.

For the big tapped hole, the Hole Wizard is again set to remove the threads. The missing tapered thread is modeled back in using a sweep along a tapered helix.

Three configurations are used to control this model. Figure 6 shows the “No Threads” configuration in the graphics window. All three of the thread features—5/8-18, ¼-28, and ¼ NPT—are suppressed in this con-figuration. For comparison, Figure 3

A CAD model that is excellent for making 2D drawings may, at the same time, be a catastrophe in fabrication.

shows the model in the modified configuration.So now we hammer home the CAD caveat: If the STEP file

is going to be used for manufacturing, it is possible that the modeled configuration that works for making a 2D drawing will not work as a billet for machining. Without the threads in place, the modeled billet is too small for the external threads and too large for the internal threads.

Here’s the CAD tip: Import your export and evaluate it as a billet for machining. Are the holes too big? The pegs too small?

Gerald would love for you to send him your comments and questions. You are not alone, and the problems you face o� en are shared by others. Share the grief, and perhaps we will all share in the joy of finding answers. Please send your questions and comments to [email protected].

Dec20FAB_PrecisionMatters.indd 41Dec20FAB_PrecisionMatters.indd 41 11/30/20 8:30 AM11/30/20 8:30 AM


http://fmamfg.org/annualmeeting


EXPERTISE » CONTINUOUS IMPROVEMENT

Read more from Jeff Sipes at www.thefabricator.com/author/jeff-sipes

Weave lean thinking into decision-makingAnd do it intentionally

By Jeff Sipes

Decision-making is a way of life for manu-facturers and fabricators. This is as true for front-line employees as it is for senior exec-

utives. Of course, the scope and magnitude of de-cisions at different levels of the organization vary, but there is no denying that decisions are made all day, every day.

With the pandemic and all its challenges, you’re making decisions that would have seemed com-pletely foreign a year ago, utterly off your radar. And still you have the typical “get the product out the door” challenges to deal with every day. Do you weave lean thinking into those decisions? More im-portantly, do you do so intentionally?

Why the Need to Be Intentional?Under normal circumstances, unplanned events—such as machine breakdowns, supply chain disrup-tions, or key personnel absences—create easy dis-tractions. They break your regular rhythm, causing short-term workarounds and sometimes even long-term deviations.

Enter the pandemic and business as usual be-comes a distant memory. There were (and continue to be) many decisions to be made about social dis-tancing among employees, product flow, and infor-mation flow. Just think how many Zoom meetings you’ve attended during the past few months.

Incorporating lean thinking into your pandemic response (or any other major unplanned crisis) will enhance, not hinder, your efforts. And your result-ing strategy will be more robust for handling the cri-sis now and after it passes.

Lean thinking can be an effective source of conti-nuity and structure to make decisions that meet the challenges of whatever issue you face while main-taining as much of the rhythm as possible. Inten-tionally keeping lean thinking front and center will create a balance between overreacting to external influences and maintaining effective operations. This is all in the spirit of keeping your workforce safe and gainfully employed. Be intentional!

Examples of Intentional Decision-MakingDecisions made with lean thinking tackle the root cause, and they don’t kick the can down the road. For instance, let’s say you have a poorly perform-ing business segment. Deliveries are inconsistent, quality is suspect, and customer confidence is wan-ing. The day you plan to start a formal kaizen event to focus on this product line happens to be a day when the customer’s supplier development person is visiting your plant. The shipment might not get on the truck today because some of the people who build the product are on the kaizen team. You are the manager in charge of this part of the business. What do you do?

The traditional decision would be to cancel the kaizen event or go find other employees to be on the kaizen event while the regulars go make today’s product for the truck. Unfortunately, tomorrow will likely be another day of scrambling to “make the truck.”

Here’s a more enlightened approach that incor-porates lean thinking. You inform the supplier de-velopment person that you’re conducting the kai-zen with the aim of identifying and implementing permanent solutions to your operating problems. Meanwhile, you reallocate resources from other parts of the operation to get today’s product on the truck. You’re not kicking the can down the road.

In another scenario, say you need to reconfigure the work flow to minimize employees’ exposure to one another. Knee-jerk reactions might be to stretch the line or move individual operations away from one another into separate departments to create distance. Without the underlying lean ideas of mini-mized travel distance and one-piece or small-batch flow, you could end up with disconnected and iso-lated operations. You might even revert to where things were before you implemented lean.

Here’s an approach that weaves in lean thinking: You maintain social distancing while preserving lean fundamentals within your operation. You have effective 5S, and you continue to perform audits to measure and reinforce positive behavior—after all, the cleanliness aspect of 5S has become more criti-cal than ever during this pandemic. Next, you redis-

tribute the work content to separate workers in the process and then, to ensure changes are applied consistently, revise and retrain with new standard work instructions.

What about your sheet metal assembly cells, where you worked so hard to keep employees close together so they could communicate and collabo-rate? Here again, lean thinking wins the day. You maintain social distancing by keeping the spacing 6 ft. apart; but to keep the product flowing from sta-tion to station, you use gravity-fed chutes and short sections of roller conveyors to connect adjacent operations. In fact, these solutions actually improve operations in the assembly cell. No longer must as-semblers manipulate awkward workpieces from one station to the next. They now just slide them down a conveyor. The resulting operation is now safer, ergonomic, and more efficient than ever.

In yet another scenario, production planning seeks to “optimize” the plant’s operations by plan-ning larger batch sizes and fewer shop orders, with the noble intent of having fewer orders and simpler planning. But wouldn’t that be a step back toward pre-lean operations? Processing large order quanti-ties increases the likelihood of split orders or incor-rect information due to an order being open on the floor for longer periods of time. All this creates more interaction between the office and floor, leading to even more complexity, not less.

Instead of larger batch sizes and fewer shop or-ders, the lean thinking approach would be to focus on rhythm and flow and tickety boom (that is, a con-sistent rhythmic pattern that gets to the same ideas behind takt time). Doing so creates a predictable and stable process that results in less chaotic reac-tions to problems. If you can still maintain the es-sence of your cell, you then can have fewer report-ing points, less inventory, and clearer line-of-sight management in the process.

A final scenario is where you as a senior manag-er, faced with all the pandemic’s challenges, must decide whether to continue with the lean journey, including training, improvement projects, and lean strategy development. If you backtrack, you make it more difficult to maintain a safe workplace. The

Dec20FAB_ContImprov.indd 42Dec20FAB_ContImprov.indd 42 11/18/20 4:37 PM11/18/20 4:37 PM

http://www.thefabricator.com/author/jeff-sipes

YOU’LL HEAR FROM:David Bohrer, CEOHastings Air Energy Control, Inc.

David Bohrer is Hastings Air Energy Control’s Chief Executive Offi cer

and Chairman of the Board. Under David’s leadership, the company has

grown 2400% and has developed award-winning and patented products that have revolutionized the air fi ltration industry. In addition to David’s executive duties, he remains one of the company’s top business development engineers. His client list includes numerous Fortune 500 and Fortune Global 500 companies who have chosen Hastings to design air fi ltration systems for their global facilities. David’s expertise is solving indoor air pollution with a specialty in on-demand general ventilation systems.

It’s one thing to control your dirty air from manufacturing processes, it’s another to do it intelligently!

• IVEC Systems saves money by managing energy consumption

• IVEC Systems provides clean air on-demand and remote access to information for seamless management of your system

• IVEC Systems guarantees a safe work environment

Join us for a webinar about the revolutionary IVEC ULTRA®

ventilation systems that offer a substantial ROI due to the reduction of plant exhaust and very low use of horsepower and compressed air. By incorporating individual units, our general ventilation solution adapts to deliver the cleanest air and meet the most stringent governmental standards. See you online January 21st!

Controlled Process Ventilation: Save Money, Save Lives

January 21, 20212:00 p.m. Eastern

(1:00 p.m. Central)

This free webinar is brought to you by:

Register today atwww.thefabricator.com/webcastDECEMBER 2020 The FABRICATOR 43

EXPERTISE » CONTINUOUS IMPROVEMENT

continued training, whether at senior levels or on the front line, may need to be less intimate; you cannot squeeze the training group around a small table in the conference room for a simulation exercise, for example. But with a mixture of creativity, patience, and technology, training can be effective and still advance your company’s lean journey.

Be IntentionalThese scenarios just scratch the surface of the issues you face every day but are representative of the current situation. The decisions in these scenarios can be made without lean thinking, but they will come at a cost. By intentionally using lean thinking, you will make more effective decisions for the good of your com-pany and your employees.

Lean thinking, effectively done, affects all parts of your manufacturing busi-ness. It deals with the processes your people work in; the respect with which your people are treated; and the performance of your business, which affects all your stakeholders.

Lean thinking needs to happen everywhere. Senior executives demonstrate lean thinking as they build corporate metrics that reflect important lean ideas like cleanliness, velocity, and people development. Front-line managers dem-onstrate lean thinking by the way they continually work with staff to find better and safer ways to manufacture. Welders demonstrate lean thinking as they cre-atively work at everyday kaizen.

It’s easier than ever now to make short-sighted, short-term decisions that feel good but deliver little value to the organization. Intentional decision-making based on lean thinking helps you make it through the short term while being true to your long-term success. In this period of uncertainty and pandemic, keep doing what you’re doing. Weave lean thinking into your decision-making—and do it intentionally.

Jeff Sipes is principal of Back2Basics LLC, 317-439-7960, www.back2basics-lean.com. If you have improvement ideas you’d like to read about, email him at jwsipes@back 2basics-lean.com or Senior Editor Tim Heston at [email protected].

In this period of uncertainty and pandemic, keep doing what you’re doing. Weave lean thinking into your decision-making—and do it intentionally.

Dec20FAB_ContImprov.indd 43Dec20FAB_ContImprov.indd 43 11/18/20 4:37 PM11/18/20 4:37 PM

http://www.thefabricator.com/webcast

http://www.back2basics-lean.com




http://eriez.com


EXPERTISE » BENDING BASICS

Read more from Steve Benson at www.thefabricator.com/author/steve-benson

How about a little quiz?The more you know, the better your parts will be

By Steve Benson

I get many questions every month that are quite similar. With that in mind, I thought that I would put these recurring questions into a quiz format.

This quiz will give those readers the answers to their questions while allowing the rest of you to test your knowledge.

Some are multiple choice and some are true or false, but all will be challenging. If you have fol-lowed my column for any length of time, you will realize that I have given you the answers at some point in time. The answers and explanations follow the quiz.

The QuestionsQuestion 1: Defining the k-factor. When a bend is made the metal elongates. This elongation is why the flat blank is smaller than the sum total of the formed part’s outside dimensions. The k-factor plays an essential role in that elongation:

A) as a multiplier to predict the location of the neutral axis within the material.

B) as it represents the total amount of material that needs to be removed from each bend before forming.

C) as the measured length around the radius of the bend at the neutral axis.

D) as it represents the tangent of half the bend angle, which in turn is used to calculate the bend deduction.

Question 2: Using the k-factor. Whether you are using bend deductions or bend allowances to de-velop your flat pattern, where is the k-factor applied in the formulas shown below?

Bend allowance = [(0.017453 × Inside bend radius) + (0.0078 × Material thickness)] × Degrees of bend angle

on the outside of the bend

Outside setback = (Tangent of half the bend angle) × (Inside bend radius + Material thickness)

Bend deduction = (2 × Outside setback) - Bend allowance

A) The k-factor is not applied here.

B) In the 0.017453 value.

C) The k-factor is the bend deduction.

D) In the 0.0078 value.

Question 3: More on the k-factor. Mathemati-cally, you can calculate a k-factor value and sub-sequent neutral axis location greater than 50% of the material thickness. When this occurs, you must bring the k-factor value back to 0.50 before making any further calculations.

A) True

B) False

Question 4: Defining the minimum bend ra-dius. Your customer’s print calls for a “minimum” bend radius, which means you use the smallest punch nose radius you have available to work with.

A) True

B) False

Question 5: About air bending. When air form-ing sheet metal, you use the punch nose radius to calculate the bend allowance, outside setback, and the bend deduction.

A) True

B) False

Question 6: Types of radii. Of the five orders of inside bend radii, which one will suffer large amounts of springback without separating from the punch radius?

A) Sharp

B) Minimum

C) Perfect

D) Surface, or radius, bend

E) Profound

Question 7: About springback. The springback factor:

A) helps predict springback.

B) tells you how far past 90 degrees you need to bend to compensate for springback.

C allows you to determine the actual inside radius of a bend.

D) takes springback into account when determining the k-factor.

The AnswersQuestion 1. The answer is A. When a bend is made in sheet metal, the material expands on the out-side and compresses on the inside. In between the expansion and compression is a theoretical area known as the neutral axis. This neutral axis goes through no physical change, no compression or ex-pansion.

During bending, the neutral axis moves inward to-ward the center of the bend radius. This movement elongates the material. The k-factor is then used to calculate the neutral axis relocation by multiplying it by the material thickness. Note that there are dif-ferent k-factors based on the forming method and type of materials being formed.

Question 2. The answer is D: 0.0078 = π /180 × k-factor, assuming that the k-factor is 0.4468: π /180 × 0.4468 = 0.0078. If you want to use a k-factor other than the standard 0.4468, you can simply swap the 0.4468 with the new k-factor value.

Question 3. The answer is A, true. The reason is sim-ple: Compression on the inside of the bend cannot be greater than the expansion on the outside of the bend, meaning the largest k-factor possible is 0.5.

Question 4: The answer is B, false. A minimum bend radius is the smallest radius you can put into a piece of material and still avoid cracking or separating the grains on the outside of the bend. While this mini-mum inside bend radius can be calculated, it is com-monly referred to in terms of multiples of the mate-rial thickness—1x, 2x, etc. Those values are based on the different types of material and their temper. The mill usually can provide this information.

Question 5. The answer is B, false. In air forming, the radius is developed as a percentage of the die width (also called the die opening). If you calculate the bend functions—bend allowance, outside set-back, and bend deduction—based on the punch nose radius, chances are your numbers will be wrong.

I say “chances are” because you may be getting it partially right. For the best results, it is best to pick a punch nose radius that is as close as possible to the naturally formed (or floated) inside bend radius.

Dec20FAB_BendingBasics.indd 44Dec20FAB_BendingBasics.indd 44 11/18/20 4:44 PM11/18/20 4:44 PM

http://www.thefabricator.com/author/steve-benson


EXPERTISE » BENDING BASICSThe floated bend radius can be calculated using the 20% rule, a name based

on the percentage used for certain stainless steels. The baseline material is 60-KSI carbon steel, which forms at about 16% of the die width. Note that this is only an estimate, and the percentage changes with the material type and ten-sile strength. For instance, 120-KSI stainless steel would have a floated radius that’s about 32% of the die opening: (120/60) × 0.16 = 0.32. If your punch nose radius exceeds the naturally floated inside bend radius, the bend will take on the punch’s larger radius.

On the other end of the scale, if the bend turns sharp, the punch nose begins to penetrate the material. At that point the inside radius becomes a parabolic shape as the punch passes through the inside of the bend.

Except when the punch nose is larger than the inside bend radius, if you calcu-late the bend functions based on the nose radius rather than the floated inside radius, the bend functions will be off.

Question 6. The answer is D, the surface bend. This radius type begins at 125% of the material thickness up to 10 to 12 times the material thickness, depending on the material type. When the radius is greater than 10 to 12 times the material thickness, by the time you have penetrated so far into the die space to compen-sate for all the springback, the material separates from the nose of the punch. The part’s radius gets smaller in relation to the punch radius the farther past 90 degrees you go. This phenomenon is known as multibreakage.

Question 7. The answer is C. The springback factor allows you to determine the bend’s actual inside radius. As you release a piece of sheet metal from the form-ing load, elastic memory within the metal causes the bend angle to open up. That’s springback, but that’s not the only thing happening. Not only does the bend angle open, but the inside radius of the bend also opens slightly. If the ra-dius changes, so do the bend deduction, outside setback, and bend allowance. You fundamentally change the part.

The effects of the relaxing bend radius should be taken into account. Take the bend angle before being released from forming pressure (the bent-to or bent angle), then the angle measurement after the release (the bend angle). Say a 92-degree bent-to angle measures 90 degrees after it’s released from forming pressure. Divide the bent angle from the bend angle, 92/90 = 1.0222. This is your springback factor.

To apply it to the real world, you multiply the expected inside bend radius by the springback factor, and you have a much more accurate radius value to work with when calculating the bend functions. If the inside radius was expected to air-bend to a 0.062-in. inside bend radius, and you multiply that by the 1.0222, you get 0.0633 in., your new inside bend radius. This means that you should use 0.063 rather than 0.062 in the calculations. Sure, it’s a minimal radius change and perhaps adds only 0.003 in. to the bend deduction; it just comes down to how precise you want your parts to be.

How’d You Do?If you want to know more about any of these topics, check out “Predicting the inside bend radius when bending with the press brake” from August 2015; “A grand unified theory of bending on a press brake,” a series that ran from Sep-tember through December 2015; “How to predict an air formed radius with pre-cision” from November 2018; and “The basics of applying bend functions” from November 2012. You can find them all by typing the article title in the search box.

I hope that you did well, or at least learned a few things that will make your products just a little bit quicker to produce with fewer errors.

I hope that you did well, or at least learned a few things that will make your products just a little bit quicker to produce with fewer errors. The more you know, the better your parts will be.

Steve Benson is a member and former chair of the Precision Sheet Metal Technology Council of the Fabricators & Manufacturers Association International®. He is the presi-dent of ASMA LLC, [email protected]. Benson also conducts FMA’s Preci-sion Press Brake Certificate Program, which is held at locations across the country. For more information, visit www.fmamfg.org/training, or call 888-394-4362. The author’s latest book, Bending Basics, is available at the FMA bookstore, www.fmamfg.org/store.

Dec20FAB_BendingBasics.indd 45Dec20FAB_BendingBasics.indd 45 11/18/20 4:44 PM11/18/20 4:44 PM


http://www.fmamfg.org/training

http://www.fmamfg.org/store

http://www.akyapakusa.com



By Tim Heston

The metal fabrication industry’s business case for high laser cutting power has evolved over the years. In the early years

of CO2 laser cutting, more power let you cut faster and thicker. Especially for custom fabricators, a higher-powered laser broadened a shop’s capabili-ties, which in turn opened the door to new custom-ers and markets.

Then in the late 2000s came the fiber laser and a whole new ballgame. Cutting thin stock, a fiber laser could run circles around a similarly powered CO2. The fiber laser pushed the industry’s cutting capac-ity skyward, so much so that many shops struggled to feed the beast. Sure, a shop could automate the material handling, but even so, a laser that cuts extraordinarily quickly can overwhelm processes downstream, especially bending and welding. It’s

about order-to-ship throughput: If a shop beefs up its cutting capacity only to shove the bottleneck downstream, what good is all that cutting power?

Turns out, all these assumptions might oversim-plify the chess-like strategy needed to foster opti-mal throughput, especially once you take a deep dive into operations that have installed 10, 15, even 20 kW of fiber laser cutting power.

A prime example, Raytec LLC has found plenty of good in more cutting power. On the shop floor sit two fiber lasers, one 15 kW and the other 20 kW. To understand why the fabricator invested in such im-mense cutting power requires a closer look at the throughput chessboard.

Not Just for Bragging RightsGlen Zimmerman, one of Raytec’s owners, had been eyeing high-powered laser cutting for years. “In la-ser cutting, you need to stay current or you’re going

to be out of the game,” Zimmerman said. “Technol-ogy is evolving so rapidly.”

He wasn’t eyeing high laser power for bragging rights, but because the technology fit the shop’s overall growth strategy. Zimmerman’s grandfather founded Raytec as a small fab shop in 1956 (the shop is named a� er Zimmerman’s father, Raymond). The company grew by o� ering products for the building and agriculture industries, from residential gutter components to specialized carts used at dairy and pig farms.

As the company’s collection of CNC fabrication equipment grew, so did its demand for job shop work. Today the company’s New Holland, Pa., plant produces a mix of job shop work as well as sheet metal parts for its own product lines. A plant in nearby Ephrata and a location in Missouri perform stamping and roll forming for the company’s build-ing product lines.

The New Holland plant, which serves all three businesses—building products, ag products, and job shop work—has limited space. Getting the most throughput out of that space has driven the shop’s equipment investment strategy since it bought its first CO2 laser cutting machines in the late 1990s. It replaced those with a 4-kW fiber laser in the 2010s. And then in 2019 the shop made its first plunge into ultrahigh laser power, purchasing a 15-kW fiber la-ser. In 2020 the shop followed that up with another fiber laser, this one all of 20 kW. Both are Eagle laser systems.

The Cutting Head BarrierIn sheet and plate cutting, the fiber laser itself hasn’t been the constraint. Eye-popping fiber laser power has been around for years, being used in special-ized welding, military, and other applications. The constraint has been the laser cutting machine itself, specifically the laser cutting head.

The cutting head has been ultrahigh-power laser cutting’s Achilles’ heel. A machine might have a sol-id frame, linear drives, and very high cutting speeds, but all those advantages go out the window if a shop keeps blowing cutting heads. And it’s usually not for lack of maintenance. Extraordinarily high-power laser beams need extraordinarily clean optics. The smallest imperfection—like infinitesimally tiny de-bris that falls from a moving component within the head—can cause heat to build up uncontrollably. Similarly, continually replacing the protective cover glass doesn’t help cleanliness or throughput either; cover glasses aren’t free.

The latest cutting heads are changing the game, however, which is one big reason that more and more 10-kW-plus machines are reaching the mar-ket. “We had been watching the high-powered laser for years,” Zimmerman said. “We knew some shops

Raw stock is staged for laser cutting. Work flows quick-ly from blanking to bending and hardware insertion on the far side of the plant.

Cutting withmore kilowattsHow a Pennsylvania metal fabricator cuts with ultrahigh laser power

COVERSTORY

Dec20FAB_EagleLaser.indd 46Dec20FAB_EagleLaser.indd 46 11/18/20 4:51 PM11/18/20 4:51 PM


were starting to dabble with machines 12 kW and above, but we also knew that they had trouble with the cutting heads.”

The Eagle machines on Zimmerman’s shop floor have no moving parts within the beam path in the head, and the collimation components are posi-tioned outside the head itself. The cover glass is also recessed far inside the head cavity. Debris from piercing or cutting must make its way 14 in. through a downflow of assist gas to reach the protective glass window.

Finally, there’s the beam’s energy density that, the machine manufacturer states, is decreased by the large optical elements. “When we looked at these fiber lasers, we analyzed how much stress is going through the cutting lens,” Zimmerman said. “With these new machines, we see they can put 15 kW through an area with less energy density that our older 4-kW fiber laser had.”

The Business CaseWhen people think of ultrahigh-powered fiber la-sers, they automatically think of thick stock. But as Zimmerman explained, that’s not why Raytec jumped into the fray of double-digit-kilowatt laser cutting. Sure, the company has cut 0.75-in. stock, and it’s experimenting with gas mixes and laser pa-rameters to make its thick plate cutting even more effective, but that’s not why the fabricator has two ultrahigh-power machines.

Raytec’s market for ultrathick-plate laser cutting is small, at least relative to the 0.25-in.-thick-and-less market. Of course, the shop could establish a strong niche, perhaps take work away from other thermal cutting operations that, because of critical edge requirements, follow up with edge machining. If a laser can eliminate a machining step, it can save a customer a lot of money.

These niches can diversify a shop’s job portfo-lio, but the demand for such cutting might not be enough to be a primary revenue driver. As Zimmer-man explained, the throughput potential drove the operation toward such high-power machines. The two new lasers give Raytec tremendous cutting throughput—the ability to cut more in less time, es-pecially in material 0.25 in. and thinner—allowing the shop to quote work extremely competitively. They also give shop ample capacity both for work that requires downstream forming and hardware as well as cut-only work. The increased throughput changes the cost and price equation, which in turn could bring more work into the laser cutting fold.

Operational FactorsOf course, the business case makes sense only if the operation can indeed increase throughput. Like a finely tuned race car, a fab shop with ultrahigh-pow-ered laser cutting needs every operational variable tuned for maximum throughput and material yield.

Can We Fill a Sheet? “It starts with communicat-ing with your customer,” Zimmerman said, espe-cially when it comes to sheet and plate utilization. Work that fills a standard sheet size increases mate-rial yield and can save the customer money while simplifying part flow and remnant management.

Raw Material Purchasing. Such communication carries over to raw material purchasing. Laser cut-ting, as with all thermal cutting, releases residual stress in the sheet, and parts could bow or distort in some way. Technology in the laser cutting machine can prevent such bowing from hindering through-put (as described later), but no laser cutting ma-chine can change the physics of sheet metal and plate.

As Zimmerman explained, if severely bowed pieces required leveling before being sent to down-stream processes or to the customer, that second-ary operation would add costs and hinder optimal throughput. All the cutting speed in the world doesn’t matter if a piece requires a leveling step or a serious amount of rework.

Edge Quality, Power, and Assist Gas. The same argument goes for flat-part deburring. Raytec does have a flat-part deburring machine, and as Zimmer-man explained, some jobs require edges the laser and punch just can’t produce on their own. But these are the exception, not the rule. Cutting opera-tions minimize the need for deburring with beam control and highly controlled speed around corners and contours; the machines’ cutting head is driven linearly, not with rack and pinions.

The shop also makes strategic use of assist gas, using either straight nitrogen or, for thick stock (7 ga. and thicker) normally susceptible to dross, a carefully controlled blend of nitrogen and oxygen. The nitrogen evacuates the molten material and al-lows the laser to maintain its speed, while the oxy-gen provides a burning action that, when tuned cor-rectly, can leave a clean edge.

As Zimmerman said, “When you reach enough la-ser power, you can start doing unique things with blended assist gas that won’t have the same effect when you have half the laser power.”

Cutting Performance. Although cutting inches per minute still plays a role in throughput, IPM is still only a piece of the puzzle, and it’s one that has to be viewed in a broader context. A cutting head’s speed in a straight line is one thing, but what about corners and contours? How about the piercing cycle and, for that matter, overall process stability?

A 15-kW laser at Raytec LLC performs a pierce. To pro-tect the sensitive optics from spatter, the cover glass is recessed.

The two ultrahigh-power lasers have loading automation; part offload is handled using conventional techniques.



Here, Zimmerman said, is where linear drives play a role. The two Eagle systems have linear drives in X, Y, and Z. The X and Y allow for high acceleration, all of 6 Gs, according to the machine manufacturer. Quick acceleration means quick cut-to-cut traverse times, of course, but it has another implication for ultrahigh-power laser cutting: the use of full laser power (and, hence, maximum speed) through a greater portion of the entire nest.

If a slowly accelerating head cuts long, straight kerfs on a sheet, it has enough time to accelerate to full speed and make full use of its laser power. But if that same head spends most of its cutting cycle accelerating and decelerating within each cut as it negotiates through intricate patterns and holes, it never reaches its maximum IPM for the material thickness and grade it’s cutting, so (at least from a cutting speed perspective) there’s no need for such a high level of laser power.

And as Zimmerman noted, the quick motion of a linear Z axis is especially important. First, it allows the head to pierce higher on some hole geometries and then immediately drop down to cut.

“It’s also a big deal with part tip-ups and prevent-ing head crashes,” Zimmerman said, adding that sensors on the head (and via other head design attributes) sense part touches and tip-ups quickly. Once the head senses such process instability, it stops immediately and rises instantly. “It then auto-matically recenters itself and, if it can, corrects the problem and keeps going, continuing where it left off.”

The head has several more crash protection safe-guards beyond capacitive sensors, each of which kicks in depending on the nature of the collision hazard. Regardless, Zimmerman said, when laser cutting so fast, having high levels of crash protec-tion is critical to maintain process stability and maximum throughput.

Material Loading and Part Offloading. As fiber laser cutting machines become more and more powerful, “feeding the beast” becomes a greater concern, hence the need for automated material

feeds with a fast pallet change. Zimmerman said the shop invested in an automated loader/unloader but not a complete tower storage system (though Ray-tec has an alternative solution in the works). The floor space is at a premium, and besides, “when you think about it, feeding the system is the easy part. Offloading and part sorting is a different animal.”

According to Zimmerman, Raytec’s part mix is such that automated or robotic part sorting isn’t an option, at least currently. (The shop does, however, heavily utilize sorting automation for punching, as will be discussed soon.) Also, as laser cutting ma-chines reach extreme speeds, cutting cycle times are extremely short. In other words, at least for Raytec’s operation, automated part sorting would create a bottleneck. So now the lasers offload to a separate table where a team denests the sheet us-ing traditional methods.

That said, Zimmerman knows that chaotic part sorting can be a bottleneck, too, and a severe con-straint on throughput, especially if poor sorting leads to lost or damaged parts that need to be recut.

This is where strategic nesting comes into play. First, the shop minimizes nests with remnants.

Again, this occurs through good customer com-munication (adjusting an order so it fills a sheet) as well as through strategic use of filler parts made to stock, either for consistently ordered job shop work or pieces for Raytec’s own product line.

Next comes the actual nesting strategy, a balanc-ing act between high material yield, optimal process stability, grain restraints for bending or cosmetic reasons, and, again, ease of part sorting. Tabbing in the right place helps keep parts secure and pre-vent them from creating a head-crash hazard. On the other hand, excessive tabbing—either using too many, making them too thick, or both—can make part denesting a bear.

In fact, the absolute ideal for cutting efficiency, material yield, and sorting ease is common-line cut-ting with no tabs at all. According to Zimmerman, edge quality problems on two common-cut parts

Raytec has a mix of bending technologies, including a CNC folder, several press brakes, and (pictured) a TRUMPF cell consisting of an automated press brake dedicated to small parts.

This 0.75-in.-thick part in the as-cut condition was la-ser-cut with a nitrogen-oxygen blended assist gas.

Raytec’s New Holland plant has limited space, hence the need to squeeze a lot of cutting power over a small footprint. A 15-kW laser faces a 20-kW machine, both from Eagle, and both are adjacent to a Prima Power punch/shear system.



usually aren’t an issue, but skeletal integrity can be a problem. So programmers common-cut where they can; nest with web sections when needed; orient parts’ longer dimension perpendicular to the slats so the parts stay stable even with-out tabbing; and, finally, tab only when necessary.

Operators also observe the cutting action and, if needed, adjust tabbing in the program directly on the machine control. “On the new machines, the operator can actually add tabs to features that didn’t have any,” Zimmerman said, “and effectively remove tabs from other features right at the controls, on-the-fly.”

Operators can also adjust a tab’s thickness. Zimmerman said that for the most part, operators choose to make tabs more robust to ensure process stability; the potential for a head crash is far worse than a slightly less efficient denesting process. But programmers also make sure they don’t overuse tabs and make the shake-and-break harder than it needs to be.

Skeleton cutting also plays a role. Skeleton cutting is standard practice on oxyfuel and plasma tables cutting thick plate; it’s a faster way to remove scrap, and it doesn’t tie up a crane. For lasers cutting sheet or thin plate, it’s been a dif-ferent story—until, that is, extreme cutting speed has made those extra inches of kerf, made to chop up the skeleton, essentially irrelevant. Again, because ultrahigh-powered lasers are so fast, cutting portions of the skeleton—making both denesting and scrap collection easier—becomes a no-brainer.

Part Identification. A lost part doubly hinders throughput. The operation spends time cutting the part, looking for it, and possibly recutting it if it’s not found. For some jobs at Raytec, a slight change in hole location might be all that differentiates one part from another.

The operation tackles part identification on several fronts. First, it laser-marks parts on the machine when it can. Second, Raytec doesn’t rely only on laser cutting for its blanking needs. It also has a fully automated Prima Power punch/shear. Some of this has to do with formed features like embosses that only punch tooling can create. The punch/shear has integrated tapping as well. But it also has to do with part identification challenges that, as Zimmerman ex-plained, the punch/shear’s automated sorting helps overcome. True, parts are sent down one of four chutes; they aren’t stacked neatly. Regardless, the parts are separated automatically from the scrap, which itself is cut and sent to a final bin for recycling.

“That machine processes a lot of parts where, when you glance at them, you can hardly tell them apart,” Zimmerman said. “The hole locations are just so similar. But [on the punch/shear] with automatic separation, we don’t have to worry about sorting these parts.”

Forming Capacity. Raytec does have spot welding and hardware insertion, but the New Holland facility does not have a welding department, which is a common constraint in the cut-form-weld-grind-finish-ship cycle. The company does offer forming with five press brakes; one CNC folding machine; and its most recent and largest forming investment to date, a TRUMPF robotic forming center tailored for small-parts bending.

“This allowed us to take the tedious, time-consuming small parts out of our other press brakes and completely automate our small-parts-bending opera-tion,” Zimmerman said. “It’s been a life-saver for our small-parts forming. We’re running that thing 24 hours a day.”

He conceded that, yes, with the shop’s tremendous cutting capacity, bending still is the constraint operation, but the mix of forming technologies makes that constraint much less severe. In fact, both the automated small-parts bending and the folder take away the least productive work on the conventional CNC press brakes. Thanks to the folder, brake operators need not struggle to support a large part as it swings up to make a narrow flange; thanks to the robotic brake for small parts, they also need not tie up a wide press brake bed with a narrow punch and die set to bend small bracketry.

The mix of forming technology helps keep the flow. And with so much blank-ing capacity, the company could add even more press brakes and other forming equipment to boost throughput even more.

2020: Not So Bad After All“Back when the pandemic started, we weren’t sure what to expect,” Zimmer-man said. “Our natural inclination was to pull back, because bad things were going to happen with that much market disruption. But we’ve experienced the opposite. For pretty much all of the business segments we serve, it’s just been crazy busy. In fact, some months we were pushing 40% year-over-year growth.”

By the end of the year, 2020 revenue could exceed 2019 revenue by between 20% and 25%. The New Holland plant employs only 15 people, and the com-pany has 46 employees across all facilities.

“We feel very fortunate and blessed. And we were so glad to have the equip-ment we have. We were able to increase throughput without having to increase labor.”

That in a nutshell has been the story of metal fabrication: Increasing through-put (sales) per employee makes each employee more critical to the shop’s suc-cess, and technology has given those employees the tools to make that success happen.


Raytec LLC, www.raytecllc.com

Fairmont Machinery, Eagle, www.fairmontmachinery.com

Prima Power, www.primapower.com

TRUMPF Inc., www.trumpf.com

Picot Plate Rolls Mean Savings

BENDING, CUTTING & PUNCHING MACHINERY800-354-3737 | [email protected] | youtube.com/boschertsales

Picot’s three-roll plate rolls, in combination with patented EASY Roll software, bring astounding effi ciency to fabricators producing cylinders for transportation, manufacturing, and architecture. Picot has capacity for ¾-inch plates up to six meters in length. Picot EASY Roll guarantees near-perfect pre-bending and fi nished parts, while reducing skill requirements, man-hours and materials waste. Roll into savings with Picot.

Let the Savings Roll!

BoschertHV_Picot_April19FAB.indd 1 3/20/19 1:53 PM



http://www.raytecllc.com

http://www.fairmontmachinery.com

http://www.primapower.com

http://www.trumpf.com



http://youtube.com/boschertsales


By Tim Heston

The press brake department is the heart of many a fabrication operation. The elonga-tion bending creates governs the blank size

upstream in cutting, and the precision of forming governs the efficiency of welding and other pro-cesses downstream.

Bending also requires fine-tuned information-gathering protocols. Without those protocols, trou-bles in bending can be a significant speed bump to product flow and overall throughput.

So how does an operation fine-tune its informa-tion gathering? To answer that question, The FABRI-CATOR spoke with Jonah Higgs, a longtime fabrica-tor who is currently the technical services leader at Schofield, Wis.-based Applied Laser Technologies, and also the creator of Bend Genius, a web-based tool to improve a shop’s precision bending perfor-mance, allowing jobs to sail smoothly through cut-ting, forming, and ideally, all the way to the custom-er’s receiving dock.

As Higgs explained, “We either have to remove the speed bumps from the process, or we’ve got to put up the appropriate signage that says, ‘This is a speed bump, but we’re warning you it’s a speed bump, so there’s no surprise.’ The speed bump is built into the fabrication strategy. This allows my technical teams to build problem-solving strategies before they turn into emergencies.

“When you boil it all down, smooth flow comes down to one thing. It’s about minimizing surprises.”

Who’s Accountable?Higgs has a passion for bending and can opine with utter fascination about how a specific material alloy forms over a certain kind of V die. But, he also real-izes that expecting everyone to learn such technical intricacies simply isn’t realistic.

“Part of removing the speed bumps from the bending process is making sure you’re giving your team the best tools. Bending has specific risk factors that need to be identified before parts arrive at our brakes, so our front office people need to be able to spot these problems early. Technical training is important to establish a baseline of understanding for our teams, but most of today’s workforce will not retain, or will struggle to apply, these rules and for-mulas.

“As the owners of technical rule sets, it’s our re-sponsibility to arm our teams with the tools that take the guesswork out of their jobs. Engineers love an opportunity to get out their calculator and crunch some numbers, but it is not fair for us to ex-pect that from the rest of our teams.

“It’s easy to get angry at sales, estimating, and design teams for missing something that causes a speed bump in manufacturing, but disciplinary ac-tion and constant retraining are not the solution. It’s our responsibility to equip our teams with the tools that make it easy for them to know when they’re safe, and when to ask for assistance.”

Higgs added that this perspective has in a foun-dational manner changed the direction of his man-

agement style over the years. He recalled espousing details on flange lengths and V-opening-to-materi-al-thickness ratios to various shop personnel, from operators to estimators, only to be met with blank faces and tired eyes.

It’s about identifying who excels at what. A shop needs people with knowledge, but just as if not more importantly, it needs the people who execute the day-to-day tasks that keep the business profit-able. “On the one hand, we have seasoned fabrica-tors who are well-versed in the technical details,” Higgs said. “But our job is really to support the people who are doing the work”—that is, those who operate the machines and make part flow happen.

He even goes so far as to say that the skilled labor crisis is directly linked to the tendency of the cur-rent workforce to place higher value on speed than on rote knowledge. “We see our workers using cell-phones to look up answers to questions that once required hours reading a book or sitting in a class-room. Deep technical training and data retention are becoming things of the past. The new workforce will work as fast as the tools we can provide for them.”

Expertise is needed; a fabricator simply cannot function without it. But education is a two-way street. People need to be receptive to new informa-tion and eager to learn. Brake operators might not be fascinated by going deep into the weeds of bend-ing, but they might be fascinated with other aspects of the fab shop.

Thing is, you’d never know if a technical lead keeps pushing technical details that the operator isn’t interested in learning. A technical lead expect-ing an unreceptive operator to learn anything and everything about bending becomes the fab shop’s Sisyphus, pushing the rock of bending knowledge up an unsurmountable hill, forever going nowhere.

What Kind of Fabricator Are You?Fabricators aren’t a homogenous bunch, and Higgs conceded that his information-gathering approach for bending doesn’t apply to every one of them. The approach mainly applies to precision fabrication job shops and contract manufacturers, those whose business model involves pushing the precision po-tential of bending, and where customers might re-quire the forming department to hold tolerances of within 0.010 or even 0.005 in. At these fabricators, processes on the floor and in engineering are geared to handle serious precision-bending challenges.

This approach might not make sense in some operations. First, the market has plenty of room for fab shops that measure most parts with tape mea-sures, not calipers. “I recall speaking with one fab shop owner who told me, ‘I don’t think we ever had a part we couldn’t bend.’ And I asked him, ‘What do you mean?’ It turned out they just weren’t a preci-sion shop,” Higgs said. “They measured their parts with 25-ft. tape measures, and if parts are within a quarter inch, they’re fine.”

Avoid the bending speed bumps

A good information-gathering strategy can smooth production

Dec20FAB_InfoFlow.indd 50Dec20FAB_InfoFlow.indd 50 11/18/20 4:57 PM11/18/20 4:57 PM


Picture a precision bending operation as a one-way highway with guardrails on either side. The middle of the highway is the bending operation’s sweet spot, its technical strength. Anything near the guardrail is a challenging job.

Depending on the shop and the markets it serves, a custom fabricator with a dynamic, high-perform-ing bending operation—that is, a wide highway with flexible guardrails—can differentiate itself by quot-ing jobs others wouldn’t dare to touch. This isn’t because one shop’s capabilities are better, just dif-ferent, all based on the tooling, equipment, and ex-pertise a bending operation has.

Regardless, before a shop establishes its commu-nication strategy, it must determine which jobs are sweet spots, right in the middle of the road; which approach the guardrails; which go beyond those guardrails; and how far beyond those guardrails the shop is willing to go.

“For instance, maybe your shop does a lot of hem-ming,” Higgs said. “Or maybe you work at a short-flange shop.” A job that calls for a narrow flange might represent middle-of-the-road work for certain fabricators yet approach the guardrails for others.

Levels of Technical AptitudeOnce a fabricator defines its technical strengths and weaknesses, it then can define the kinds of people who work in the shop, both in estimating and in the press brake department.

Some operations might try their best to impart to their front-line team—the CAD technicians, es-timators, and salespeople—varying levels of deep forming knowledge. “What I’ve found through the years, however, is that forming requires a high level of technical aptitude in one operation, the press brake,” Higgs said. “But estimators need to look at blueprints and think about every single operation on the floor. Normal people don’t have fun digging down into the technical weeds of press brake work.”

Exceptions abound, he said, but for the most part estimators don’t have the interest or time to dig into the weeds—and that’s a good thing. The job in estimating and sales is to win work. If they con-tinually think of every technical implication in every request for quote (RFQ) with a forming operation, they might not respond with a bid in time. And even if they were a wizard at the press brake and could respond quickly, estimators might try to squeeze in the guardrails, perhaps even turn down major growth opportunities, all in the name of optimal manufacturability.

At the same time, estimators need some ground rules. They should push to open the guardrails, but not ignore them completely. And they should consider at least certain basics. It’s a balancing act: Estimators need to quote a broad range of jobs to ensure the shop can grow, but they still need to per-form a few basic checks—what Higgs calls his “dif-ferent levels of bending fundamentals.”

Level I: Setting the FoundationThe first level deals with what happens to sheet metal as it’s formed inside a V die. He emphasized that these are just top-level fundamental checks that need to be completed before anything else.

Higgs added that who answers these questions depends on shop practices and its business devel-opment goals. For instance, some operations might have salespeople or account managers answer all Level I questions before passing a job on to an estimator, who delves into the details covered in Level II. Regardless, answering these questions as early as possible—and certainly before a job hits the floor—will help plan for or even eliminate any speed bumps to work flow.

V-Opening-to-Material-Thickness Ratio. As Higgs explained, “You need a set range.” Fabrica-tors can turn to various sources for rules of thumb, including Steve Benson’s Bending Basics column in this magazine, “but every company needs to adopt and share their own rule set when it comes to deter-mining the V-opening-to-material thickness range.”

That’s because every precision shop has a differ-ent mix of products it forms. Also, the range for this ratio will change depending on the material grade and tensile strength. A vast majority air-bend, but special tools and processes can still alter the ratio beyond those found in typical air-bending opera-tions. If the range doesn’t account for this, estima-tors could end up turning away work that the bend-ing department could successfully form without much trouble.

Minimum Flange Length. “Now, we need to guide engineers and estimators to give me enough information to suggest the right-sized V opening based off the part we’re trying to bend,” Higgs said. “Then we need to make sure the part is designed with a flange that’s long enough so we can bend it in that tool.”

Again, this can vary depending on the kind of tools a shop has. The estimator doesn’t need to know the intricacies: like, say, a certain bull nose ra-dius tool with a urethane bottom die having a step

on the die shoulder that allows an operator to form effectively with no minimum flange length. As Higgs explained, Level I is no place for such detail. All es-timators need to know is if the flange is possible to form with conventional tooling.

Is the Inside Bend Radius Critical? “Some cus-tomers care less about the inside bend radius, some care a lot,” Higgs said, “because they design their parts to very close tolerances because, for instance, of how one sheet metal part might interact with an-other part in an assembly.”

In an air bend, the radius forms as a percentage of the die opening. What percentage goes back to those technical rules of thumb that, again, estima-tors and even others in the front office don’t nec-essarily need to know. But the earlier a fabricator knows whether bend radii are critical—whether the called radii on the drawing are needed within a certain tolerance or are just there for reference—the better.

How Close Are Holes and Other Cutouts to Bend Lines? According to Higgs, estimators should look for holes and cutouts to check how close any of them are to bend lines. “Is the part tapered on one end? Does it have holes or slots? What passes through or gets close to that bend line?”

Like everything else in Level I, estimators just need to know a range. This is an information-gather-ing stage only. A shop might, for instance, have wing dies that can form certain bends across holes and

“I’ve found that press brake operators love it

when they get to work with a lead person on

a technical project. And as a technical lead,

I’ve been there. We have fun, challenge each

other’s solution on how we should handle

a problem, and do high-fives when we’ve

found a new way.”

—Jonah Higgs



other features just fine. But those tools might not be available at every brake, and besides, the tools might not work in every situation. Regardless, those details don’t matter at this stage. Simply knowing how close holes and other cutouts are to bend lines dictates what technical checks are required.

Can You Accommodate the Bend Angle Plus Springback? As Higgs explained, this question can be particularly critical if the vast majority of angles the brake department forms are 90 degrees. A “non-90” bend can make determining other bend vari-ables more complex.

Bending acute angles can be particularly prob-lematic. For instance, what if an operator needs to bend a part to a 30-degree internal angle? Does the tool set—including the space in the die opening—allow for the depth of penetration to achieve that angle plus the required overbend for springback?

Again, a shop need not dive into the weeds here. At this stage it’s about defining ranges. Estimators and engineers know the range of easily bendable angles (considering bend angles alone, not poten-tial collisions or obstructions, which occur in later technical checks). If they see an angle on the draw-ing outside this range, they flag it for further techni-cal review. If everything falls within a defined range, they can progress.

What’s the Bending Tonnage? “I need to make sure the tools and press brakes can handle the job,” Higgs said, adding that, of course, this should be one of the last Level I considerations. That’s because ton-nage hinges on the material type, the material-thick-ness-to-V-opening ratio, the die chosen to produce the inside radius the jobs needs (if the customer cares about radius), bend lengths, and the tonnage capacities of the press brakes on the floor.

“That’s Level I,” Higgs said, “which covers the fun-damentals. We’ve got to get these factors out of the way before we can have a conversation about the things that make a particular part unique. If you’re stuck here, you need to resolve the problems before you go on to the next stage of the dance.

“Just the Level I data already might seem too heavy or technical for most people,” Higgs said, “but these are absolutely critical to preventing loss of production on the shop floor.”

Level II: Now, the Fun Part“This is why a lot of people work in this business,” Higgs said. “It’s the fun, abstract, and allows us to think creatively.”

This level mainly involves part geometry factors that could lead to tool collisions or part handling problems. Higgs added that, yes, many of these problems can be caught by offline bend simulation software that’s becoming more common across the industry, but he warns that the software is a finite resource. “Programmers running simulations need solid models,” Higgs said, “and shouldn’t be spending all their time trying out part after part, especially if the jobs haven’t been won, and especially if—with a bit of training—engineers and estimators could simply see problems by quickly looking over a 2D blueprint.”

Where Are the Bends in Relation to Each Other? This question helps catch some basic bend sequence challenges. Say a part has one up-bend after another after another in the same direction, or perhaps a sequence of down-bends. Or perhaps the part has a series of positive and negative bends. What if two up-bends create a tall, narrow channel? Will available tooling be able to access the bend? What’s the risk of collision?

Offsets apply here as well. Is an offset so odd that it requires a special tool? Or is it a conventional offset, but one that—due to part handling challenges—really could benefit from a dedicated standard offset tool set? Or could it be performed with two hits with a standard punch and die? Also, how critical are the offset’s bend angles? A critical offset dimension—like one that requires a specific angle or radius—might require further review and, more than likely, a customer call.

Can the Operator Handle This Part? “Here, we consider part handling challenges,” Higgs explained. If a large piece has a narrow edge flange, how will the operator (or operators) support the part as it swings upward? Is it too thick and heavy or is it thin and floppy? Either extreme can create accuracy issues.

Similarly, how will the operator gauge the part? If, late in the bend sequence, the part has no flat area that can slide against a backgauge finger, the piece might need special gauging.

Are There Unusual Alloys or Finishes? The ma-terial grade and thickness enter the conversation from the get-go, right when factoring in the radius-to-die-opening ratio in Level I. Material consider-ations in Level II come into play when the job calls for the unusual: perhaps aluminum diamond plate, armored plate, or perforated material.

What’s unusual depends on the shop’s part mix; what’s near the guardrails for one shop might be right in the center of the highway for another shop. “Regardless, addressing this allows you to develop a plan,” Higgs said, “so that when the job hits the shop floor, you have no surprises.

“At this point, it becomes fun, because it requires serious brain work,” Higgs continued. “It can get complicated, but Level II really can be boiled down to a simple question: Does anything about this part look weird?”

Level III: The Really Fun PartAt this point, most obvious problems have been worked out. Everyone knows what if any speed bumps a job might present; the only question now is how large those speed bumps will be.

These jobs might require special tools. If the spe-cial tools will be designed in-house, toolroom per-sonnel need to collaborate with bending personnel to determine the bend sequence, potential colli-sions, and other factors. The same thing goes if the tooling is outsourced.

Some shops might choose to use a prototype or pre-production area—staffed with the fabricator’s technical gurus—to test or qualify challenging jobs before they hit the shop floor. Alternatively, a note might be placed on the job traveler, telling the press brake operators to contact the technical lead before starting the job.

Of course, this happens only for a select few jobs, and it’s an expected speed bump that’s accounted for in the schedule. By no means is it a surprise.

Such collaboration, Higgs said, can create some of the best workdays a press brake operator can experience. “I’ve found that press brake operators love it when they get to work with a lead person on a technical project. And as a technical lead, I’ve been there. We have fun, challenge each other’s solution on how we should handle a problem, and do high-fives when we’ve found a new way.”

Higgs paused, then chuckled. “Let me tell you, those are good days.”


Applied Laser Technologies, www.aplaser.com

Bend Genius, www.bendgenius.com



http://www.aplaser.com

http://www.bendgenius.com



https://lasersystems.ipgphotonics.com/products/Handheld-Systems/Handheld-Laser-Welding-System?utm_source=TheFabricator&utm_medium=digitalad&utm_campaign=HandHeldWelderWelder


By Travis Stempky

In every industry, products are being designed, redesigned, or reevaluated for better materials or functionality. The final products are made

from many components, and these components need to be joined in some way. One of these join-ing methods is laser welding.

Laser welding uses a high-intensity beam of light to create a molten weld pool to fuse materials to-gether. It’s a noncontact process, has low heat input relative to other fusion processes, offers high pro-cessing speeds, and produces deep fusion zones in a single pass.

Of course, to take full advantage of all these ben-efits and to ensure a high-quality, repeatable pro-cess, fabricators need to consider how laser welding compares to other fusion welding processes. Joint and fixture design also plays a role. As with any metal fabrication technology, smart implementa-tion starts with a good understanding of the process fundamentals.

Laser Welding 101Laser welding uses a beam of light focused to a small point at the workpiece. Generated from some form of medium, the light exits the laser source and be-gins to diverge. It is then collimated so that the beam is parallel and doesn’t grow. The distance from the exit to the collimation surface is called collimation length. The beam stays collimated until it hits a focus surface. Then the beam narrows into an hourglass shape until it becomes in focus at its smallest point. The distance from the focus surface to the smallest point is called focal length. The size of the focus spot is determined by the following equation:

Fiber diameter × (Focal length/ Collimation length) = Focus diameter

The distance the focus diameter is within 86% of the focal area is called the depth of focus. If the focus position shifts outside this area, expect the process

results to change. The larger the ratio between the focal length and collimation length, the larger the depth of focus becomes for a given fiber.

Larger fibers have a larger depth of focus com-pared to smaller fiber diameters. The larger ratios and fibers have a larger spot size that causes a de-crease in power density and, therefore, a decrease in penetration.

There are two forms of laser welding: heat con-duction welding and keyhole welding. In heat con-duction welding, the laser beam melts the mating parts along a common joint, and the molten materi-als flow together and solidify to form the weld. Used to join thin-wall parts, heat conduction welding uses pulsed or continuous-wave solid-state lasers.

In heat conduction welding, energy is coupled into the workpiece solely through heat conduction. For this reason, the weld depth ranges from only a few tenths of a millimeter to 1 mm. The material’s heat conductivity limits the maximum weld depth, and the width of the weld is always greater than its depth. Heat conduction laser welding is used for corner welds on the visible surfaces of device hous-ings as well as other applications in electronics.

Keyhole welding (see Figure 1) requires extreme-ly high power densities of about 1 megawatt per square centimeter. It is used in applications requir-ing deep welds or where several layers of material must be welded simultaneously.

In this process, the laser beam not only melts the metal but also produces vapor. The dissipating va-por exerts pressure on the molten metal and partial-ly displaces it. The material, meanwhile, continues to melt. The result is a deep, narrow, vapor-filled hole, or keyhole, surrounded by molten metal.

As the laser beam advances along the weld joint, the keyhole moves with it through the workpiece. The molten metal flows around the keyhole and so-lidifies in its trail. This produces a deep, narrow weld with a uniform internal structure. The weld depth may exceed 10 times the weld width. The molten

material absorbs the laser beam almost completely, and the efficiency of the welding process rises. The vapor in the keyhole also absorbs laser light and is partially ionized. This results in the formation of plasma, which puts energy into the workpiece as well. As a result, deep-penetration welding is distin-guished by great efficiency and fast welding speeds. Thanks to the high speed, the heat-affected zone (HAZ) is small and distortion is minimal.

Fusion Welding Comparison Compared with other processes, laser welding of-fers the highest weld quality, lowest heat input, and highest penetration in a single pass. It has one of the highest ranges of material combinations and part geometries, is extremely controllable and re-peatable, and is one of the easiest to automate. All this allows for new joint designs, and parts can be produced at a higher rate with less postweld pro-cessing.

Laser welding also has one of the highest initial investments, tooling costs, and weld joint fit-up re-quirements These must be accounted for when se-lecting laser welding as the joining method for your production process.

Joint Considerations Deep-penetration welding allows for a single weld to replace multiple welds in different joint designs. Figure 2 shows some typical laser welding joint configurations. Butt welds do not require a cham-fer for thicker pieces, T-joints can be welded from a single side with full strength, and lap welds can be welded through the top sheet or along the seam. This allows for flexibility when designing your parts and weld locations.

Butt welding requires high positional accuracy. Typical welding spot sizes are from 50 to 900 µm in diameter. The allowable positional tolerance must be less than half the beam diameter to ensure that the laser beam interacts with both sides of the joint. The allowable gap is typically 10% of the thinnest material or less than 50% of the weld beam diam-eter. Therefore, fixturing is critical in these joint con-figurations to ensure high positional repeatability and minimal gap.

Common ways to account for this are to design the part to be press-fit or to design robust fixturing.

Essential considerations for

laser weldingFrom component design to implementation

Keyhole

Molten Material

Weld

Laser Beam

DissipatingMetal Vapor

Workpiece

Direction of Machining

FIGURE 1 Keyhole welding requires extremely high power den-sities and is used in applications that require deep welds.

Dec20FAB_LaserWelding.indd 54Dec20FAB_LaserWelding.indd 54 11/19/20 12:20 PM11/19/20 12:20 PM


Some might use a vision system to ensure part posi-tioning, but this will add some cycle time and com-plexity to the programming for production. It is also important to select the correct spot size at the part. Larger spot sizes accommodate larger variations but require much more energy input to achieve the same weld penetration depth.

Butt welding has many benefits. The weld strength is determined by the amount of weld along the seam, so the amount of penetration determines the amount of weld strength. Narrow, deep welds produce less heat input, which creates a small HAZ and limits distortion. It also allows for less material because no overlap is needed.

Lap welding has many different considerations. The allowable gap typically is 10% of the top mate-rial thickness. The weld width and the fusion at the interface between the two materials determine the weld strength. Compared with butt joints, such lap configurations lead to higher energy input, a larger HAZ, and more distortion.

If welding through the top sheet (3 in Figure 2), the laser beam must penetrate through the top sheet and into the bottom sheet, and all that energy spent penetrating the top sheet doesn’t add any weld strength. Lap welds must be wider to increase their strength. This requires more energy input, achieved either through a larger spot size or by os-cillation with a smaller spot size. If minimal distor-tion is critical, the weld should only partially pen-etrate the bottom sheet. If applications require low heat inputs and either low power or high processing speeds, partial-penetration joints can be ideal. They create a surface on the back side of the weld unaf-fected by heat input and, hence, a class A surface.

With partial-penetration welds, the minimum penetration into the bottom sheet should be be-tween 20% and 50% for thinner materials and 0.5 mm for thicker materials to ensure repeatable fu-sion that accounts for variation in production. The easiest design for welding is to have the thinnest material on top and the thicker material on the bot-tom. If the top sheet is thicker, partial penetration into the bottom sheet becomes more difficult to control, which also makes it harder to maintain a class A surface on the back side of the weld.

Nevertheless, lap welding has many benefits. It doesn’t require high positional accuracy, which al-lows for fixturing without stringent positioning re-quirements. Compared to butt welding, lap welding has a larger process window, mainly because pen-etration depth is more flexible.

Joint Access and PostprocessingLaser welding also allows for access to joints that were previously not achievable. Because it is a non-contact process, welding in holes and in tight spaces is possible if the beam width as it comes into focus is considered. This allows flexibility in joint design, and parts can be designed with less material.

Postweld heat treatment is not needed in many cases because of laser welding’s small HAZ and low

overall heat input. There is also little weld protru-sion on the top or back side of the weld that needs to be machined after welding. The process can have minimal spatter to create visually clean welds, es-pecially with the addition of shielding gases. This eliminates the need to do a lot of postweld machin-ing and cleanup.

Fixture Design Considerations Fixture design needs to be much more accurate for laser welding than for more traditional welding pro-cesses. Since it is a noncontact process, the tooling can be closer to the part, but the tooling also must do all the positioning and tolerance control. The process has no added contact like in resistance and ultrasonic welding where the horns add pressure to ensure there is no gap. The laser also produces a small, repeatable melt pool and requires much tighter part tolerances. All of this must be consid-ered when designing parts and fixturing.

Figure 3 shows a rigid fixturing for a corner weld. This style of fixturing is common for butt welding and edge welds for tubular or rectangular parts. The clamps are very close to the seam and apply pressure to ensure a minimal gap. There is no tool-ing above the joint that could interact with the weld beam as it comes into focus.

The configuration also provides clearance for a shielding gas nozzle if shielding gas is required for aesthetic purposes or for metallurgical reasons in certain metals such as titanium. Fixtures must re-peatably hold the joint in the same Z position rel-ative to the beam so that the laser beam is in the same focus position. This is critical to get the same power density to ensure repeatable results.

Lap welding requires less robust fixturing. Figure 4 shows a typical fixture design. Instead of long, rigid clamps to hold the entire seam in place, multi-ple clamps ensure proper contact between the two sheets over a large area. Such fixturing can be au-tomated with pneumatic clamps. In the example, a scanning optic quickly welds all the required joints. Galvo mirrors—high-speed mirrors inside the weld-ing optic—position the beam for welding and pro-vide all the motion for the weld path. This allows for a simple robot path.

For especially critical welds, a single large fix-ture, designed with the weld path machined out, can ensure ideal part fit-up. The fixturing method has higher tooling costs but is also very robust and repeatable. Applying a large load evenly across the part surface, such fixturing can be ideal for stamped parts with large variations in surface flatness.

Unleashing CreativityLaser welding allows for creativity and some free-dom in part design, as long as all the essential vari-ables are considered. For example, what spot size is needed for a given process? Larger spot sizes of-fer more melt area and a larger depth of focus but require more energy to achieve the same welding depths.

Similarly, what joint configuration is best? Butt welding requires accuracy and process repeatability but can achieve strong welds with minimal heat in-put. Inversely, lap welding requires less accurate fix-turing and has a larger process window but requires more heat input to achieve stronger welds.

With all of laser welding’s process considerations also come myriad opportunities. It’s a great tool to advance manufacturing with new, creative part de-signs that not only increase quality but also—thanks to fewer manufacturing steps, including less sec-ondary processing—have the potential to reduce costs dramatically.

Travis Stempky is a laser technology specialist at TRUMPF Inc.’s Laser Application Center, 47711 Clipper St., Plymouth, MI 48170, 734-454-7200, www.trumpf.com.

(1)

(2)

(3) (5)

(4)

FIGURE 2 Laser welding offers a variety of joint configurations: butt (1); lap, either along the seam (2) or through the top sheet (3); and T, through the top sheet (4) or from a single side (5).

FIGURE 4 This lap welding fixture uses multiple clamps to ensure proper contact between two sheets.

FIGURE 3 This rigid fixture ensures a repeatable corner weld.

Dec20FAB_LaserWelding.indd 55Dec20FAB_LaserWelding.indd 55 11/19/20 8:15 AM11/19/20 8:15 AM




By Allan Flamholz

If you want to learn to drive a car, you go to a nearby parking lot where you practice pulling into parking spaces, making turns, driving in

reverse, going different speeds, and employing emergency braking. If you want to learn to drive a race car, you are going to need a lot more prac-tice, the right equipment, the right track, and a team behind you. In other words, it’s a big leap from driving a family sedan around an empty mall parking lot to taking Kevin Harvick’s Ford around a NASCAR road course.

The same thinking can be applied to operating a plate rolling machine. Anyone can load material into a machine and hit a button on the CNC to make it go. That doesn’t mean that things go right, however.

Plate rolling is still an art, even in the day of ad-vanced CNC. Material thickness and hardness can vary from plate to plate, while still being within a specified tolerance range, which introduces variabil-

ity to an already challenging endeavor. Careful oper-ation helps to maintain a safe working environment and encourages precise work, but a shop floor is al-ways under pressure to increase throughput. In an age when set-it-and-forget-it control technology has appeared on everything from laser cutting machines to even automated press brake cells, an experienced hand on a plate rolling machine is always welcomed.

Unfortunately, an experienced operator is not al-ways available. There aren’t a lot of shops that roll plate, and as a result, the industry simply doesn’t produce a lot of skilled plate rolling machine op-erators. In fact, in certain cities you’ll see a good operator bounce around from one manufacturer to another, claiming small raises at each stop, because companies value the skill this employee has.

Shops that are looking to jump into plate rolling might be forced to grow their own experts. That’s not necessarily a bad thing because a company knows more about the person it might like to be an operator for the machine rather than an unknown

quantity coming from another manufacturer. With that in mind, here is some guidance for those shops that may be hoping to develop some plate rolling expertise within their own ranks.

1. Find a Prospective Operator Who Knows How Metal Reacts During a Bending Process.A person with a basic metal fabricating background is going to be much more aware of how metal reacts during the bending process. For instance, someone with metal forming experience understands that as material is being formed it moves along a stress-strain curve, which has peaks and valleys. Eventu-ally the operator gets to the point where he is able to apply just enough stress on the material, and the process moves down the valley, where it becomes much easier to move the material. But as the opera-tor comes out of that valley, the material becomes much harder to manipulate.

This is not an uncommon problem in heavy fab shops where someone is rolling plate back and forth on a manual machine, gradually bringing the plate down to the needed diameter. When the operator gets close, he brings the bending roll up just a hair, but the diameter gets too tight. The operator has no idea how the material moved so much after being so resistant. Experience would have had him be much

When plate is being rolled on machines of this size, the job has to be done right. Shops can’t afford to scrap a workpiece that doesn’t meet customer specifications.

Getting ready for

plate rollingWhen you don’t have an expert, you need to grow one

Dec20FAB_PlateRolling.indd 56Dec20FAB_PlateRolling.indd 56 11/18/20 2:11 PM11/18/20 2:11 PM


more aware of dramatic material changes after having worked it so much in the rollers. A scrapped cylinder made of ½-in. carbon steel is bad news for everybody.

The operator also needs to recognize that differ-ences exist in what might be considered the same material. Different aluminum alloys have different characteristics, with some considered softer and easier to form than others. Also, material properties can change as it ages. For instance, if a shop is just stacking laser-cut aluminum blanks and the work-pieces at the bottom are not used because newer blanks are always stacked on top of it, a plate rolling machine operator has to be cognizant that the old-er aluminum blanks at the bottom are likely more hardened than the more recently cut blanks.

A person with press brake experience might be the closest a shop can come to finding that person with metal forming experience, but it’s not exactly the same as plate rolling. In press brake forming, bending is static. It’s a little easier to measure the load that it takes to get the metal to a certain point. Plate rolling is a constant process where the materi-al and bending rolls are moving simultaneously. It’s a little more complicated. But someone with that press brake experience at least has some familiar-ity with how metal reacts when it is under bending stress, so he may be a bit more cautious when work-ing with much more expensive material.

2. Invest in Training for All Shifts.More often than not, training for a newly purchased plate rolling machine takes place during the first shift and the prospective plate rolling equipment operator is there. That’s OK if the company has only one shift. But if the company is running second and third shifts, the operators on those shifts need to be at the training as well. And having the third-shift op-erator stay over for an extra two hours for two days does not count.

3. Coordinate With Upstream Processes.Rolling with the plate’s grain structure is going to require less force than working against the grain because the material’s ductility is readily stretched when the plate is made at the mill. The problem is that no computer on a plate rolling machine can tell what the grain direction is on a plate that is loaded into the rollers. That’s left up to the operator.

But upstream processes can help. Instead of a la-ser cutting machine operator just cutting blanks and stacking the pieces in some random way without taking into account grain patterns, the operator can take the time to ensure that each laser-cut blank is stacked so that the grain pattern in each piece flows in the same direction. That way the plate rolling equipment operator can load in the blanks and ex-pect the pieces to form somewhat similarly without having to worry about the random plate piece that will have him rolling against the grain.

4. Don’t Rely Totally on a Tape Measure.When a shop gets a new plate rolling machine, many will rely on a tape measure to check the ra-dius. That literally means that they take the rolled plate off of the machine and then use the tape mea-sure to check it.

Creating a template makes a lot more sense. Fab-ricators have the plasma or laser cutting machine nearby, so they should cut a template of the speci-fied radius. Then the template can be applied to the rolled plate while it is still in the rollers. If it’s not the correct size, the machine can be engaged to put the finishing touches on the rolled shape.

5. Consider a Four-roll Plate Rolling Machine.A four-roll machine is easier to operate for anyone new to plate rolling. First, it’s easier to load the plate into the machine than a three-roll machine because the rear bending roll can be used like the backgauge of a shear.

The operator lifts the rear bending roll as the plate is being loaded into the machine and moves the ma-terial until it hits the rear bending roll in the center, squaring it up like a press brake operator would do with a workpiece and the backgauge. The bottom roller is then brought up to pinch the material. With this four-roller arrangement, the material is held by the rollers for the entire bending sequence.

Now, a four-roll machine is not as versatile as a three-roll machine because of the four-roll ma-chine’s limited opening between the top and bot-tom. Also, when the material is pinched in the four-roll machine, the equipment is subjecting the plate to the crown of the rolls. (The rolls are crowned to help deal with deflection during the bending pro-cess.) It is almost inevitable that a four-roll machine

will impart some sort of odd shape to the material, although in most instances the barrel or hourglass shape is still well within tolerances for the job.

If budget were of no concern, a manufacturer interested in processing 16-ga. to 0.5-in. mate-rial could buy a four-roll plate rolling machine with 18-in.-dia. rolls that are straight instead of crowned. (The straight rollers can handle the deflection be-cause they are much larger than typical rollers for a machine that can roll the same material thick-nesses.) The reality, however, is that few companies are interested in buying an oversized machine with straight rolls. Most shops have distinct applications in mind when purchasing a plate rolling machine so they are looking to get the most for their investment.

Getting a Good Part From the StartPlate rolling results are better when an experi-enced operator can oversee the operation, but that doesn’t mean that less experienced operators can’t make good parts. If management can put someone in place who has a desire to learn about the forming process and is comfortable around controls that are similar to mobile phone interfaces, the company is in a good position for success.

Early training from the machine tool supplier won’t cover every scenario that the fabricator is going to encounter with its new plate rolling ma-chine, but the supplier should be available for im-mediate consultation. Challenges are to be expect-ed. Luckily, they make the engaged plate rolling machine operator that much more capable and better prepared for the next challenge that is ulti-mately going to arise.

Allan Flamholz is president, Trilogy Machinery Inc., P.O. Box 70, Belcamp, MD 21017, 410-272-3600, trilogy machinery.com.

Getting consistent rolled plates is much easier than it used to be thanks to modern control software and machinery advancements, but an engaged operator also is an integral part of the process.

Dec20FAB_PlateRolling.indd 57Dec20FAB_PlateRolling.indd 57 11/18/20 2:11 PM11/18/20 2:11 PM




By Joe Girard

In 2019 no one in manufacturing could have pre-dicted the U.S. would go from 3.5% unemploy-ment in February 2020 to more than 30 million

people claiming unemployment since March. Yet amid the pandemic, the reality of recruitment and retention struggles in manufacturing hasn’t changed too drastically.

Manufacturing demand is still high, and manu-facturers are still hiring. So rising wages and talent wars, especially the fight to retain their most valu-able people, continue. The need to retain your most experienced workers is still a top priority, especially if your new hires are inexperienced and require ex-tensive training.

One employee retention strategy that has stood the test of time is the gemba walk. Gemba is a Jap-anese term that means “the actual place” and in manufacturing has been loosely translated to mean go and see “where the value is created.” It’s a struc-tured walk through the plant with stops along the value stream to observe the process. 

Gemba walks became a regular facet of the lean production system in the mid-1900s. They got company leaders out to the production floor, where the value was being created, to observe pro-cesses. Think of the 1980s “managing by wander-ing around” era, but instead of leaders randomly meandering through the facility, gemba walks are more structured and have problem-solving and employee engagement elements, which in turn lead to a culture of continuous improvement and employee satisfaction.

The Society for Human Resource Management—arguably the gold-standard association for surveys and trends related to employment issues—notes that having a bad manager has been consistently cit-ed as one of the top reasons people leave their jobs. Good managers build relationships with employees at every level of the organization. They develop, mentor, and coach others and can detect problems as they occur and eliminate them quickly. The prop-erly executed gemba walk is one among many tools good managers use, and it can be effective with or without a formal continuous improvement program.

That said, it’s important to conduct gemba walks the right way. The seven steps that follow can make a tangible difference. They break down something amorphous like “company culture” into steps you can follow to make a real difference in employee retention.

Instituting the Gemba Walk1. Prepare the production team for the change. Your team needs to understand that you’re out there to observe processes, not people. Commu-nicating your true intention is the key here, as you don’t want to create a “big brother is always watch-ing” perception that could hurt employee morale.

2. Tap leaders and set ground rules. Gemba walks work best in teams. The key functional areas that should be represented include supply chain, engi-neering, maintenance, operations, human resourc-es, and safety. Explain that gemba walks are not op-tional and that the team walks together. 

3. Plan your route. Start at the end of the value stream and work your way up. You might uncover

How gemba reduces staff turnover“Go and see” improves employee retention

a problem downstream at a secondary operation, but the most effective corrective action might need to occur upstream. When you reach that upstream process, you can address the problem.

4. Vary the route and the time of day. When you vary your route and time, you’ll see more processes and be able to talk with different operators. 

5. Create metrics at each key area you’d like to address. Create no more than three or four met-rics. Have something at the workstation to record discovered problems, including what the issue is, when it occurred, and who should be involved to develop corrective action. Review problems, but do not try to solve them during the gemba. The team should spend no more than five minutes at each sta-tion (see Metrics on the Gemba Walk sidebar).

6. Follow up. Nothing derails employee engage-ment and the flow of ideas faster than a lack of fol-low-up. Follow up every idea, even if it’s something you don’t wish to pursue. Employees will respect that and potentially devise an even better solution. In some cases, an employee might have an idea that’s quick to implement and will help improve the area immediately. In those cases, empower your employees to “just do it.” If you want to see em-ployees engaged, give them the chance to carry out their own ideas for improvement.

7. Adjust as necessary. The frequency, the routes, the times—these will all change the more gemba walks you do and the more you understand where the issues are. In most cases, there’s no need to change your gemba walk every week, but it shouldn’t stay the same forever either. The gemba walk should evolve with your operation. You may begin by stopping at your largest bottleneck sta-tion every day. As your team makes and sustains improvements, your bottleneck will move. At that point you might stop at the original bottleneck area only three times per week. Communicate the new route and schedule, but don’t go overboard on how often they change.

A Gemba StoryImagine you land a job as the new CEO of a $25 million custom metal fabricator with high staff turnover. Its reputation is suffering and it’s losing money. Your managers, especially those in HR, are already stressed from the turnover, and now you’re facing the possibility of losing some of your largest customers because of quality problems.

Customer demands are well within market norms, so what’s the problem? You could blame operator error, a messy shop, inefficient processes, poor maintenance practices, or a lack of process

Dec20FAB_Gemba.indd 58Dec20FAB_Gemba.indd 58 11/18/20 1:54 PM11/18/20 1:54 PM


documentation and training—but these aren’t the root causes. The dominant root cause can be traced back to one thing: a strict top-down management style that basically dictates everything that employ-ees do. Now mind you, you cannot change a culture quickly. It’s akin to turning around a battleship; it’s doable, but it takes time.

How do you eat an elephant? One bite at a time. And in this case, that first bite involves manage-ment coaching and, not least, the gemba walk. You take your first walk with the operations director, who walks with you down a long, wide aisle with machines on either side. You see flotsam every-where, even customer prints lying on the floor in some places.

When you approach the first obvious debris in the aisle, you stop and pick it up. The operations direc-tor gives you a strange look. “Don’t worry about it,” he says. “That stuff is all over the place. Someone on third shift goes around at night and cleans this up.”

Whatever you ignore will be unimportant to em-ployees who look to you for leadership. You might ig-nore the small stuff—like debris on the shop floor—but the small stuff can eventually ripple outward to everything else that happens in the operation. Regardless, if the operators are not concerned with keeping their areas clean and safe, and the company leadership does not seem concerned with improving these areas, quality and safety will surely suffer.

Note that all this isn’t at all like the top-down management style that has plagued the company for years. Top-down management proliferates when chaos reigns. Managers engage with their teams only when something goes awry. They never really talk with front-line employees; they instead talk at them to tell them what they did wrong.

On the contrary, picking up debris during a gemba walk gets people thinking about the work environ-ment, which in turn sets the foundation for process improvement. The better the process, the less fire-fighting you have, and the less chance there is for a strict top-down management style to spread. And in this case (as in many others), it all starts with basic improvements in safety and housekeeping.

A week later you gather six members of your lead-ership team and walk the same aisle. The ops direc-tor stops to pick up a broken piece of a pallet that was lying in the middle of the floor. He begins to set an example. Within the next few weeks, you can see the place really starting to look much cleaner and safer.

When you speak with operators during the weeks that follow, you begin to see how they’re taking pride in their work areas and noting safety and housekeep-ing issues without fear of reproach. Your ops director is also proud of how rapidly his team is improving.

Employees become open to discussing things like safety and housekeeping, which in turn leads them to being more open about how to improve the processes they work every day. In the past no-body had bothered to ask them about how their jobs could be improved, so they continued to do things the way they were told to do them. Now that’s starting to change.

The transformation is incredible to watch. Even after years of poor management tactics, the opera-tions director is able to drive a variety of improve-ments and gain the trust of the workforce. That’s what happens when management buys in and em-braces improvement.

This sets the tone for other improvements made during the ensuing years. Turnover plummets, prof-its improve, the OSHA incident rate drops dramati-cally, scrap is reduced, and on-time delivery reaches world-class levels. As you can probably guess, this is all based on a true story—and it all started by pick-ing up a piece of debris on a gemba walk.

Changing Employee Perceptions Amid the pandemic, social distancing is a priority, and following public health recommendations can help ensure you conduct gemba walks safely. It could be argued that gemba walks are more im-portant now than ever. If those on a walk see an as-sembly operation requiring operators to stand close together, they can start to do something about it.

All this helps change how employees perceive their managers. In fact, changing perception can have a bigger impact on employee retention than benefits or pay. Keeping your experienced team not only improves productivity and increases revenue but also saves money. The average cost to recruit, hire, and train a new manufacturing employee is more than $7,000—and this doesn’t even take into account the work slowdown that occurs during the hiring and training process.

Would you rather work for a manager who incor-porates a gemba walk into his or her daily routine, or someone you rarely see unless you do something wrong? The former builds a culture of improvement while the latter creates an environment where ev-eryone keeps their heads down and mouths shut as they dream of finding another job.

Joe Girard is a consulting services manager at Wipfli, 10000 W. Innovation Drive, Milwaukee, WI 53226, 414-431-9300, www.wipfli.com.

Metrics on the Gemba WalkOne of the best tools to use for gemba walk metrics is something called an MDI board. MDI stands for managing for daily improvement, but you can certainly put your own spin on it and call it whatever you’d like. Color-coded for clarity, an MDI board consists of one column dedicated to the issue being addressed next to adjacent columns dedicated to topics like safety, quality, delivery, and cost. A final column could have your hour-by-hour tracker for production if needed, or you could post announcements or other company information.

During their walk, the gemba team stands around the MDI board and the area leader summarizes the metrics—quickly. In fact, some of the best MDI boards abide by the five by five rule: Standing 5 ft. away from the board, you should know whether you’re winning or losing within 5 seconds. That’s it. There’s no need for someone to spend hours on detailed pie charts or other graphics that nobody will look at.

Dec20FAB_Gemba.indd 59Dec20FAB_Gemba.indd 59 11/18/20 1:54 PM11/18/20 1:54 PM

http://www.wipfli.com


http://www.lissmac-usa.com


correct threads or nut size or shape, weld spatter in the threads (there’s spatter again!), and orientation issues (is it upside down?).

What does a welding system need to ensure it has the right nut in the right place at the right time? That depends on the application, where the sensor can be placed, and when exactly the sensors need to sense a nut. Problems are usually di� icult to cor-rect with one standard technology.

Cable Damage. A simple cable can be one of the hardest things to protect (see Figure 4). Weld cells demand the toughest connections. Weld debris can shorten the life of a cable in several ways. Spatter can build up on the jacket, pulling the cable out of the connector. Weld sparks can burn through the ca-ble, causing shorts in the connection, and extreme temperatures can cook components. Intermittent communication and signal issues can be caused by the smallest weld berry across two conductors in a hidden part of the fixture.

5 Steps to Operational Excellence Many manufacturers struggle through these weld-ing automation challenges. The best companies, however, follow some basic steps to get their house in order. Note that all these steps require collabora-tion among those in engineering, maintenance, and

By Will Healy III

Keeping a projection nut welding line running at high e� iciency can be challenging. Deliv-ering bad parts to customers can devastate

a fabricator’s profitability and reputation, and one of the most frustrating quality issues comes from welding nuts to parts.

Is device failure costing productivity in your weld cells? Damaged devices and burned cables cause unplanned downtime and reduced production, driv-ing up overtime wage costs and creating a delivery timeline crunch. Poor application of a weld nut to a part is one of the most challenging and damaging quality errors in production, can cost thousands of dollars, and can require herculean corrective action downstream or, even worse, at customer plants.

Welding throws debris, spatter, and molten metal. Such an environment makes it di� icult for standard automation products to survive. Operators loading parts hour a� er hour can a� ect sensors and physi-cally damage components.

Sensors and related components are o� en found at the top of most hit lists in a welding production line. Even so, in harsh welding automation environ-ments, nothing is spared from harm. Everything can, unfortunately, fail.

The Causes of FailureWeld Spatter. Red-hot molten metal can burn through even the most robust defenses, given enough time and repeated abuse. Destroying ev-erything from pneumatic cylinders to sensor I/O blocks, weld spatter can cause more downtime than anything else on the floor.

Traditional automation sensors with plastic sens-ing faces and basic housings are destroyed daily by manufacturers around the world. Spatter burns through these plastic faces, shorting electronics and damaging the sensor coil (see Figure 1). The heat from buildup on a sensor body can cook the components and hasten sensor failure. At many facilities, weld spatter destroys at least one sensor per shi� . That’s easily a thousand sensors per year thrown away, just at one plant.

Load Impact. Heavy impacts can destroy a sen-sor. Operators might hit sensors as they load parts, a problem made worse if the sensor was improp-erly mounted in the first place. As sensors fail, sig-nificant downtime ensues as maintenance steps in. Even small, repeated impacts can damage the sens-ing face over time and lead to failure (see Figure 2).

Faulty Weld Nut Detection. One of the more common and frustrating applications in automated welding is reliably detecting the presence of weld nuts (see Figure 3). Production defects have many possible causes: missing nuts or location errors, in-

How a mindset change boosts performance in welding automation

FIGURE 1Weld spatter can burn through plastic faces, shorting electronics and damaging the sensor coil.

FIGURE 2Sensors can undergo mechanical damage for various reasons. Even small, repeated impacts can damage the sensing face over time.

FIGURE 3 Common problems in automation come from failure to detect the presence of weld nuts.

Cracking the (weld) nut of operational excellence

Dec20FAB_OperationalExcellence.indd 60Dec20FAB_OperationalExcellence.indd 60 11/18/20 5:24 PM11/18/20 5:24 PM


purchasing, all of whom make a commitment to improving applications in high-consumption work-cells and operations.

1. Get started … now. It’s easier than you think. Some small initial efforts can lead to significant im-provement and help build momentum. First, identi-fy those workcells and operations that are the most troublesome. If you aren’t sure, ask operators and maintenance crews; they definitely know.

Systematically review downtime to determine what is causing it (see Figure 5). Begin with docu-menting why, where, and how often components are failing. After tracking this information for a few weeks, you can determine where the problem areas are and which you need to address first.

Audit the high-downtime cells to determine which applications need the most attention. Many manufacturers find that only a small percentage of their applications cause the most substantial mate-rial replacement costs.

2. Attack individual sensing applications. At-tack individual applications one at a time. For each application, document the possible return on in-vestment (ROI) of new technologies. While imple-menting more robust technology sounds like an ob-vious plan, you will sometimes need to justify that paying more upfront will actually save money in the long run. Test different technologies and compare them by calculating the savings of one system over another.

Automation sensors come in many forms, sizes, and functionalities. Determine what is needed by looking at what the sensor is exposed to and why the installation is failing. An automated cell could benefit from sensors with coatings, steel-face sen-sors, protective brackets, or multimetal sensing to extend the life of the application. Ask yourself:

• Does the sensor have excessive weld spatter accumulation?

• Would a different technology make more sense?

• Is there a better mounting or location for the sensor?

• Is physical contact causing damage?

Also check the connection between the control and the sensor itself. Is it protected? Failures are of-ten blamed on a sensor but in reality are caused by the cable failing. Cables made of specialty materials like silicone and certain polymers (such as FEP, PTFE, PUR, or TPE) are designed to resist weld debris. With the right cable material, what needed to be replaced every day could be replaced every few months.

Weld nut application problems can be incredibly costly. Different solutions—vision systems, nut de-tection sensors, proximity sensors, touch probes, and photoelectric sensors—all have their place. Applying weld nuts is a challenging application, so unfortunately, no one technology can solve every problem.

3. Improve purchasing and the tool crib. Over time and through multiple projects, most manu-facturers accumulate a diverse and scattered col-lection of parts in the tool crib. Such an unmanage-able, unwieldy situation can seriously frustrate MRO purchasing departments.

Operational excellence requires that you dive into the dark of the crib to commonize inventory, control consumption, reduce waste, eliminate stockouts, and reduce overall inventory. Find common parts that can be used across applications, and reduce the number of parts you hold in inventory. Doing both simplifies purchasing and reduces stockouts.

Simplifying the crib might require buying more expensive components that (ideally, at least) last longer. Calculate the ROI and make decisions based

not on the individual component costs, but on the long-term total cost of ownership. By putting in the upfront work, you can simplify purchasing and stay within the allocated budget.

4. Fix the future. The capex process should go beyond the “keep it running” mindset. It should consider new or disruptive technologies—traceabil-ity, vision, augmented reality—and account for the engineering time to implement them.

Also pay attention to how you specify capex proj-ects. Set clear expectations, document what you need to accomplish, specify the exact equipment you need, and be sure you receive equal quotes that allow you to compare apples to apples. After all this, when the equipment arrives in the plant, it should be ready to support operational excellence.

5. Create a mindset of responsibility. Some things are worth doing repeatedly, but replacing a proximity sensor every shift is not one of them. To create a mindset of responsibility you need to get everyone beyond a “get it running” mentality to look at the total cost of ownership of the problem.

Commit to revisiting the problem, audit why the failure occurred, and openly discuss improvements. Documenting application improvements and moni-toring their value will give employees fewer fires to fight in the future and drive them to take ownership of problems. Managers, engineers, maintenance technicians, and operators all need to be comfort-able talking about an application’s failure rates, in-vestigating solutions, and calculating their ROI.

Set clear expectations. Train employees on new philosophies, technologies, and strategies for re-ducing costs and boosting productivity. When ev-eryone works together and commits to change, they establish a mindset of responsibility—a key in-gredient of operational excellence.

Will Healy III is the industry strategy manager at Balluff Inc., 8125 Holton Drive, Florence, KY 41042, 800-543-8390, www.balluff.com.

1

2

4

10

4

2

7

3 3

2

3

OP

100

OP

105

A

OP

110

A

OP

120

B

OP

140

A

OP

20L

OP

30B

OP

50L

OP

50R

OP

70R

OP

90

Number of FailuresCD4 Fr MCW3

5%

19%

10%

7%

54%

5%

Types of FailureBurnt Sensor Cable & Face Damage Cable Damage

Crushed Face Damage Intermittant

FIGURE 4 Welding demands tough connections. A simple cable can be one of the hardest things to protect in a harsh welding environment.

FIGURE 5A detailed review should incorporate the types of failures and their causes.

When everyone works together and commits to change, they establish a mindset of responsibility—a key ingredient of operational excellence.

Dec20FAB_OperationalExcellence.indd 61Dec20FAB_OperationalExcellence.indd 61 11/18/20 5:24 PM11/18/20 5:24 PM

http://www.balluff.com


By Dan Davis

For most of the 20th century, metal fabricators relied on an ironworker and a punch to make holes of a consistent size. It proved to be such

an efficient method that a lot of manufacturers and shops still use the approach to this day.

But holemaking is one of the most common operations in the world of sheet metal and plate manufacturing, so it makes sense that companies gravitated to more efficient means to accomplish the task. The last 30 years have seen the emergence of laser, plasma, and waterjet cutting technologies that can produce holes of various tolerances in a lot of materials. Even a drill, which could make a hole in a piece of structural steel in 10 to 20 seconds, can do the job today in 3 to 5 seconds. Manufacturers have a plethora of choices when it comes to holemak-ing, but the punch still remains relevant even if the ironworker is no longer the metal fabricating work-horse on the shop floor that it once was. In a way, the punch is kind of symbolic of how things change while also staying the same in the metal manufac-turing world.

Holemaking of a Traditional KindJeff Sizemore started his job running Mining Manu-facturing, Salt Rock, W.Va., at a crucial time. The company needed to transition to new work because its traditional mining customer base was drying up. The administration of President Barack Obama pushed for cleaner energy, proving to be no friend of the state’s coal mining industry.

In an interesting twist, Mining Manufacturing found new customers in the solar industry, fabricat-ing the post systems on which the giant panels sit. The posts are actually huge I-beams that are driven deep into the ground. The company uses its 300-ton press brakes to punch slots as large as 0.6875 by 3.5 in. in the web and flanges of I-beams.

“That’s the type of work we’re doing now,” Size-more said. “We’re doing about 2,000 tons per month. We’re a little West Virginia company doing that.”

Sizemore and the company’s 27 employees have also ventured into truck and trailer manufacturing. These large structural shapes have much simpler holes, but they still challenge the punches, as some of the workpieces have as many as 12 holes put in them.

“These beams that the guys are handling can be between 400 and 500 lbs.,” he said. “Well, we don’t pick them up. We use forklifts and roller systems to move them around.”

Leaning on a punch design specialist has allowed Mining Manufacturing to focus on the business and keep things moving forward, Sizemore said. It’s good to have a supplier that can not only design the special tooling that is needed, but also suggest changes, such as the use of a die block for a large slot instead of a more traditional round die, for ag-gressive punching jobs.

Dan Timmerman is fighting the good fight of survival as well. He’s the second generation to run Timmerman Manufacturing, a Conover, N.C.-based business that has been making metal component parts for the wood furniture industry since 1962.

Needless to say, the furniture industry has

changed a great deal over the past couple of de-cades, as almost everything was sent overseas, mostly to China. Timmerman Manufacturing hung in there with a core collection of customers and by expanding its fabrication capabilities to include rail-ings and gates. In 2014 the company added a pow-der coating line that has 200 hooks on it and a 10- by 10- by 25-ft. oven for curing long pieces of metal.

“You either evolve or dissolve,” Timmerman said. “We’re definitely not China, and we’re never going to be like them. We’re going to make what a custom-er needs, and then we’ll have it available to them as soon as possible.”

Luckily, some of that furniture manufacturing is coming back. With that reshoring activity comes a desire to have the metal decorative parts made do-mestically as well.

“Once the manufacturers figured out that you didn’t get the same color or the same quality … we started telling people that we were able to make whatever they wanted and they could get less than a container load. You get the same color and con-sistency from order to order,” Timmerman added. “And if you needed to talk to me, you could chew me out in English and I’d be about 15 minutes away, instead of half of a world away.”

Timmerman Manufacturing is working with gauge material, but the punch tooling is still vital. An example of a part is an “ear,” as Timmerman calls it, that has a punched hole on it, which is then weld-ed to a metal tube. The end customer then uses a screw to connect the metal tube to the wooden piece of furniture.

Like Sizemore with Mining Manufacturing, Tim-merman said that by being able to lean on a punch-ing tool expert, his company has been able to cap-ture efficiencies in manufacturing, even though the shop doesn’t have the latest in automation tech-nologies. Timmerman pointed to a specialty punch and die that can cope tubing as something that has proven to be valuable to the company. The tooling, which sits in a 7-ton punch press, knocks out the shapes in the 0.75-in.-dia. tubing quickly and easily, Timmerman said.

The punch at the center of it allOne holemaking tool connects a diverse metal fabricating industry

Punch tooling is the common denominator for the many different metal manufacturing sectors that make up the world of fabricating.

With coal mining slowing down dramatically, Mining Manufacturing has taken on new projects, such as punching holes in structural beams that are used to support solar panels. The punching tooling is important as it must stand up to the large press brake tonnages and the structural steel.

Dec20FAB_Punching.indd 62Dec20FAB_Punching.indd 62 11/19/20 9:41 AM11/19/20 9:41 AM

http://W.Va


“It filled a big gap that we had,” he said. Bob Olson is the owner and president of Ameri-

can Punch Co., Euclid, Ohio, the designer and mak-er of the punches Mining Manufacturing and Tim-merman use. He’s been around toolmaking since 1976, and in 1990 he and his father started Ameri-can Punch. He has seen the market for his compa-ny’s products gradually shift over the years, from traditional ironworker usage on things like plate and beams to more specialty applications in metal forming. In a way, the business remains the same in the sense that they have to be open to hearing what the customer needs and seeing if they have tooling in stock, if they can modify in-stock tooling for a quick turnaround, or if they have to make spe-cial tooling. The big difference is that those folks in the stamping business work in a much more precise manufacturing world.

“With the ironworker tooling, you can usually work with a couple of thousandths,” Olson said. “In stamping, you are working with tolerances within a couple of tenths.”

The continual shift in business has pushed Ameri-can Punch to expand a couple of times over the past 12 years. Two 25,000-sq.-ft. expansions, one in 2008 and another in 2018, created room for more ad-vanced equipment for manufacturing tooling and for additional engineering workspace.

Olson said over the past couple of years the com-pany has invested more than $3 million in new equipment. That covers state-of-the-art wire EDM, machining centers, multiaxis lathes, and 5-axis grinders that can deliver the accuracy and repeat-ability necessary to make precision tooling for the metal forming market.

The new equipment also helps with quicker turn-around of tooling orders. A lot of the non-value-added activity, such as material handling, has been eliminated.

“We used to run a workpiece on one machine, take it to another one, and then finish it in another one. Now we have machines that will do all three, even four or five, operations all on the same ma-chine,” Olson said. “We’ve had to adapt our busi-ness like this just to remain competitive.”

Holemaking of a Precision KindBay Products, established in 1985 and located in Fraser, Mich., is one of these precision manufactur-ers that sources its punching tooling on a regular basis. It’s a manufacturer of punching and pierc-ing systems for workpieces that have already been welded, such as truck frames and engine cradles. These systems are designed to maintain high toler-ances so that precise mating and assembly of com-ponents can take place later.

Tom Bayagich pointed out that his company, too, has changed over the years. When the business was first starting out, manufacturing was much more of a high-volume nature. (In fact, the company actu-ally was an advertiser in The FABRICATOR in those days.) Now the volumes are lower, and OEMs are looking for more cost-effective ways to punch holes in workpieces than manual drilling.

“We’ve turned into a specialized custom designer and custom builder,” Bayagich said of his 22-person company. “We don’t supply anything that is off-the-shelf like a press or a piercing unit.

“So we built up our niche market, mostly automo-tive,” he continued. “We service some other mar-kets, of course, such as working on solar products and electric vehicles.”

The specialized equipment needs specialized tooling as well.

“Everything that we order is specials,” Bayagich said. “You look underneath a truck and you think that a 20-mm hole is a 20-mm hole, but it’s not.”

So what kind of tolerance are we talking about for this type of work? The actual holes sizes are around 0.005 in. and sometimes even less than that, ±0.002 in., according to Bayagich. The real challenge is holding tolerance over the entire length of the workpiece. The location tolerance can be anywhere from 0.25 mm to 3 mm across an entire truck frame, which can be difficult to hold.

“That’s pretty tight because when you weld those truck frames, they turn into bent and deformed structures,” Bayagich said.

Bay Products works on about 20 to 30 projects during a year, most with lead times of at least six months. Urgent tooling requests aren’t always needed, so delivery of punch tooling in a six-week time frame works out OK.

Bayagich said that they will lean on their suppli-ers like American Punch to talk about more exotic tooling needs. Discussions about cryogenics and carbide tooling have occurred as Bay Products is faced with more challenging punching and piercing requests from its customers.

Still Serving the CustomerEven with the dichotomy in customers, they still have the need for punches. They may have different requirements and time tables, but they still need to make holes.

Olson jokingly said that things were much eas-ier when tolerances were that of “a football field instead of a pinhead,” but as most of American Punch’s customers have learned, evolution is a ne-cessity for survival.

So that’s why American Punch has made invest-ments. Olson pointed out how the company now has about 10 different types of software packages just to accommodate the many different ways that customers send them prints and drawings to be able to pull out all the details embedded in the customer files. It sounds meticulous, maybe even overkill, but that’s where manufacturing is today. Metal fabrica-tors and manufacturers still need holes; they just need to make them faster, consistently the same size, with good quality, and at an acceptable price.

As Timmerman said, “You either evolve or dissolve.” Editor-in-Chief Dan Davis can be reached at [email protected] Products Inc., www.bayproductsinc.comMining Manufacturing, 304-736-4217Timmerman Manufacturing, www.timmermanmfg.comAmerican Punch Co., www.americanpunchco.com

Bay Products Inc. uses punches for the post-pierce systems it builds for its automotive customers. The systems make the punched holes in welded structures.

Timmerman Manufacturing, a manufacturer of wrought iron furniture and metal parts for the wooden furniture industry, has been around long enough to see furniture manufacturing sent overseas and now coming back to North Carolina. It relies on punch tool-ing to make holes and slots in the metal pieces that help to hold furniture together.

Dec20FAB_Punching.indd 63Dec20FAB_Punching.indd 63 11/18/20 1:31 PM11/18/20 1:31 PM


http://www.bayproductsinc.com

http://www.timmermanmfg.com

http://www.americanpunchco.com

http://www.punchtools.com




ACCURPRESS AMERICA INC., Rapid City, SD

Accurpress Advantage H 4 52-240 51-198 175 6 8 14 10 115-200 24 180-300 4 4 4 4

Accurpress Advantage H 4 96-288 76-246 500 8 10 18 10-12 65 18 112 4 4 4 4

Accurpress Advantage H 4 168-432 132-390 1,500 7 12-14 20-22 12-14 40-50 10-14 60-80 4 4 4 4 4

Accurpress Edge EHP 4 48-240 37-198 250 8 10 18 10-12 320-440 24 260-320 4 4 4 4 4

Accurpress Accell EHP 4 72-240 58-198 285 8 14 22 16-18 300-480 24-48 240-320 4 4 4 4 4

Accurpress Edge EHP 4 120-240 102-198 500 8 12 20 14 320 24 260 4 4 4 4 4

Accurpress Edge EHP 4 192-360 174-318 850 8 14 22 18 320 24 260 4 4 4 4 4

Accurpress Accell EHP 4 120-360 102-318 985 8-10 14 22-24 18-20 160-300 20-24 120-240 4 4 4 4 4

Accurpress Accell EHP 4 192-480 146-434 3,000 10 14-24 24-34 20-22 100 12 100 4 4 4 4

ADIRA, Porto, Portugal

PM 13530 EHP 4 120 100.4 149 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PM 16030 EHP 4 120 100.4 176 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PM 13540 EHP 4 159.5 124 149 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PM 16040 EHP 4 159.5 124 176 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PM 22040 EHP 4 159.5 124 242 9.46 10.24 19.7 15.75 307.09 18.89 200.78 4 4 4 4 4

PA 13530 EHP 4 120 100.4 149 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PA 16030 EHP 4 120 100.4 176 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PA 13540 EHP 4 159.5 124 149 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PA 16040 EHP 4 159.5 124 176 9.46 10.24 19.7 15.75 354.33 23.62 236.22 4 4 4 4 4

PA 22030 EHP 4 120 100.4 242 9.46 10.24 19.7 15.75 307.09 18.89 200.78 4 4 4 4 4

AMADA AMERICA INC., Buena Park, CA

HG1003 Auto Tool Changer EH 4 118.1 106.2 110 13.6 9.8 23.4 17.7 520 47 590 4 4 4 4

HG2204 Auto Tool Changer EH 4 161.4 148 243 13.6 9.8 23.4 17.7 520 47 590 4 4 4 4

HG5020 EH 4 84 67 55 10.7 9.8 20.5 17.7 520 47 590 4 4 4 4

HG8025 EH 4 102 87 88 10.7 9.8 20.5 17.7 520 47 590 4 4 4 4

HG1303 EH 4 122 106 143 10.7 9.8 20.5 17.7 520 47 590 4 4 4 4

HG2203 EH 4 122 106 243 10.7 9.8 20.5 17.7 520 47 590 4 4 4 4

HG2204 EH 4 169 148 243 10.7 9.8 20.5 17.7 520 47 590 4 4 4 4

EG4010 E 4 41.3 27.9 44 10.7 5.9 16.5 9 520 60 520 4 4 4 4

EG6013 E 4 50 39.7 66 10.7 5.9 16.5 9 520 60 520 4 4 4 4

HRB1003 Auto Tool Changer

EH 4 120 106.3 110 10.6 9.8 20.5 17.7 355 36 355 4 4 4 4

ASSISTMACH, Bursa, Turkey

Ultra-1260 H 4 94.5 51 60 7 15.75 23.5 330

AUTOMEC INC., Waltham, MA

CoastOne C9 E 4 56.70 31.81 25 9.84 5.91 15.75 7.87 236.0 23.6 236.0 4 4 4 4 4

CoastOne C9X E 4 56.70 31.81 25 9.84 5.91 31.50 7.87 236.0 23.6 236.0 4 4 4 4 4

CoastOne C12 E 4 75.00 48.00 50 9.84 9.84 19.68 5.90 236.0 23.6 236.0 4 4 4 4 4

CoastOne C15 E 4 87.80 60.24 50 9.84 9.84 19.68 5.90 236.0 23.6 236.0 4 4 4 4 4

CoastOne C15X E 4 87.80 60.24 50 9.84 9.84 31.50 5.90 236.0 23.6 236.0 4 4 4 4 4

CoastOne G20 E 4 117.72 86.60 60 8.66 11.00 19.70 n/a 236.0 23.6 236.0 4 4 4 4 4

CoastOne G25 E 4 137.80 106.00 80 8.66 11.00 19.70 n/a 236.0 23.6 236.0 4 4 4 4 4

CoastOne G30 E 4 157.87 126.00 100 12.60 11.00 23.60 n/a 236.0 23.6 236.0 4 4 4 4 4

CoastOne G40 E 4 198.03 165.00 150 12.60 11.00 23.60 n/a 236.0 23.6 236.0 4 4 4 4 4

BLM GROUP, Novi, MI ProBend H EH 240 660 4

ProBend E E 204 276 4 4

BETENBENDER MANUFACTURING INC., Coggon, IA

4 x 20T H 4 54 40 20 6 4 10 4 12 120 135 4 4 4

4-16 x 50T H 4 63-207 30.5-174.5 50 6 8 14 8 66 66 62 4 4 4

E=Electric EH=Electric Hydraulic EHP=Electronic-Hydraulic Position EM=Electric Mechanical H=Hydraulic HM=Hydromechanical M=Mechanical P=Pneumatic PM=Pneumatic Mechanical This information is provided by the manufacturers. For more information, use the links in the online buyers’ guide at www.thefabricator.com. ©Copyright 2020 by FMA Communications Inc. Reproduction in full or in part without written permission of the publisher is prohibited. Buyers’ guides are a part of the Forming & Fabricating Industry Directory.

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le

OverallBetween Housings Ra

pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back

2020 FORMING & FABRICATING® PRESS BRAKE BUYERS’ GUIDE©

Due to space considerations, listings are limited to 10 entries per company. To see each company's full listing, please visit www.thefabricator.com/guide/press-brake

Dec20FAB_PressBrakeBuyersGuide.indd 64Dec20FAB_PressBrakeBuyersGuide.indd 64 11/18/20 1:15 PM11/18/20 1:15 PM


http://www.thefabricator.com/guide/press-brake


4-16 x 70T H 4 63-207 30.5-174.5 70 6 8 14 8 44 44 63 4 4 4

6-22 x 95T H 4 100-274 54.5-251 95 6 8 14 8 114 50 168 4 4 4

6-22 x 120T H 4 100-274 54.5-251 120 6 8 14 8 87 40 115 4 4 4

6-22 x 160T H 4 100-274 54.5-251 160 6 8 14 8 68 31 86 4 4 4

6-16 x 190T H 4 100-207 54.5-174.5 190 6 8 14 8 55 25 66 4 4 4

6-16 x 240T H 4 100-207 54.5-174.5 240 6 8 14 8 50 25 70 4 4 4

6-16 x 300T H 4 100-207 54.5-174.5 300 6 8 14 8 50 25 70 4 4 4

6-16 x 350T H 4 100-207 45.5-174.5 350 6 8 14 8 50 25 70 4 4 4

BOSCHERT USA, Butler, WI

Boschert Gizelis G-TurboBend

H 4 61 61 44 9.8 614 47 472 4 4 4 4

Boschert Gizelis G-Flex H 4 82-161 61-139 80-210 10 16 24 4 4 4 4

Boschert Gizelis G-Bend Plus

H 4 82-133 61-120 80-290 9.8 15 24 4 4 4 4

Boschert Gizelis Heavy Duty G-HD

H 4 122-279 100-238 330-880 12.5-15 19.6 283 23.4 4 4 4 4

Boschert Gizelis Elec-troBend Press Brake

E 4 82.6-122 84.6-124 100 13.7 282 46.8 4 4 4 4 4

Stierli Manual Horizontal Bending, Straightening Machines

H Adj. Tooling Adj. Tooling 9-660 4.72-31 4-40 23.6 4

Stierli Simple CNC Horizon-tal Bending, Straightening Machines

H Adj. Tooling Adj. Tooling 13-660 6.7-31 23.6 4 4

Stierli Graphical CNC Bending, Straightening Machines

H Adj. Tooling Adj. Tooling 24-90 8-14 23.6 4 4 4

Stierli Radial Bending Machines

H Adj. Tooling Adj. Tooling

1,850- 9,588 ft./

lbs.12.5 RPM 4 4

Stierli Hori-zontal Bend-ing Machines for Railroads

H Adj. Tooling Adj. Tooling 240-485 21.6 24 4 4 4

BOSCHERT MEXICO—GRUPO IDEMET. SA DE CV, Benito Juárez, DF Mexico

Profi 28 Quick Bend EH 4 39 35 30 7.87 12-

15.75 7.87 9.84 10 7.87 4 4 4 4 4

Gizelis G-Bend 6290 H 4 240 199 290 9.85-

13.75 20-24 15.75-19.5 6 .39 4.75 4 4 4 4 4

Gizelis G-Bend 4140 E 4 204 163 220 13.75 23.5 4.75 0.79 3.94 4 4 4 4 4

G Turbobend H 61 61 44 7.85 15.75 10.25 .79 7.87 4 4 4 4 4

Profi 56/ 2200 Quick Bend EH 4 87 83 56 8 12-

15.75 7.87 9.75 8-10 7.87 4 4 4 4 4

Gizelis G-Electro-brake 2060 E 4 122 84.5 66 13.75 23.5 4.7 .79 3.94 4 4 4 4 4

Gizelis G-Bend 2080 H 4 125.5 61 88 9.84 20.25-

24.2515.75-19.50 7 .79 6.3 4 4 4 4 4

Gizelis G-Bend 3110 H 4 134 120 110 10 20 15.75-

19.5 7 .787 6.3 4 4 4 4 4

Gizelis G-Electrobrake 2580

E 4 142 104 88 13.75 23.5 25.4 .79 3.94

Gizelis G-Bend 3290 H 4 134 120 290 10 20-24 15.75-

19.5 6 .6 4.75 4 4 4 4 4

BYSTRONIC INC., Elgin, IL

Xpert 40 EHP 4 40.5 41.7 44 7.8 20.2 19.7 708 59 708 4 4 4 4 4

Xpert 80 EHP 4 60.2 61.8 88 7.9 20.3 19.7 591 59 591 4 4 4 4 4

Xpert 150 EHP 4 100-161 86-147 165 8.5 19.7 16 591 47 472 4 4 4 4 4

Xpert 200 EHP 4 100-161 86-147 220 8.5 19.7 16 591 47 472 4 4 4 4 4

Xpert 250 EHP 4 122-244 108-200 275 10.4 21.6 16 472 47 472 4 4 4 4 4

Xpert 320 EHP 4 122-283 86-240 352 10.4 21.6 16 449 47 472 4 4 4 4 4

Xpert 400 EHP 4 122-323 102-280 440 10.4 21.6 16 284 24 272 4 4 4 4 4

Xpert 500 EHP 4 161-323 142-280 550 14.4 25.6 19.7 236 24 272 4 4 4 4 4

Xpert 650 EHP 4 161-323 138-280 715 14.4 25.6 19.7 236 24 224 4 4 4 4 4

Xpert 800 EHP 4 200-323 173-280 880 14.4 25.6 19.7 189 24 224 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back




http://Adj.To

http://Adj.To

http://Adj.To



CINCINNATI INCORPORATED, Harrison, OH 40, 60GX E 4 40, 60 36 40, 60 7 10 17 8 400 60 400 4 4 4 4

90, 175BX H 4 120, 144 96, 120 90, 175 7 8, 10 15, 17 16 400, 300 24 240, 190 4 4 4 4

60 PF+ H 4 72 54 60 9 8 17 10 180 70 195 4 4 4 4

90 PF+ H 4 96-144 78-126 90 7 8 15 7 260 80 280 4 4 4 4

135 PF+ H 4 96-168 78-150 135 7 8 15 7 200 55 185 4 4 4 4

175 PF+ H 4 96-168 78-150 175 7 10 17 8 180 40 200 4 4 4 4

230 PF+ H 4 120-192 102-174 230 7 10 17 8 155 35 175 4 4 4 4

350 PF+ H 4 120-192 102-174 350 8 10 18 10 105 20 95 4 4 4 4

150HX EH 4 144 127 150 7 14 21 18 500 60 500 4 4 4 4

90, 135MX H 4 96-144 78-126 90, 135 7 8 15 7 700 75, 55 565, 540 4 4 4 4

CML MACHINERY INC., Concord, ON, Canada

Vimercati PHSY 3012 EHP 4 49.2 39.37 30 14.37 7.09 7.28 5.9 472 24 354 4 4 4 4 4

Vimercati PHSY 50 EHP 4 80-164 61-140 50 7.68 8.46 16.14 12-20 472 24 324 4 4 4 4 4

Vimercati PHSY 100 EHP 4 80-164 61-139 100 7.48 10.63 18.11 12-20 472 24 312 4 4 4 4 4

Vimercati PHSY 125 EHP 4 80-240 61-198 125 7.48 10.63 18.11 20 472 24 300 4 4 4 4 4







COLE TUVE INC., White Marsh, MD

AP/AT 1020-150 H 40 40 165 0 11.8 10.8 21 12 24

AP/AT 1020-100 H 40 40 110 0 11.8 12.8 19 12 24

AP/AT 1520-100 H 60 60 110 0 11.8 12.8 19 12 24

AP/AT 1520-150 H 60 60 165 0 11.8 10.8 21 12 24

COMEQ INC., White Marsh, MD Euromac 2550 E 4 100 100 55 10 18.5 -

15.5 472 24 472 4 4 4 4 4

Euromac 1547 E 4 60.2 60.2 52 10 18.5 -

15.5 472 24 472 4 4 4 4 4

Euromac 1023 E 4 40.15 40.15 25 7.716 18.5-

15.5 472 24 472 4 4 4 4 4

Vicla First H 4 49.21 49.21 45 15.75 7.87 39.17 590 24 590 4 4 4 4 4

Vicla Smart H 4 up to 12 Up to 124 600 22.83 13.78 42.32 19.69 425 24 425 4 4 4 4 4

Vicla Superior H 4 Up to 144 Up to 124 600 22.83 13.78 42.32 19.69 472 24 472 4 4 4 4 4

DURMA/DURMA NORTH AMERICA INC., Lake Orion, MI AD 60 EHP 4 49/80 41/67 66 10.6 10.4 21 13.7 472 24 283 4 4 4 4 4

AD 100 EHP 4 102-120 86-102 110 11 10/14 21/25 16 425 24 283 4 4 4 4 4

AD 135 EHP 4 120 102 150 11 10/14 21/25 16 378 24 283 4 4 4 4

AD 175 EHP 4 120-168 102-146 195 11 10 21 16 283 24 283 4 4 4 4 4

AD 220 EHP 4 120-240 102-200 245 11 10 21 16 283 24 283 4 4 4 4 4

AD 320 EHP 4 120-240 102-200 350 11 14 25 16 236 24 236 4 4 4 4 4

AD 400 EHP 4 120-240 102-200 440 11 14 21 20 236 21 189 4 4 4 4

AD 600 EHP 4 159-240 142-200 660 13 14 27 20-60 188 16 165 4 4 4 4 4

AD 800 EHP 4 240-277 200 880 12 15 27 24-60 188 17 165 4 4 4 4 4

AD 1000 EHP 4 277-360 200-252 1100 12 19 31 24 189 12 141 4 4 4 4 4

ERMAKSAN, Des Plaines, IL

Speed Bend 4 x 44 T EHP 4 50 41 44 6.69 15.22 13.78 331 40 402 4 4 4 4 4

Speed Bend 10 x 110 T EHP 4 122 102 110 10.83 20.87 16.14 472 28 449 4 4 4 4 4

Speed Bend 10 x 149 T EHP 4 122 102 149 10.83 21.65 16.14 472 28 449 4 4 4 4 4

Speed Bend 10 x 193 T EHP 4 122 102 193 10.83 21.65 16.14 425 28 449 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back






Speed Bend 10 x 242 T EHP 4 122 102 242 10.83 21.65 16.14 425 24 437 4 4 4 4 4

Speed Bend 10 x 286 T EHP 4 122 102 286 10.83 21.65 16.14 331 26 319 4 4 4 4 4

Speed Bend 10 x 352 T EHP 4 122 102 352 14.76 25.59 16.14 331 25 354 4 4 4 4 4

Speed Bend 12 x 193 T EHP 4 148 128 193 10.83 21.65 16.14 425 28 449 4 4 4 4 4

Speed Bend 12 x 242 T EHP 4 148 128 242 10.83 21.65 16.14 425 24 437 4 4 4 4 4

Speed Bend 12 x 352 T EHP 4 148 128 352 14.76 25.59 16.14 331 25 354 4 4 4 4

FAB-LINE MACHINERY LLC/BAYKAL, Saint Charles, IL APHS 40 H 4 49 42 44 9.5 8.4 17.9 16 378 24 307 4 4 4 4

APHS 60 H 4 82 62.9 66 10.5 8.2 18.7 16 354 24 307 4 4 4 4

APHS 90 H 4 122 100 100 10.6 10.2 20.8 16 378 24 307 4 4 4 4

APHS 120 H 4 122 100 132 10.6 10.2 20.8 16 378 24 307 4 4 4 4

APHS 160 H 4 145 127 175 10.6 10.2 20.8 16 401 24 307 4 4 4 4

APHS 200 H 4 145 127 220 10.6 10.2 20.8 16 354 24 283 4 4 4 4

APHS 240 H 4 145 127 265 10.6 10.2 20.8 16 330 24 260 4 4 4 4

APHS 300 H 4 161 139 330 12.5 12.5 25 20 283 18 212 4 4 4 4

APHS 440 H 4 240 200 480 9.9 12.5 22.4 20 212 18 165 4 4 4 4

APHS 660 H 4 240 200 660 10.3 14.1 24.4 20 189 16 165 4 4 4 4

FABRICATION SOLUTIONS & TECHNOLOGIES, Longview, TX Warcom Evoluta 60/25-400/40

H 4 4 86-165 70.8-145.6 60-400 19.6 2.34-4.68 .45-.1875 3.54-5.16 4 4 4 4 4

Warcom Dinamica 60/20-400/40

H 4 4 86-165 61-139.7 60-400 19.6 2.34-4.68 .45-.1875 2.82-4.2 4 4 4 4 4

Warcom Futura 40/17-1000/100

H 4 4 66-397 47.2-336.6 40-1,000 19.6 1.884-4.68 .15-.45 1.62-4.2 4 4 4 4 4

Warcom Logica 850/ 25-3000/80

E 4 4 33-120 29.5-100.3 25-80 9.4 4.68-6.36 .45 4.68-6.36 4 4 4 4 4

FERRIC MACHINERY INC., Cambridge, ON, Canada

Speed Bend 4 x 44 Ton EHP 4 50 41 44 6.69 15.22 13.78 331 40 402 4 4 4 4 4










GASPARINI, Avon, OH X-Press 25/1250 EHP 4 50 47 25 6 13 600 24 402 4 4 4 4 4

X-Press 50/2000 EHP 4 82 63 50 8 16 12 540 24 402-530 4 4 4 4 4

X-Press 100/3000 EHP 4 122 102 100 12 20 16 540 24-48 402-612 4 4 4 4 4

X-Press 100/3000C “Front”

EHP 4 122 102 100 16 20 16 540 24-48 402-612 4 4 4 4 4

X-Press 150/3000 EHP 4 122 102 150 12 20 20 540 24-48 330-472 4 4 4 4 4


EHP 4 161 141 150 16 23.5 20 540 24-48 330-462 4 4 4 4 4

X-Press 200/3000 EHP 4 122 102 200 12 20 20 540 24-40 342-520 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back







EHP 4 122 102 200 16 24 20 540 24-40 342-520 4 4 4 4 4

X-Press 330/8000 EHP 4 319 300 330 12 20 20 236 20-24.5 200-236 4 4 4 4 4

X-Press 330/4000 EHP 4 161 141 330 12 20 20 472 20-24.5 330-472 4 4 4 4 4

HACO-ATLANTIC INC., Houston, TX

HDE 45-75 EH 4 63-122 43-102 75 7.1 3.9 11 7.8 165 19 130 4 4 4 4

HDE 120-165 EH 4 102-169 82-147 165 8.1 4.7 12.8 9.8 165 17 142 4 4 4 4

HDE 200-240 EH 4 102-169 82-147 240 9.9 7.8 17.7 11.8 189 21 224 4 4 4 4

HDE 275 EH 4 122-169 82-147 275 9.8 7.8 17.7 11.8 189 21 212 4 4 4 4

HDE 350 EH 4 122-169 102-147 350 9.8 9.8 19.6 13 189 21 245 4 4 4 4

Synchro- master 45-75 EHP 4 63-122 43-82 75 7.1 3.9 11 7.8 189 24 165 4 4 4 4

Synchromas-ter 120-165 EHP 4 102-169 82-147 165 7.9 7.8 15.7 9.8 165 24 189 4 4 4 4



Euromaster 45-75 EHP 4 63-122 43-82 75 7.1 3.9 11 7.8 189 24 165 4 4 4 4 4

INTERNATIONAL TECHNOLOGIES INC., Schaumburg, IL

Cone900 E 4 34.17 31.81 24 9.84 5.91 15.75 7.87 236 23.6 236 4 4 4 4 4

C9 E 4 33.46 31.10 24 9.84 9.84 19.69 5.91 236 23.6 236 4 4 4 4 4

C9X E 4 33.46 31.1 24 9.84 9.84 31.49 5.91 236 23.6 236 4 4 4 4 4

C12 E 4 51.18 49.21 48 9.84 9.84 19.69 5.91 236 23.6 236 4 4 4 4 4

C12X E 4 51.18 49.21 48 9.84 9.84 31.49 5.91 236 23.6 236 4 4 4 4 4

C15 E 4 63 61 48 9.84 9.84 19.69 5.91 236 23.6 236 4 4 4 4 4

C15X E 4 63 61 48 9.84 9.84 31.49 5.91 236 23.6 236 4 4 4 4 4

G20 E 4 86.6 80.31 67 11.02 23.62 O Frame 236 23.6 236 4 4 4 4 4

G25 E 4 106 100.39 89 11.02 23.62 O Frame 236 23.6 236 4 4 4 4 4

G30 E 4 126 120.47 111 11.02 23.62 O Frame 236 23.6 236 4 4 4 4 4

KAAST MACHINE TOOLS INC., Aidan, PA

HPB E EH 4 49 39 40 8 5.1 13.2 12 200 20 200 4 4

HPB E EH 4 102 84 100 8 5.5 13.5 12 200 20 200 4 4

HPB E EH 4 122 100 550 8 10 18 15.75 240 24 240 4 4

HPB E EH 4 161 141 550 8 12 20 19.5 240 24 240 4 4

HPB E EH 4 240 200 1,100 12 20 32 19.5 240 24 240 4 4

HPB CNC EHP 4 49 39 45 8 5.1 13.2 12 200 20 200 4 4 4 4 4

HPB CNC EHP 4 102 84 100 8 5.5 13.5 12 200 20 200 4 4 4 4 4

HPB CNC EHP 4 122 100 550 8 10 18 15.75 240 24 240 4 4 4 4 4

HPB CNC EHP 4 161 141 550 8 12 20 19.5 240 24 240 4 4 4 4 4

HPB CNC EHP 4 240 200 1,100 12 20 32 19.5 240 24 240 4 4 4 4 4

KNUTH MACHINE TOOLS USA INC., Lincolnshire, IL

AHK H CNC 15060 EHP 4 59 51 60 8.04 8.1 16.14 12 480 23.4 283 4 4 4 4

AHK H CNC 20080 EHP 4 83 67 80 8 8.1 16.14 12 360 23.4 283 4 4 4 4

AHK H CNC 26100 EHP 4 102 87 100 11 8.1 19.09 16 360 23.4 260 4 4 4 4

AHK H CNC 30100 EHP 4 122 102 100 11 8 19.09 16 360 23.4 260 4 4 4 4

AHK H CNC 30135 EHP 4 122 102 135 11 8.1 19.09 16 360 23.4 236 4 4 4 4

AHK H CNC 30175 EHP 4 122 102 174.6 11 8.1 19.09 16 300 23.4 236 4 4 4 4

AHK H CNC 30220 EHP 4 122 102 219.5 11 8.1 19.09 16 300 23.4 236 4 4 4 4

AHK H CNC 30320 EHP 4 122 102 319 8.63 14.4 23.03 20 240 21 212.4 4 4 4 4

AHK H CNC 37220 EHP 4 146 126 219.5 8.69 10.4 19.09 16 240 23.4 236 4 4 4 4

AHK H CNC 40175 EHP 4 161 142 174.6 8.69 10.4 19.09 16 300 23.4 236 4 4 4 4

LVD STRIPPIT, Akron, NY

Dyna Press Plus 24-40 E 4 49-60 47-60 26-44 3.9 5.9-7.8 9.8-11.8 3.9 236 59 236 4 4 4 4

Dyna Press Pro 40 E 4 60 60 44 7.8 7.8 15.7 6.9 236 59 236 4 4 4 4

Dyna-Cell 40-15 E 4 60 60 44 7.8 7.8 15.7 6.8 236 59 236 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back






PPED 50-200 EHP 4 78-157 61-124 55-220 7.8 7.8 15.7 7.8-11.8 377 24 236 4 4 4 4 4

PPED 260-320 EHP 4 120-157 100-124 285-350 10.6 11.8 22.4 11.8 212 24 212 4 4 4 4 4

PPEB 80-220 EHP 4 59-240 41-198 90-240 7.8 7.8-15.7 15.7-23.6

15.7-19.6 425 59 472 4 4 4 4 4

PPEB 220 Plus EHP 4 120-240 102-198 240 10.6 11.8-19.6

22.4-30.3

15.7-19.6 283 50 472 4 4 4 4 4

PPEB 320 EHP 4 120-240 102-198 350 10.6 11.8-19.6

22.4-30.3

15.7-23.6 283 33 307 4 4 4 4 4

PPEB 400 EHP 4 160-240 124-198 440 10.6 11.8-19.6

22.4-30.3

15.7-31.4 236 26 283 4 4 4 4 4

PPEB 500 EHP 4 160-240 124-198 550 10.6 11.8-19.6

22.4-30.3

15.7-31.4 236 21 189 4 4 4 4 4

MC MACHINERY SYSTEMS—MITSUBISHI LASER, Elk Grove Village, IL

BB306 EBB4013 E 50 51 40 6 17 4 237 48 237BB6013 E 51 35 60 6 17 16 225 48 225BH8525 EH 102 87 85 10 21.6 16 472 24 472 4 4

BH13530 EH 122 106 135 10 21.6 16 472 24 472 4 4

BH18530 EH 122 106 185 10 21 16 472 24 472 4 4

BH18540 EH 165 146 203 10 21 123 472 24 472 4 4

BH25030 EH 122 106 250 10 21 16 472 24 472 4 4

BH25040 EH 161 146 275 10 21 16 472 24 472 4 4

BB6020 E 83 83 60 6 17 16 225 48 225

MVD INAN MACHINE, Konya, Turkey

iBend C Series C44x4 EHP 4 49.2 43.3 66 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4

iBend C Series C66x6 EHP 4 82.6 63 66 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4

iBend C Series C66x8 EHP 4 102.3 82.6 66 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4

iBend C Series C110x10 EHP 4 122 102.3 110 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4


IBend C Series C240x10 EHP 4 122 102.36 240 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4


iBend C Series C150x12 EHP 145.6 126 150 12.2 11.8 20.25 19.65 425 24 425 4 4 4 4 4



NC MEC USA INC./YAWEI, Buford, GA

PBE 30 E 4 49 40 30 8.24 4.72 16.73 9.84 354 47 354 4 4 4 4 4

PBE 50 E 4 80 68.8 50 8.24 6.88 17.3 13.7 472 47 472 4 4 4 4 4

PBC 30 EHP 4 39 37 30 8.24 4.7 17.7 3.5 472 47 472 4 4 4 4 4

PBC 80 EHP 4 88.5 84.6 80 8.24 6.88 17.3 13.7 472 42 472 4 4 4 4 4

PBC 110 EHP 4 122 102.3 110 8.24 8.46 18.9 16.1 472 40 472 4 4 4 4 4

PBC 160 EHP 4 161 141.7 160 8.24 8.46 18.9 16.1 400 33 432 4 4 4 4 4

PBC 220 EHP 4 161 141.7 220 8.24 8.46 18.9 16.1 312 130 360 4 4 4 4 4

PBM 80 EHP 88.5 82.6 80 8.24 6.69 14.9 13.7 472 48 472 4 4 4 4 4

PBM 110 EHP 4 122 102 110 8.24 8.66 16.9 15.7 472 42 472 4 4 4 4 4

PBM 160 EHP 4 161 141.7 160 8.24 8.66 16.9 15.7 472 36 472 4 4 4 4 4

PACIFIC PRESS TECHNOLOGIES, Mt. Carmel, IL

FK or K 1500 H 4 240-540 206-506 1,500 12 18-48 30 18 56 9 65 4 4 4 4 4

FK or K 1750 H 4 240-540 194-494 1,750 12 18-48 30 18 62 8 56 4 4 4 4 4

FK or K 2000 H 4 240-540 194-494 2,000 12 18-48 30 20 48 8 52 4 4 4 4 4

FK or K 3000 H 4 192-480 120-408 3,000 12 24-48 30 20 48 8 50 4 4 4 4 4

Plate Forming Cell H 4 192-720 3,000 10 12-36 24-60 24-64 108 20 132 4 4 4 4 4

XL Plate Forming Cell H 4 480-1,620 6,000 10 12-36 24-60 24-64 146 26 146 4 4 4 4 4

FK or K 100-225 H 4 72-192 53-173 225 5 10-24 15-17 6-8 380 50 290 4 4 4 4 4

FK or K 300 H 4 96-360 77-341 300 8 12-36 20 10 146 26 146 4 4 4 4 4

FK or K 350 H 4 96-360 77-341 350 8 12-36 20 10 146 26 146 4 4 4 4 4

FK or K 400 H 4 96-480 76-460 400 8 12-36 20 10 146 26 146 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back






PARAMOUNT MACHINERY INC., Mississauga, ON Canada

AIZAWA APB-204 E 4 16.5 18.9 22 7.08 5.9 13 7.87 283.5 47.2 283.5 4 4 4 4

AIZAWA APB-4013 E 4 51 41.7 44 7.08 5.9 13 16.14 283.5 47.2 283.5 4 4 4 4

AIZAWA AVP-206 E 4 24 20 22 9.64 6.1 15.74 11.8 354 24 354 4 4 4 4

AIZAWA APL 8025 H 4 98.4 86.3 88 5.71 6.1 15.74 16.1 235.8 21 307 4 4 4 4

AIZAWA APL 110.31 H 4 122 108 120 5.73 8.07 13.8 16.1 236 23.6 200 4 4 4 4

AIZAWA APL 160.41 H 4 161.4 145.4 176 5.7 8.07 17.71 16.1 235.8 21 260 4 4 4 4

AIZAWA APL 250.41 H 4 161.4 142.9 275 5.71 10.03 19.68 16.1 235.8 12 260 4 4 4 4

AIZAWA APL300.41 H 4 161.4 142.5 330 5.71 10.03 19.68 16.1 235.8 12 260 4 4 4 4

PIRANHA—A DIVISION OF MEGAFAB., Rockford, IL T-Series EH 4 48 - 156 40 - 120 35-280 7.87-16.9 4 4

P-Series EH 4 48 - 480 40 - 480 35 - 3,000 4 4 4 4

PRIMA POWER NORTH AMERICA INC., Arlington Heights, IL

eP-0520 E 4 133 85 61 12.25 24/26/28 O-Frame 425 24 425 4 4 4 4

eP-1030 E 4 173 124 118 12.25 24/26/28 O-Frame 260 24 260 4 4 4 4

eP-1336 E 4 197 155 150 12.25 24/26/28 O-Frame 213 24 213 4 4 4 4

eP-2040 E 4 223 161 220 12.25 24/26/28 O-Frame 236 24 236 4 4 4 4

ROTO-DIE—A MEMBER OF THE FORMTEK GROUP, Warrensville Heights, OH

#5 H 4 60 60 16 ga. 3 4 4 4

#10 H 4 120 120 16 ga. 3 4 4 4

#15 H 4 120 120 14 ga. 3 4 4 4

#15/12 H 4 144 144 14 ga. 3 4 4 4

SAFANDARLEY BV, Lochem, Netherlands

E-Brake 35-1250 E 4 49.2 49.2 38.5 11.41 11.81 23.22 4 4 4 4

E-Brake 40-1600 E 4 63 63 44 11.41 11.81 23.22 4 4 4 4

E-Brake 50-2050 E 4 80.70 80.70 55 11.41 11.81 23.22 4 4 4 4

E-Brake 80-2550 E 4 100.39 100.39 88 11.41 11.81 23.22 4 4 4 4

E-Brake 100-3100 E 4 122.05 122.05 110 11.41 11.81 23.22 4 4 4 4

E-Brake 150-3100 E 4 122.05 122.05 165 11.41 11.81 23.22 4 4 4 4

E-Brake 200-4100 E 4 161.42 161.42 220 15.36 11.81 27.17 4 4 4 4

E-Brake Dual Drive 300-4100

E 4 161.42 161.4 330 15.36 15.74 31.10 4 4 4 4

H-Brake 500-1250 H 4 1375 4 4 4 4

H-Brake 175-400 H 4 122-244 98-200 192-440 11-16 12-14 23-30

SALVAGNINI AMERICA INC., Hamilton, OH

B3 170/4250 H 4 215 143 187 9.8 13.8 23.6 17.13 519.7 23.6 519.7 4 4 4 4 4

B3 170/4250XL H 4 220 142 187 9.8 17.7 27.6 20.47 519.7 23.6 519.7 4 4 4 4 4

B3 220/4250 H 4 220 142 242 9.8 17.7 27.5 20.47 519.7 23.6 519.7 4 4 4 4 4

B3 220/5100 H 4 252 181 242 9.8 17.7 27.5 20.47 519.7 23.6 519.7 4 4 4 4 4

B3 320/4250 H 4 220 142 352 9.8 17.7 27.5 20.47 519.7 23.6 519.7 4 4 4 4 4

B3 220/3000 H 4 173 102 242 9.8 17.7 27.5 20.47 519.7 23.6 519.7 4 4 4 4 4

B3 100/3000 H 4 173 103 110 9.8 11.8 21.6 15.75 590.6 23.6 590.6 4 4 4 4 4

B3 135/3000 H 4 175 103 149 9.8 13.8 23.6 17.13 590.6 23.6 590.6 4 4 4 4 4

B3 135/4250 H 4 215 143 149 9.8 13.8 23.6 17.13 519.7 23.6 519.7 4 4 4 4 4

B3 320/5100 H 4 252 181 352 9.8 17.7 27.5 20.47 519.7 23.6 519.7 4 4 4 4 4

SHANDONG JIAYI MACHINERY CO. LTD., Shanghai, China

GPMINI H 4 49.21 47.24 25 7.48 5.90 13.38 1.81 7.87 IPS .39 IPS 6.69 IPS 4 4 4 4 4

G-TOP60-2000 H 4 118.11 62.99 60 5.91 9.84 15.75 11.81 9.84 IPS .39 IPS 6.69 IPS 4 4 4 4 4

G-TOP125-3000 H 4 122.05 102.36 125 7.87 11.81 19.69 19.69 10.63 IPS .39 IPS 6.69 IPS 4 4 4 4 4

G-TOP185-4000 H 4 196.85 141.73 185 7.87 11.81 19.69 19.69 10.63 IPS .39 IPS 5.51 IPS 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back






X-BRAVO60-2000 H 4 118.11 62.99 60 7.68 7.87 15.55 10.43 7.87 IPS .39 IPS 6.69 IPS 4 4 4 4 4



TRILOGY MACHINERY INC., Belcamp, MD Warcom Dinamica H 4 72-168 66-¬†440 7.85 15.75 23.60 19.7 472 23.6 425 4 4 4 4 4

Warcom Evoluta H 4 96-169 66-440 7.85 15.75 23.6 19.7 472 47 520 4 4 4 4 4

Warcom Futura H 4 72-480 66-1,650 7.9 9.8 17.7 19.7 472 23.6 425 4 4 4 4 4

Warcom Logica E 4 30-120 27-88 8.7 9 17.7 9.5 638 47 638 4 4 4 4 4

Warcom Unica H 4 72-480 66-1,650 7.9 9.8 17.7 19.7 472 23.6 425 4 4 4 4 4

TRUMPF INC., Farmington, CT

TruBend 2100 EHP 4 120 133 110 5.9 7.8 13.6 472 35 472 4 4 4 4

TruBend 3066 EHP 4 80 93 73 5.9 8 14 472 35 472 4 4 4 4

TruBend 3100 EHP 4 120 133 110 5.9 8, 13.7 14, 19.6 472 35 472 4 4 4 4

TruBend 3170 EHP 4 160 173 187 5.9 13.7 19.6 401 23 401 4 4 4 4

TruBend 5085 EHP 4 87,107 69, 89 94 6.5, 6.7 8.5, 17.5 15, 24.2 16.5 520 59 520 4 4 4 4 4

TruBend 5130 EHP 4 127 106 141 6.5, 6.7 8.5, 17.5 15, 24.2 16.5 520 59 520 4 4 4 4 4

TruBend 5170 EHP 4 127, 167 106, 145 187 6.7 17.5 24.2 16.5 520 59 520 4 4 4 4 4

TruBend 5230 EHP 4 127, 167 106, 145 253 6.7 17.5 24.2 16.5 520 59 520 4 4 4 4 4

TruBend 5320 EHP 4 174 145 353 6.7 17.5 24.2 16.5 520 59 520 4 4 4 4 4

TruBend 7036 E 4 40 36.7 40 7.1 4.7 11.8 5.9 520 59 520 4 4 4 4

URSVIKEN INC., Elgin, IL

Optima 1800 EHP 4 715 637 1,800 7.28 51.2 58.2 63 3-189 3-23.6 3-189 4 4 4 4 4

Optima 2200 EHP 4 715 637 2,200 7.28 51.2 58.2 63 3-189 3-23.6 3-189 4 4 4 4 4

Optima 2750 EHP 4 715 637 2,750 7.28 51.2 58.2 63 3-189 3-23.6 3-189 4 4 4 4 4

Optima 3300 EHP 4 715 637 3,300 7.28 51.2 58.5 63 3-165 3-23.6 3-165 4 4 4 4 4

Optima 4400 EHP 4 715 637 4,400 7.28 51.2 58.5 63 3-165 3-23.6 3-165 4 4 4 4 4

Optiflex 110-145 EHP 4 96-156 96-156 110-145 5.9 15.7 21.7 8 3-400 3-45 3-425 4 4 4 4 4

Optiflex 175-230 EHP 4 96-156 96-156 175-230 5.9 15.7 21.7 8 3-400 3-43 3-425 4 4 4 4 4

Optiflex 275-350 EHP 4 120-240 120-240 275-350 5.9 23.6 35.4 8 3-283 3-30 3-340 4 4 4 4 4

Optima 440 EHP 4 362 321 440 7.28 39.4 46.6 59 3-189 3-23.6 3-236 4 4 4 4 4

Optima 550 EHP 4 362 321 550 7.28 39.4 46.6 59 3-189 3-23.6 3-¬†236 4 4 4 4 4

VARTEK MACHINERY, Bursa, Turkey

PrimaForm EHP 4 82-161 59-139 330 11 11 21 19 425 24 378 4 4 4 4 4

AccuraForm EHP 4 59-319 39-279 2,000 11 11 21 19 425 24 378 4 4 4 4 4

AdvanceForm EHP 4 59-319 39-279 2,000 11 11 21 19 425 24 378 4 4 4 4

W.A. WHITNEY CO.—A DIVISION OF MEGAFAB, Rockford, IL

125-10 (B or P) EHP 4 122 102 125 8.8 8.5 17.3 16 472 33 378 4 4 4 4 4

180-10 (B or P) EHP 4 122 102 180 8.8 8.5 17.3 16 401 26 330 4 4 4 4 4

250-13 (B or P) EHP 4 161 141.5 250 9.2 8.5 17.7 16 307 23 283 4 4 4 4 4

250-16 (B or P) EHP 4 200 165 250 9.2 8.5 17.7 16 307 23 283 4 4 4 4 4

280-13 (B or P) EHP 4 161 141.5 280 9.2 8.5 17.7 16 283 21 248 4 4 4 4 4

56-60 E 4 80 68 56 9.5 7.8 17.3 11.8 472 47 472 4 4 4 4 4

90-08 (B & P) EHP 4 100 84.5 90 8.8 6.9 15.7 13.7 472 33 401 4 4 4 4 4

125-13 (B or P) EHP 4 161 141.5 125 8.8 8.5 17.3 16 401 26 330 4 4 4 4 4

180-13 (B or P) EHP 4 161 141.5 180 8.8 8.5 17.3 16 401 26 330 4 4 4 4 4

250-10 (B or P) EHP 4 122 102 250 9.2 8.5 17.7 16 307 23 283 4 4 4 4 4

WESTWAY MACHINERY, Mississauga, ON Canada APHS 4 50 42 44 4 4 4 4 4

APHS 4 124 102 99 4 4 4 4 4

APHS 4 124 102 132 4 4 4 4 4

APHS 4 124 102 176 4 4 4 4 4

APHS 4 148 124 220 4 4 4 4 4

APHS 4 148 124 330 4 4 4 4 4

APHS 4 148 124 440 4 4 4 4 4

APHS 4 244 204 550 4 4 4 4 4

APHS 4 244 204 1100 4 4 4 4 4

Series Type

(E, E

H, EH

P, EM

, H,

HM

, M, P

, PM

)

Upst

roki

ng

Dow

nstro

king

Maximum Tonnage

Length (in.)

Shut

Hei

ght (

in.)

Stro

ke Le

ngth

(in.

)

Open

Hei

ght (

in.)

Thro

at D

epth

(in.

)

Maximum Speed (IPM)

Offlin

e Pro

gram

min

g

Gauges

Light

Curt

ain

Netw

ork C

apab

le


pid

Appr

oach

Pres

s Sp

eed

Retu

rn

Spee

d

Fron

t

Back






CLASSIFIED ADVERTISINGSERVICESPRODUCTS FOR SALE

TOOLS & SUPPLIES

Need information about print or

online classifieds?

Contact Jerry Gunderson [email protected]

815-227-8257

ADVERTISERS INDEXAdvanced Laser Machining. . . . . . . . . . . . . . . . . . . . . . . . . . 32www.Laser27.com

Akyapak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45www.akyapakusa.com

Amada America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7www.amada.com

ATI Industrial Automation. . . . . . . . . . . . . . . . . . . . . . . . . . . 14www.ati-ia.com

Betenbender Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . 30www.betenbender.com

Bluco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26www.bluco.com

Boschert Precision Machinery. . . . . . . . . . . . . . . . . . . . .37,49www.boschertusa.com

Carell Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30www.carellcorp.com

Cincinnati Incorporated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9www.e-ci.com

COLE-TUVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11www.coletuve.com; 877-989-0700 Toll Free

COMEQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17www.comeq.com

Diamond Ground Products. . . . . . . . . . . . . . . . . . . . . . . . . . 31www.diamondground.com

Donaldson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20www.donaldsontorit.com

Eagle Laser/Fairmont Machinery . . . . . . . . . . . . . . . . . . . . . .3www.fairmontmachinery.com

Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43www.eriez.com

Fabrication Solutions & Technologies. . . . . . . . . . . . . . . . 15www.fststeelfab.com

Fabricators & Manufacturers Association, Intl.. . . . . . . . 41www.fmanet.org

FABTECH® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73www.fabtechexpo.com

Faccin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75www.faccin.com

Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22www.greinerindustries.com

Haeusler AG Duggingen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23www.haeusler.com/en

Hastings Air Energy Control . . . . . . . . . . . . . . . . . . . . . . .16,43www.hastingsair.com

Heck Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31www.heckind.net

Hougen Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18www.hougen.com

Hypertherm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25www.hypertherm.com

IPG Photonics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53www.ipgphotonics.com/en

Kalamazoo Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33www.kalamazooind.com/fab/

Laser Mechanisms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33www.lasermech.com

LISSMAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59www.lissmac-usa.com; 518-326-9094

Mazak Optonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2www.mazakoptonics.com

Metalforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5770-631-0002

MG Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29www.mgsrl.com

Midwest Finishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . 33www.midwestfinishingsystems.com

Mitsubishi Laser / MC Machinery Systems . . . . . . . . . . . . 21www.mcmachinery.com

MITUSA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25www.mitusaproducts.com

Paperless Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27www.paperlessparts.com

Peddinghaus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24www.peddinghaus.com

Punch-Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63www.punchtools.com

Quantum Machinery Group . . . . . . . . . . . . . . . . . . . . . . Insertwww.quantummachinery.com / 909-476-8007

Radan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

T J Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31www.tjsnow.com

Tenex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30www.tenexincorporated.com

Trilogy Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19www.trilogymachinery.com

TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Voortman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18www.voortman.net

Waldemar Design & Machine . . . . . . . . . . . . . . . . . . . . . . . . 32931-946-8474

Weil Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35www.weilengineering.com

Wila . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13www.wilausa.com

Statement of Ownership,Management, and Circulation

(Required by 39 U.S.C. 3685)Publication Title: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The FABRICATOR®

Publication No.:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0568-690Filing Date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . September 22, 2020Issue Frequency:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MonthlyNo. of Issues Published Annually: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Annual Subscription Price: . . . North America-Qualifi ed Free, USA $75, All Other Countries $140Complete Mailing Address of Known O� ce of Publication:2135 Point Boulevard, Elgin, IL 60123-7956, Kane CountyComplete Mailing Address of Headquarters or General Business O� ce of Publisher:(Same as above)Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor:Publisher: Andy Flando (address same as above)Editor-in-chief: Dan Davis/FMA Communications Inc. (address same as above)Owner: FMA Communications Inc. Fabricators & Manufacturers Association, Int’l. 2135 Point Boulevard, Elgin, IL 60123-79561 Percent or More of Total Amount of Bonds: None

Extent and Nature of Circulation:

Avg. No. Copies Each Issue During Preceding

12 Months

No. Copies of Single Issue Published Nearest

to Filing Date Total No. Copies (Net Press Run) 40,983 38,553Paid and/or Requested Circulation:1. Paid/Requested Outside- County Mail Subscriptions Stated on Form 3541 38,530 36,829

2. Paid In-County Subscriptions — —3. Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other Non-USPS Paid Distribution 5 6

4. Other Classes Mailed Through the USPS — —Total Paid and/or Requested Circulation: 38,535 36,835Free/Nonrequested Circulation:1. Outside- County Mail Stated on Form 3541 (Samples, Complimentary, and Other Free) 1,066 996

2. In- County Mail Stated on Form 3541 (Samples, Complimentary, and Other Free) — —3. Distribution Through USPS by Other Classes Mail (First-Class, Package Services Rates, Other) — —4. Free Distribution Outside the Mail (Trade Shows, Showrooms, Other) 315 88Total Nonrequested Distribution 1,381 1,084Total Distribution 39,916 37,919Copies Not Distributed 1,067 634Total 40,983 38,553Percent Paid and/or Requested Circulation 96.5 97.1Requested and Paid Electronic Copies 18,426 18,624Total Requested and Paid Print Copies + Requested/Paid Electronic Copies 56,961 55,477Total Requested Copy Distribution + Requested/Paid Electronic Copies 58,342 56,561Percent Paid and/or Requested Circulation (Both Print & Electronic Copies) 97.6 98.1

72-73 DEC20FAB.indd 7272-73 DEC20FAB.indd 72 11/19/20 9:32 AM11/19/20 9:32 AM


http://www.Laser27.com

http://www.akyapakusa.com

http://www.amada.com

http://www.ati-ia.com

http://www.betenbender.com

http://www.bluco.com


http://www.carellcorp.com

http://www.e-ci.com

http://www.coletuve.com

http://www.comeq.com

http://www.diamondground.com

http://www.donaldsontorit.com

http://www.fairmontmachinery.com

http://www.eriez.com

http://www.fststeelfab.com

http://www.fmanet.org

http://www.fabtechexpo.com

http://www.faccin.com

http://www.greinerindustries.com

http://www.haeusler.com/en

http://www.hastingsair.com

http://www.heckind.net

http://www.hougen.com

http://www.hypertherm.com

http://www.ipgphotonics.com/en

http://www.kalamazooind.com/fab/

http://www.lasermech.com

http://www.lissmac-usa.com

http://www.mazakoptonics.com

http://www.mgsrl.com

http://www.midwestfinishingsystems.com

http://www.mcmachinery.com

http://www.mitusaproducts.com

http://www.paperlessparts.com

http://www.peddinghaus.com


http://www.quantummachinery.com


http://www.tjsnow.com

http://www.tenexincorporated.com

http://www.trilogymachinery.com


http://www.voortman.net

http://www.weilengineering.com

http://www.wilausa.com

http://www.mistcollectors.com

http://www.reddarc.com


http://www.skmproducts.com

http://sdtime.com/shop-floor

http://pressbrakerepair.com

NORTH AMERICA’S LARGEST METAL FORMING, FABRICATING, WELDING AND FINISHING EVENT

FABTECH provides an unparalleled opportunity to engage a captive audience of high-level decision makers. Exhibit at FABTECH to fill your sales pipeline and meet the pent-up demand of your customers.

There has never been a more critical time to come together and move the metal fabrication industry forward.

Your safety, security, and health are always our top priority. Safety protocols will follow all recommended guidelines.

Reserve your booth today.fabtechexpo.com

SEPT 13-16, 2021McCormick Place \ Chicago, IL

RESERVE YOUR

FABTECH 2021 EXHIBIT SPACE

72 DEC20FAB.indd 7372 DEC20FAB.indd 73 11/18/20 10:48 AM11/18/20 10:48 AM

http://fabtechexpo.com


By Eric Lundin, Contributing Editor

Around age 5, most of us aren’t too artistic, but some of us get a head start in creative pursuits. Metal sculptor David Madero first

learned to weld when he was a mere 5 years old. Introduced to it by his father, Madero soon came to realize that red-hot steel was an artistic medium, not unlike the modeling clay that would have been appropriate for his age. And while some parents want their children to be self-sufficient, encour-aging them to explore and learn on their own, his father took that idea to an extreme: After showing David some basic welding techniques, he provided no other instruction. Eventually he found his own way without instruction from his father or anyone else. Without the benefit of any coursework, he runs entirely on intuition.

“I don’t know how to draw and I don’t know the science behind welding,” he said. “I start with a vi-sion and I use metal to fill space.” Madero doesn’t consider himself a welder. He’s a sculptor who loves metals.

Visions and TechniquesTraditional sculptures represent people or animals, but many of Madero’s works are a bit abstract. He has the ability to make a sculpture appear to seep out of, or blend in with, its background. In one of his sculptures, a welder doing some overhead weld-ing on a pipe seems to be part of the pipe itself. In another, a skull is adorned with a beard that swirls around, forming a sort of base; the base fits neatly over a liquor bottle and the two blend together.

Madero is especially adept at making a static work appear to be dynamic. Many artists rely on

years of schooling to impart a sense of flow, but Madero pulls it off extremely well without the ben-efit of formal instruction. In many of his works, it goes beyond motion; often the exertion is palpable.

No Starving ArtistLike many top-tier artists, Madero earns a living strictly by making sculptures on commission. A ca-reer highlight occurred when representatives of the largest steel producer in Mexico asked him to sculpt the symbol of Mexico, an eagle devouring a serpent.

A work in 5 tons of steel and standing 24 ft. high, it has details that are so exquisite that they defy be-lief. The eagle doesn’t appear to be covered in feath-ers; Madero made thousands of individual feathers. Likewise, he made thousands of individual scales to cover the snake. As on an actual bird of prey, the feathers on the wings are uniform in orientation but the feathers on the legs aren’t as orderly. On the snake, the scales lie flat where the contours of the snake’s form are gentle and splay where the snake’s body is curved more aggressively.

It’s on permanent display in Mexico City near Los Pinos, which until 2018 was the presidential residence.

Building a ReputationHis reputation has grown beyond the art world. A partnership with ESAB and a subsidiary, Victor, introduced Madero to many people in the weld-ing community when they invited him to Chicago in 2019 to attend the FABTECH expo. In support of ESAB’s We Shape the Future campaign, he created a sculpture in the company’s booth to demonstrate techniques and possibilities.

“I had never visited FABTECH before,” he said. He was aware of the exposition and had thought about attending, but had never followed through. “Now I plan to never miss a show,” he said.

His reputation went so far as to get the attention of clothing manufacturer Dickies, which partners with creative types in a program called United by In-spiration, United by Dickies. Highlighting the many variations of Dickies products, the campaign stress-es the clothing’s durability, warming and cooling fabrics, and stretchy materials for people who do a lot of bending and kneeling in their vocations.

“Dickies has a lot of appeal to anyone who works with their hands, especially grinding and welding, when the sparks are flying,” Madero said.

What can come of a reputation that keeps spread-ing like Madero’s does? Certainly, he’s interested in maintaining sponsorships and a steady stream of commissions, but his social media presence and the seminars he hosts hint at something that runs deeper. Second only to welding, he enjoys teaching welding.

“It’s good for my soul,” he said. “It feeds me. I’d like to see everyone go out and make something new—not just my welding students, but every single person. Not necessarily high art, but just to do something creative.”

Contributing Editor Eric Lundin can be reached at [email protected].

David Madero, Madero/Co., maderoco.net

THE BACK PAGE

Artist brings a stunning sense of realism to sculpturesDesign skill and welding techniques impart lifelike textures, sense of motion to metal

The FABRICATOR® (ISSN 0888-0301) is published 12 times yearly by FMA Communications Inc., 2135 Point Blvd., Elgin, IL 60123. The FABRICATOR® is circulated free upon request to those who qualify and who are involved in metal fabricating; sub scription to all others is $75.00 per year. Inter national subscription is $140.00 per year. Periodical postage paid at Elgin, Illinois, and additional mailing offices. POSTMASTER: Send address change to 2135 Point Blvd, Elgin, Illinois 60123. Printed in the U.S.A. ©Copy right 2020 by FMA Communications Inc. Repro duction in whole or in part without written permission of the publisher is pro hibited.

Read more from Eric Lundin at www.thefabricator.com/author/eric-lundin

Many of artist David Madero’s sculptures are epic in scale. When finished, this sculpture of Christ’s crucifix-ion stood more than 120 ft. tall.

The implied motion of two oil rig workers, which revolves around the pipe, captures and keeps the viewer’s attention.

On the full-scale version of the Mexican coat of arms, which is on permanent display near the former presi-dential residence, Madero created textures so detailed and flawless that they defy belief.

Dec20Fab_BackPage.indd 74Dec20Fab_BackPage.indd 74 11/18/20 1:06 PM11/18/20 1:06 PM


http://maderoco.net

http://www.thefabricator.com/author/eric-lundin

Dec20Fab_BackPage.indd 75Dec20Fab_BackPage.indd 75 11/18/20 1:06 PM11/18/20 1:06 PM



http://www.faccingroup.com

TRUMPF_DropAndCut_Ad_FAB.indd 1TRUMPF_DropAndCut_Ad_FAB.indd 1 11/9/20 12:25 PM11/9/20 12:25 PMDec20Fab_BackPage.indd 76Dec20Fab_BackPage.indd 76 11/18/20 1:06 PM11/18/20 1:06 PM


■ How software can optimize connections

■ The business case for in-house cambering

■ Press brake-formed tub girders accelerate bridge replacement

DECEMBER 2020A supplement to The FABRICATOR®

Speed sparks success at

Division 5Warehousing, e-commerce boost fabricator’s growth

STEELSTEELStructural

Dec20FAB_StructuralSteel_converted.indd 1Dec20FAB_StructuralSteel_converted.indd 1 11/19/20 7:52 AM11/19/20 7:52 AM



http://www.voortmancorp.com

December 2020 Structural Steel 3

The rise of Division 5Riding the e-commerce wave, Georgia- based Division 5 has become a go-to fabricator for warehouse construction. But the boom won’t last forever.

4

Beam cambering with throughput in mindTraditional hot cambering takes hours for a single beam. The latest cambering systems shorten that time to just a few minutes.

8

Press brake-formed tub girders accelerate U.S. infrastructure rebuildingAn industry task group at West Virginia University has developed press brake-formed tub girders for short-span struc-tures. The tub girders could be formed in a factory, preassembled with a con-crete platform, and installed on-site in hours or days.

10

Structural Fabrication Product Showcase

18

Published by:

FMA Communications Inc.2135 Point Blvd.Elgin, IL 60123815-399-8700www.thefabricator.com

CONTENTS

COVER STORY

FeaturesClick, tap, swipe, fabricateWhen paired with a properly implement-ed digital platform, tablets and other devices can streamline information fl ow throughout the structural fab shop.

12

Making better connectionsAn alternative, automated approach to connection design could have profound implications for metal fabrication, erec-tion, and the construction timeline.

15

Cover photo courtesy of Division 5 Inc.

DECEMBER 2020A supplement to The FABRICATOR®

The FABRICATOR

@TheFabricator_Magazine

@Fabricating

The FABRICATOR Magazine

Connect with The FABRICATOR

Dec20FAB_StructuralSteel_TOC.indd 3Dec20FAB_StructuralSteel_TOC.indd 3 11/19/20 9:12 AM11/19/20 9:12 AM


http://www.soitaabusa.com


4 Structural Steel December 2020

By Tim Heston

Bryan Hill and Rhonda Wylie, brother and sister, grew up in the Atlanta region’s structural steel business, not in fabrication but in erection. Their father owned a local

steel erector, and from the early 1980s the two witnessed the erection business in action. They knew all about erection aids, how expensive fi eld fabricating and welding was, and that some of it would have probably been far less expensive if done at the structural fabricator.

So when a local fab shop closed its doors in 2000 and two managers from that company approached the siblings about

launching a structural fabricator, they jumped at the chance. They called their new business Division 5, after the “Division 05 - Metals” section of the Construction Specifi cations Institute’s building construction standards manual that accompanies commercial construction projects.

“We were surprised the name wasn’t already taken,” Hill said. CSI’s 50 Divisions spec standard, in which metals is the fi fth, is

often referred to as the Dewey Decimal System of construction, giving the industry a standard format to clarify and streamline communications. Growing up in steel erection, the Hills saw fi rsthand how expensive miscommunication could be. More than that, a lack of communication can keep unrealized savings forever hidden, not just for the structural fabricator, but for the entire construction supply chain.

“In this business, speed is everything,” Hill said—and not just speed through the fab shop, but throughout the entire value chain, from engineering and detailing to fabrication to steel erection.

At one Southeast fabricator, speed is everything

EYEBROW

The rise of

Division 5

Dec20SS_Division5.indd 4Dec20SS_Division5.indd 4 11/19/20 8:37 AM11/19/20 8:37 AM


From Brick-and-Mortar Retail to E-CommerceWhen Division 5 launched in 2001, starting with a small loan from their father, the siblings—Hill as CEO and Wylie as CFO—won work by building on prior relationships with general con-tractors and detailers in the Southeast. They started out of a 12,000-sq.-ft. facility in Winston, Ga., west of the city, and in 2004 moved into a 30,000-sq.-ft. plant 2 miles away.

Brick-and-mortar retail comprised a large portion of the fab-ricator’s work, but then came the economic downturn, which hit Division 5 hardest in 2010. Retail work declined and the com-pany needed to shift gears. Atlanta wouldn’t exist without the railroad, which in turn gave birth to the city’s logistics industry. And without warehouses, the logistics business couldn’t exist either. Neither could e-commerce, a sector that has played a central role in Division 5’s growth over the past 10 years.

Serving the warehouse market is unique in structural fabrica-tion, mainly because of the sheer tonnage of material that must depart Division 5’s shipping dock in a short period. “A typical million-square-foot facility might take six months [to be con-structed],” Hill said. “For a million-square-foot warehouse, you need to deliver the steel in three weeks.”

Again, speed is the name of the game, and over the years Division 5 has boosted its throughput in several ways. It has of course boosted its technology investment, most recently purchasing a plasma cutting, drilling, and coping center. It also brought detailing in-house, a change that in retrospect has had the greatest impact on the shop’s throughput. A new machine can shave hours off a cycle time, but a fine-tuned in-house detailing operation can shave days or even weeks off overall delivery time.

“In 2010 we found that we were spending a few million dol-lars a year in outsourced detailing,” said Wylie. “Today we have a team of 12 detailers. We tell them exactly what we want for fabrication and erection.”

She added that this complements the company’s close rela-tionship with project engineers and general contractors. “We’ve built relationships with engineers since 2001. We generally don’t have delays because of RFIs [request for information], but if we do have a question about something, we pick up the phone to get an answer. We may sell a job today and deliver it in five weeks. A lot of time we get work that way, simply because others say they can’t do it.”

According to Hill, Division 5 makes quick delivery happen with several strategies. First is reduced material handling. Au-tomation plays a role, but so does the company’s approach to cross-training and the placement of welding stations. When a beam that requires welding emerges from the line, it doesn’t need to be carried to a separate welding station but instead is welded on the same line. Also, many who weld also fit, and vice versa, depending on the station in the shop.

“And yes, we spend a few more dollars an hour in fitting and welding,” Hill said. “But the cost savings achieved through re-duced handling blows the additional labor costs out of the water.”

The company also has a proprietary line dedicated to hol-low structural sections, designed in-house by Mark Buchanan, the GM of the company’s plant in Tallapoosa, Ga., and Chris Gravett, Division 5’s operations manager. “There’s no off-the-shelf equipment either,” Hill said. “They designed it from the ground up.”

The resulting increased throughput reduced the company’s costs to the point where it can look at the big picture and do what’s best for the overall project, not just the fab shop. One prime example comes from Division 5’s work with Walgreens. Next time you visit the pharmacy, look up, and you might see a steel canopy 12 or 14 ft. wide spanning over the front door.

“When I started in this business, we did a lot of Walgreens work in which we sent the canopy out in pieces,” Hill recalled. “We now build it all in the shop. It used to take erectors two or three days. Now it takes them three hours.”

Sure, proposing in-shop fabrication might require approval, and Division 5 might even have to subcontract with a connec-tion engineer to design the best connections and get approval

Last year Division 5 invested in a plasma center for automated cut-ting, drilling, and coping of structural beams.



from the engineer of record. And trans-porting the canopy fabrication in one piece might require extra permitting, which of course isn’t free. But compare those costs to that of on-site field work over several days, and the decision be-comes a no-brainer.

Weld splices are another example of how Division 5 maintains constant com-munication with the erector. “I remem-ber when I was an erector, before I was a fabricator, the drawings called for field welds, field welds, and more field welds,” Hill said. “We have a different mindset here. No matter who’s the erector, as a fabricator I know for a fact that welding in the shop is less expensive than weld-ing on-site.”

Scaling UpIn 2018 representatives from New York-based investment and consulting firm Applied Value Group traveled to Atlan-ta to perform some due diligence—and were impressed. “They saw how we’ve

been putting money back into the busi-ness for years,” Wylie said.

At that time Division 5 had two plants in Georgia, one in Winston and anoth-er in Tallapoosa. It had gained a strong presence in the warehousing sector, and for years it had worked to shorten lead times and increase throughput.

Earlier that year one of the siblings’ original business partners had died, so the siblings dipped their toes into the M&A market to see who the potential buyers were. “Bryan and I had numerous

offers on the business that we turned down,” Wylie said, adding that they could see a lot of investment firms were inter-ested in “flipping the business quickly.

“We had no intention of selling the busi-ness and walking away,” Wylie continued. “We wanted to have someone onboard who could give us the strong financial backing, to help us grow to be one of the larger structural fabricators in the U.S.”

They found that in Applied Value, an investment firm that also does a significant amount of consulting work on the buy side (such as OEMs) of the metals business. “We as a firm have a lot of experience in the metals industry,” said Max Sultan, Applied Value’s lead director for Division 5. “We were interested in Division 5 because of its market focus … With the boom of e-commerce, distribution and warehousing are growing incredibly fast. That’s where the initial interest came from. When Applied Value purchased Division 5, e-commerce represented about 15% of all retail. Now

The e-commerce boom is likely to continue for years, but it won’t go on forever. Photo courtesy of Getty Images.

For the foreseeable future, Division 5’s strategy remains unchanged: Consider overall costs throughout the construction value chain, maintain a cross-trained workforce, and, not least, keep an unrelenting focus on throughput.



that number is closer to 20%, depending on the source you read. Regardless, the projection is that by 2030 e-commerce will be closer to 40% of all retail.”

Since Applied Value’s purchase in No-vember 2018, the fabricator has ramped up its capital equipment investment. It’s also tapped into Applied Value’s purchas-ing expertise. Most significant, Applied Value has given the organization the capital it needs to expand its footprint in the Southeast. In July 2020 it purchased Structural Steel of Carolina (SSC) based in Winston-Salem, N.C.

Today the combined organization has more than 350 employees and 350,000 sq. ft. under roof with the capacity to process more than 75,000 tons of steel a year. The acquisition also broadened its end market—a sign that the siblings aren’t just riding high on the warehouse boom driven by e-commerce.

And a boom it has been. One of Divi-sion 5’s most recent projects is the almost 700,000-sq.-ft. Amazon fulfillment center in Stone Mountain, Ga., east of Atlanta.

The company provided only the mis-cellaneous steel for the project, but regardless, the size of the facility puts things in perspective. Two decades ago, 700,000 sq. ft. would have been con-sidered a massive warehouse. Now it’s midsized.

“Back in the 1990s, a 300,00-sq.-ft. warehouse seemed huge,” Hill said. “Now, that’s what we consider a small building. We’re fabricating steel for facil-ities that are 1, 2, even 3 million sq. ft.”

The boom has boosted growth even through the pandemic. “We really have not missed a beat in 2020,” Wylie said. “We of course put safety and cleaning protocols in place early. Sales-wise, we’ve met or beaten our goal every quarter.”

“We don’t publicize our growth num-bers,” Sultan said, “but we’ve continued to see growth and increased volumes of bids in the market, and we continue to see bigger and bigger projects coming to market. There was initial uncertainty [with the lockdown] earlier this year, but

we couldn’t see any underlying damage to the underlying market.”

Still, all booms must end, a fact that was top of mind when bringing SSC into the fold. “We didn’t want another fab-ricator that did what we do,” Hill said. “We have the warehouse market. E-com-merce is exploding and the expansion will be there for several more years, but it’s not going to last forever. We needed to diversify.”

Unlike Division 5, SSC focuses on gov-ernment work, including schools and po-lice stations, as well as health care facili-ties. “It’s diversifying our overall portfolio of work,” Wylie said.

Considering Hill and Wylie’s history in the erection business, would Applied Val-ue and Division 5 consider purchasing a steel erector? “No, we’ll keep the fab-rication and erection separate,” Hill said, who added that although he knows a few large fabricators with successful erection

divisions, “I’ve also seen putting fabrica-tion and erection under one umbrella fail. Those who work in the field are just entirely different kind of people.”

Besides the cultural differences be-tween the two types of companies, Hill said that the demand for speed has pushed the industry toward more spe-cialization. “There are many erectors that can put steel up, but there are not a lot of erectors that can put steel up as fast as it needs to be done now.”

So for the foreseeable future, Division 5’s strategy remains unchanged: Consid-er overall costs throughout the construc-tion value chain, maintain a cross-trained workforce, and, not least, keep an unre-lenting focus on throughput.


Division 5 Inc., www.division5inc.com

Applied Value Group, www.appliedvaluegroup.com



http://www.division5inc.com

http://www.appliedvaluegroup.com


http://walkermagnet.com


By Tim Heston

Because gravity works, there will always be a need for beam cambering. Walk on a floor of poured concrete, and it’s highly likely the beams underneath have been

cambered to counteract deflection under load. Roof beams can require cambering as well. In fact, unlike floor beams, which usually have a single camber point, roof beams can re-quire multiple points of camber. And some beams need to be cambered in specific ways to meet cosmetic requirements.

Beam cambering has always had a black magic quality to it, originating from the days when skilled fabricators wielded a rosebud torch back and forth in a careful pattern along the web to make the beam bend under its own weight. It required time, seriously experienced talent, and a lot of consumables—hence the growing dominance of another method: cold cambering.

Hot cambering still has a place for light, narrow beams with short web sections, as well as other beam geometries highly susceptible to crimping. Otherwise, most perform some type of cold cambering.

So who does the cambering within the construction value chain? As with so many processes in the fab shop, this depends on the volume of cambered beams fabricators process, the available talent, and the technology on the floor.

“There’s a lot of know-how that goes into beam cambering, especially if an operation doesn’t have someone dedicated to the task day in and day out,” said Ben Morrall, vice president of sales at Voortman USA, Monee, Ill. “This is why some structural fabricators lean on the service center.”

This makes sense in some supply chains. A structural fab shop might not have the volume that calls for someone to camber beams all day, every day on a dedicated machine, but a service center might. And cambering all day, every day is a good way to develop talent for what remains a subtle process. Beams bend differently depending on their web width, web thickness, and flange dimensions. They also form the hard way, on their wid-est and strongest axis. Springback and other forming charac-teristics can vary from beam to beam, especially if those beams come from different mills or heats. Bend too hard or position the beam incorrectly and the web can buckle.

One challenge with cambering lies in the handling require-ments. Sure, material handling isn’t really an issue with hot cambering. As a portion of the overall process time, the crane time is inconsequential.

But cold cambering changes the situation. If you consider the overall cycle of a cold cambering operation, much of that time involves tying up a crane, transporting the beam to and from the machine, as well as positioning the beam in the ma-chine itself.

Again, this might not be an issue if, say, a service center uses cranes to move a beam in and out of inventory anyway. But as Morrall explained, automation has changed the way beams move on the floor, particularly at the structural fabricator. To-day some shops minimize crane picks by sending a beam down conveyor systems through cutting, drilling, coping, and other

Beam cambering with throughput in mindHow to camber while keeping the flow

TECH SPOTLIGHT

A technician verifies the dimension of a cambered beam.

A cambering station (on the right) can be integrated into a broader automated line. The material handling strategy hinges on, among other factors, available floor space and the volume and variety of beam dimensions requiring cambering.

Dec20SS_TechSpotlight_Voortman.indd 8Dec20SS_TechSpotlight_Voortman.indd 8 11/19/20 8:43 AM11/19/20 8:43 AM


processes before it’s picked and moved to final fabrication or shipping. It’s about beam velocity, and another crane pick to the cambering machine can slow things down significantly.

“Say you have a stand-alone unit that’s not connected to your main processing line,” Morrall said. “You might have a staging area where you stack beams that go to this stand-alone unit. So you need to pick a beam from the line to the staging area, then pick it again to load the machine. At best, this can require three or four extra pickups of a product. All that material han-dling can be expensive.”

Beam velocity underlies Voortman’s approach to cambering, Morrall said. Instead of relying on a crane, the company’s cam-bering system uses a roller conveyor to feed beams into posi-tion. A single hydraulic cylinder secures the beam against two movable load points with ridges on top that hold the beam in place during the cambering cycle. From there, the cylinder push-es the beam to a reaction point—that is, the point at which the beam is bent before it springs back to a certain position (similar to the pre-springback “bent angle” made by a press brake ram).

“For the first piece [in a heat or lot], if it reacts the way we think it will, you can get it right the first time,” Morrall said. “If it falls short, you’ll need to bump it a little further. But the machine will remember that reaction point, so on the second beam, it will push the beam to that correct point every time.

“The machine has a system that measures where it pushes to,” Morrall continued, “and as [the beam] reacts back in the oppo-site direction, it measures where it reacted to. It knows what the difference is, and it will push further automatically after that.”

Regarding overall cambering time, especially when convey-ors allow beams to roll into and out of the process, Morrall said the machine can camber a beam every two or three minutes. He added that the quick cambering cycle time, though benefi-cial, is only part of the story. The goal is to increase the overall beam velocity from one end of the shop to the other, and that comes through automated material handling.

“Once you’ve told [the automation] what beams are on the infeed, whether it’s one or six machines connected together, the system automatically distributes the material from one ma-chine to the next throughout the total process. So near the end of the total process—after [being] shotblasted, drilled, sawed, coped, and marked—the beam gets to the cambering machine. At that point the system can automatically deliver beams that need to be cambered to the cambering station. Then anything that doesn’t need to be cambered goes to the other outfeed locations to get sent to fabrication.”

Such throughput, Morrall said, increases the business case for in-house cambering in structural fabrication. “Cambering doesn’t need to be a costly process that fabricators simply have to do as part of a job. Instead, it can be a money-maker.”


Voortman USA, www.voortman.net

Dec20SS_TechSpotlight_Voortman.indd 9Dec20SS_TechSpotlight_Voortman.indd 9 11/19/20 12:45 PM11/19/20 12:45 PM







By Kate Bachman

Editor’s Note: This article is based on a presentation at the 2019 AISC World Steel Bridge Symposium, St. Louis, April 3, 2019.

It’s no secret that America’s infrastruc-ture is due for a replacement. When the I-35 Mississippi River Bridge in

Minneapolis collapsed in 2007, killing 13 people, the whole country took notice.

Two years later the American Recovery and Reinvestment Act included nearly $50 billion in funding for transportation infra-structure to support needed repairs and long-term transformative investments.

According to the Bureau of Transporta-tion Statistics, there were more than 617, 000 bridges in 2019 in the U.S. and only 279,582—44%—are in good condition.

Time is of the essence. Almost four in 10 are 50 years or older, according to the American Society of Civil Engineers (ASCE) 2017 statement.

Chief Economist Dr. Alison Premo Black of the American Road & Transportation Builders Association (ARTBA) said, “At the current pace, it would take more than 50 years to repair America’s structurally de-fi cient bridges.”

Press Brake Forming to the Rescue of Short-span Bridges “The greatest need is in the short-span category of 140 ft. or less,” said Dr. Karl Barth, West Virginia University, Dept. of Civil and Environmental Engineering, adding that nearly half of structural-ly defi cient bridges fall in the short-span category. A short-span bridge is defi ned as a bridge that is the distance between two intermediate supports shorter than 140 ft.

Seeking new, better, faster, cheaper ways of replacing bridges to help ad-dress the U.S. infrastructure crisis, IDOT issued a challenge for the development of a viable, economical solution to re-placing the aging bridge infrastructure for short-span structures of up to 80 ft.

Design Methodology Replaces Welding With Brake Bending“We were tasked by the federal highway department to develop systems for the acceleration of short-span bridge con-struction that would be economical,” Barth said. “The goal was to use stan-dard, commonly available plate widths of 84 in., 96 in., and so forth.” The pro-cess also had to be compatible with mass production to avoid the costs of customization.

What is the system? It’s simply a straightforward steel tub girder with a precast concrete deck—with a twist.

“We wound up with a standard steel trapezoidal box but we fabricated it from press brake bending rather than conventional welding,” Barth said. “Fea-tures for the short-span can be pro-duced in about 30 to 40 minutes using press brake forming.”

The girder type is the common U.S. trapezoidal girder slope ratio of 1-4 on the edges, with a 5T bend radius, Barth explained. “We fi gured we didn’t need much compression on the fl ange. We held them at 6 in. wide. We just needed enough to hold the studs until we got the deck on there.”

The press brake-formed plate tub gird-er (PBFTG) is galvanized to extend life and is then topped with a concrete deck. “Our standard is to hot-dip galvanize them inside and out to provide 60-plus years of protection.

“It’s not hugely innovative. But it’s made in a means that can be economical in the short-span market. Bigger, more compli-cated bridge geometries with closed sec-tioned tubs have a very ideal geometry for welding applications. The problem is that you can’t scale that technology down economically to the 40-, 60-, 80-ft. short-span bridge market,” Barth concluded.

The module can be preassembled or fi eld-assembled. Modules are joined using ultrahigh-performance concrete (UHPC) longitudinal closure pours.

Press brake-formed tub girders accelerate U.S. infrastructure rebuildingPBFTGs put the brakes on collapsing bridges

West Virginia University researchers began with the form of a typical welded trapezoidal box but fabricated it via press brake bending to save cost and time. Fabrication was performed by Greiner Industries. Photo courtesy of the Short Span Bridge Alliance.

Dec20FAB_StructuralSteel_Bridge.indd 10Dec20FAB_StructuralSteel_Bridge.indd 10 11/19/20 8:47 AM11/19/20 8:47 AM


Fabrication Performed on 40-ft.-long Press BrakeDuring the research phase, the press brake bending was performed by Greiner Industries, Mount Joy, Pa. The fabricator formed the tub’s bends on a 2,750-ton, 40-ft.-long Baykal brake press, which it already had, and then purchased exten-sion tooling for the job.

The manufacturer also has a 26-ft. and 34-ft. brake that can be used together to bend 60 ft. of ¾-in.-thick plate, but it used the 40-footer because it offered a number of advantages for the 40-ft. bridge span.

The bed opening can be adjusted from 3 to 17 in. “We can bend up to 11/4-in.-thick plate the whole 40 ft.,” relayed Roll-ing and Forming Division Manager Bruce Sine. “Because it’s a single machine, we have the whole press available.”

The press brake also accommodated the multiple bends required to form the tub. “Once you get into multiple bends it gets interesting, because if you have flanges, you have to flip it over to bend those, and you have to have enough room to be able to get to the second bend without hitting anything else,” Sine said. “When you use tandem presses, depending on the throat of it, it can hit the back frame, so you wouldn’t be able to bend long legs on it. With the 40-foot-

er, we have 2 ft. of clearance, so we have plenty of clearance to bend the flanges.

“Having a single press brake with the tonnage that we had was an advantage,” Sine said.

Greiner also installed a laser light alignment tool that points to the interior bend target. “We wanted to make sure that the piece was completely aligned with the punches. That way you have a true measurement as to where you want to bend. It’s a lot more precise than a tape measure.”

The press brake is equipped with me-chanical crowning adjustments in the bed of the machine. “Crowning’s not a

problem; you just adjust the bed for that and it comes out pretty nice. And you ac-tually can adjust the Y1 and Y2 axis if one side is hitting harder than the other.”

Sine said that overall, the job was not too hard. “Once it was dialed in, it went rather easily.”

Testing Shows the PBFTG Holds Up The research team performed extensive fatigue testing of the girders to compute their yield capacities at various plate thicknesses. The team used an 84-in.-wide by 7/16-in. plate (50- and 79-KSI) steel for a host of tests for research at the university. “That is the biggest girder we could build and test to failure with our 330-kp actuator to evaluate load-carry-ing capacity,” Barth said.

The testing showed the “sweet spot” at each plate thickness (7/16 in., ½ in., 5/8 in.) and widths (60 in. through 120 in. long). The depths they finalized on are the depths of the girder superstructure after validating the capacity of the girders. For spans up to 60 ft., ½-in. plate works. For longer spans up to 80 ft., 5/8-in.-thick plate is required.

Editor’s Note: To view case studies of the PBFTG in action, read this article online at www.thefabricator.com.

Contributing Editor Kate Bachman can be reached at [email protected].

Short Span Steel Bridge Alliance, www.shortspansteelbridges.org

A plate is marked out, then two bends are made in a press brake to create the flanges (up-per left). The plate is then rotated and two more bends are made into the web. The process takes only 30 to 40 minutes rather than the several hours required to weld the flanges for a tub and girder system. In the upper right, shear studs are installed. During the develop-ment stage, the concrete deck was formed up and cast in the lab.

West Virginia University researchers began with the form of a typical welded trapezoidal box but fabricated it via press brake bending to save cost and time. Fabrication was performed by Greiner Industries. Photo courtesy of the Short Span Bridge Alliance.

In Muskingum County, Ohio., a modular PBFTG superstructure was brought to the site and installed as a sandwich plate deck in 20 minutes.

Dec20FAB_StructuralSteel_Bridge.indd 11Dec20FAB_StructuralSteel_Bridge.indd 11 11/19/20 9:55 AM11/19/20 9:55 AM



http://www.shortspansteelbridges.org



By Ryan Vander Plaats

Imagine it’s a cold winter day and you’ve just arrived at work. You ha-ven’t had nearly enough coffee. You

sit down at your computer and, sure enough, you received an email over-night about revised drawings. Panic sets in as questions begin to fly through your mind. Are those now out-of-date draw-ings in the shop? Of course they are. How many copies are there? Are we fab-ricating yet?

The lack of coffee prevents your brain from processing fast enough, but the plan begins to formulate. A quick call sends the shop supervisor on a mad dash to find the drawings in the shop. Next, you print the revised drawings, but, of course, you always have trouble print-ing when you’re in a hurry. After all the chaos, you finally have the drawings.

You head to the shop and talk with the shop supervisor who is trying to locate the last drawing. It isn’t at the workta-ble where the piece is being fabricated. Did it blow off under a rack somewhere? After tearing the shop apart, you final-ly locate the drawing in the fabricator’s toolbox (he happened to be out sick that day). With all of the drawings replaced (finally), you return to your desk for a second cup of coffee.

If this sounds familiar, you aren’t alone. This scenario plays out frequently in fab-rication shops around the world, and it’s one reason fabricators move from dis-connected, manual processes to tablets. While tablets are a step in the right di-rection, it’s important to remember that they are essentially a vessel for commu-nication. Minimizing chaos and driving productivity in the shop also require a single source where up-to-date informa-tion can be stored, accessed, and shared.

A Single Source of Real-time Information To effectively use tablets, you first need a steel fabrication information manage-ment platform that ensures everyone in the organization is viewing the same information in real time. With this, users on the shop floor can connect to the plat-form via a tablet or mobile device to view work orders and cut lists, as well as up-date production status throughout their shift. This continuous, real-time flow of information allows for better produc-tion planning and optimized schedules, informed decision-making, and higher productivity.

Again, tablets are just a vessel for in-formation, one among many that em-ployees use to access information, includ-ing mobile phones, laptops, and desktop computers. All these devices should have access to an information platform with an open interface designed to interact and exchange data with various other software systems and industry technol-ogies. The platform should also be able to share status information with those upstream and downstream from the pro-duction team. This will allow you to col-laborate with other project stakeholders who could be using a different software platform.

Click, tap, swipe, fabricateHow tablets are changing structural fabrication

Dec20FABSS_Tablets.indd 12Dec20FABSS_Tablets.indd 12 11/19/20 9:59 AM11/19/20 9:59 AM


Be sure to establish processes to pre-vent information bottlenecks as you and your employees adjust to this new way of working. This starts with an openness to making slight variations on how informa-tion is communicated between the shop floor and front office. A process that’s too rigid or a mindset of “it’s always been this way; make the software app do that” can prevent you from making a big leap forward. This is analogous to the own-er of an old horse and buggy who is in-troduced to a car and responds, “This is great, but how do I hook up my horses?” A willingness to replace old processes will lead to more efficient ways of working.

Purchasing and Protecting Tablets When it comes to purchasing tablets, keep these considerations in mind:

Cost. Tablets can cost anywhere from $80 for an Amazon Fire tablet to $500 for an iPad. The tablet you choose de-pends on the platform you use. For ex-ample, platforms accessed through a web browser don’t require an incredibly powerful tablet.

Protection. The price for protective covers can be as little as $15 or as much as $130. Ricky Horton, president of Fabri-cation Information Systems, an industry consultancy, advises, “In my experience, you don’t need to spend a lot of money on a cover because most of the damage to a tablet you will see in a shop is going to involve cracked screens.” Damage to tablets is typically caused by something being dropped directly on the screen, and most covers aren’t going to prevent this from happening.

“I’ve also seen a fabricator leave the tablet on the bucks and roll a beam over on top of it,” he said. “The best protection is a mounting place on a toolbox that en-courages the fabricator to move the tab-let out of harm’s way when it’s not in use.”

A fabricator might assume that tab-lets will be thrown around and need replacing within the first year. Under-standably, putting electronics in the same vicinity as beams and welders can

be a scary proposition. “At one point I was utilizing approximately 40 iPads in a shop and, on average, five of them required replacing screens any given month,” said Horton. “At $150 each, the cost added up, so we replaced the iPads with Amazon Fire tablets that only cost $80 each. Employees were provided with a tablet as their personal property; they each signed an agreement that stated the tablet was required for their work, and they were responsible for having it in the shop every day.”

This approach can give employees a sense of personal responsibility and ac-countability. “The employees were mo-tivated to take care of the tablets, and it was also a great recruiting tool to tell prospective employees they would re-ceive a personal tablet on their first day of work,” Horton said.

Connectivity. To use a tablet in the shop, it will need to be connected to your Wi-Fi network. The cost of this depends greatly on your needs. How many ac-cess points do you need? What kind of hardware do you need to purchase? How much bandwidth do you need?

Horton suggests doing your research. “You can needlessly spend a lot of mon-ey if you aren’t careful. Invest in a system

that meets your needs today and can scale as your company grows.”

Restrict tablets from accessing any-thing other than sites or tools needed for work. Not only will this keep the fabrica-tor’s mind on the job, but will also lower the overall bandwidth required.

Training. Implementation and get-ting up to speed will greatly depend on the platform you use to provide data to employees. The biggest barrier to utiliza-tion of the tablets is fear. Those who are new to using technology may be intimi-dated by the tablets. Fortunately, most fabricators today are familiar with smart-phones, so the tablet is very natural for most, especially when they experience the benefits.

Connected Fabrication With a single source of information; new processes in place; and employees using tablets to capture, share, and access in-formation in real time, you’ll eliminate the frenzied morning that began this ar-ticle. Instead of running around the shop to locate drawings, you’ll be able to view the latest version instantaneously, and the old version will no longer be acces-sible on the shop floor. This will reduce rework by eliminating the risk of working off of an old drawing.

Dec20FABSS_Tablets.indd 13Dec20FABSS_Tablets.indd 13 11/19/20 9:59 AM11/19/20 9:59 AM


Additionally, the worker on the shop floor would be able to reference the drawing or assembly in the context of the 3D model from a tablet or a com-puter. Access to this 3D model can often answer questions immediately, such as about missing dimensions or framing context, many of which would have cre-ated a work stoppage previously as the shop waited to hear from the detailer.

Not only can you access drawings, you can also receive materials into inventory, confirm cutting patterns from nesting to keep inventory up to date, track produc-tion progress, perform quality inspec-tions, and load trucks.

You’ll receive material into inventory as it comes off the truck and with automatic reporting, and the production manager knows when material hits the yard.

Material will be removed from in-ventory immediately following the cut process and the remnant automati-cally placed back into inventory. When

someone asks, “Where is that W14×22 in the yard?” you can pull up inventory on the tablet and quickly show its exact location.

Tracking production in real time allows for up-to-the-minute decisions such as whether to work overtime on a given week. When an engineer calls to say he is considering a change, you can pull up production status, see if the piece has been fabricated, and quickly make an in-formed decision about next steps.

Using a tablet when inspecting work brings information that traditionally ex-isted only in a paper form into a much

more usable format. Now you can see the overall performance of your shop from a quality assurance perspective and under-stand where you may have issues that are creating nonconforming assemblies.

Finally, the ability to ship via the tablet, whether from preplanned loads or loads on-the-fly, creates a streamlined process that reflects what is actually happening in the fabrication yard.

Real-time fabrication management and bringing tablets to the shop can be a game-changer and open the door to the speed and accuracy you’ll need to com-pete and stay profitable in today’s mar-ket. And it might give you enough time to enjoy a first and second cup of coffee.

Ryan Vander Plaats is product manager for management information systems at Trimble, Structures Division, 1075 Big Shanty Road NW, Kennesaw, GA 30144, 770-426-5105, www.trimble.com, www.tekla.com.

Fabrication Information Systems, www.fabricationis.com

A process that’s too rigid or a mindset of “it’s always been this way; make the software app do that” can prevent you from making a big leap forward.

Dec20FABSS_Tablets.indd 14Dec20FABSS_Tablets.indd 14 11/19/20 12:18 PM11/19/20 12:18 PM

http://www.trimble.com

http://www.tekla.com

http://www.fabricationis.com

http://www.trimble.com

http://www.obriensteel.com


By Tim Heston

As a longtime detailer, Henry Lederman knew the drill. Most structural fabricators had stan-

dards that defi ned the way they did things. Some were ¾-in. bolt shops that liked to use double-angle connections. Others preferred shear plates. And ev-eryone abided by industry-standard 3-in. vertical spacing for the bolts.

The fab shops would turn those stan-dards over to the detailing fi rm and con-nection engineers, who would design connections based on those standards and historical practices. When everyone signed off , the drawing would be re-

leased and it was off to the races, with ev-eryone aiming to eke out the most profi t while fulfi lling the owner’s need to com-plete the building as quickly as possible.

“It’s as if everyone is jumping into a fast-moving river,” Lederman said. “They go up for air now and then, but for the most part, they don’t have time to breathe. They don’t have time to plan and to get the data in a form that can re-ally help make decisions that are best for the company and the project.”

A lot of that data lies hidden forev-er, especially within a part of structural fabrication that literally ties everything together: the connections. But what if connection engineers could iterate their designs in an effi cient way, to explore all

the connection possibilities? What eff ect would that have on the value stream of the entire project as it fl ows from engi-neering and detailing to fabrication and erection?

From this sprung the idea behind Qnect. Founded in 2013, the company has developed a cloud-based analytics software that eff ectively automates con-nection design. According to the compa-ny, having the ability to iterate millionsof connection possibilities has signifi cant implications for the entire structural steel arena.

A Fast-moving RiverIndustrial and precision metal fabrica-tors serving OEMs and general industry know the benefi ts of designing for man-ufacturability. Most fab shops would agree that the more input they get on a product’s design, the more effi cient the actual fabrication is likely to be. It’s bet-ter to fi x something in the design stage rather than being forced to “make it work” on the fab shop fl oor.

Structural fabricators face similar chal-lenges, which is why they’ve developed standards. A fabricator that defi nes it-self as a “¾-in. bolted shop” has built all its fabrication processes around those kinds of connections. The connection en-gineers have their own standards, too, because, like the structural fabricator, standards streamline things. Sure, engi-

Making better connectionsSoftware optimizes connection design through data analytics

TECH SPOTLIGHT This design uses bolt optimizations to re-duce bolt quantities, which can reduce costs and erection time.

An extended shear plate eliminates beam copes and optimizes bolt spacing.

Dec20SS_TechSpotlight.indd 15Dec20SS_TechSpotlight.indd 15 11/19/20 9:08 AM11/19/20 9:08 AM


neers could iterate connection designs, but doing so takes time, with umpteen calculations to ensure loading require-ments are met, all while ensuring the new designs abide by industry stan-dards, like those from the American In-stitute of Steel Construction (AISC).

“All this just didn’t seem like a good system where you have all these dis-crete parts [of the project value chain] acting as their own profi t centers,” said Lederman, Qnect’s co-founder and chief strategy offi cer. “The detailer is a profi t center, and so is the connection engi-neer, the fabricator, and the erector. And they don’t always work in each other’s best interest.”

If a project is a fast-fl owing river, the best way to change how it fl ows is at the headwaters where, in the world of struc-tural steel construction, the detailers and connection engineers work. Of course, to truly change the headwaters, you’d need to allow connection engineers to comb through millions of connection iterations to fi nd not just the right connection for a single vertical brace, but the right combi-nation of connections for an entire build-ing—a combination that would benefi t not only the building’s design require-ments but also the structural fabricator and erector. This would have been a quix-otic endeavor a few decades ago, back when the industry lacked something that would make such an endeavor practical: computing power.

“For a vertical brace, we iterate over a billion possibilities to determine what the best connection is,” Lederman said. “You need serious computing power to run so many calculations. It doesn’t help to do those billion calculations if you have to wait a week. This is where cloud comput-ing comes into play. We’re working with Amazon Web Services, which allows us to use as many or as few computers we need for a particular job.

“Now, if detailers and fabricators say they need about six weeks to do the con-nection engineering and modeling, the These skewed connections, designed to take heavy loads, require no coping.

software can do it in about an hour. If it takes them six months to engineer and detail, the software has been able to do such a project in about three hours.”

Connection engineers still need to re-view the results, of course. The entire process still requires human interven-tion, and it always will. “All the engineer-ing has to be PE stamped by a connection engineer,” Lederman explained. “Also, ev-ery Qnect joint is consistent, defi ned by all the limit states of the AISC codes.”

Shortly after launching in 2013, the company tested its software through peer review. As Lederman recalled, “We received many positive comments. But we had a few cases in which connection engineers challenged us, only to fi nd out we had a more refi ned approach to the connection.”

Optimized ConnectionsUsing software that iterates design con-nections automatically, simultaneously ensuring connections adhere to load re-quirements—all while following a base-line of AISC standards—the connection engineer now can off er options upfront, at the headwaters of the project.

Lederman fi rst gave a simple example: changing the 3-in. vertical bolt spacing. “It’s a basic requirement and recom-mended practice that the connection ba-sically needs to be half the depth of the beam. But in order for it to be half the

depth, and if you’re using 3-in. spacing, you might have to add a couple more bolts. If you simply designed the bolted connection with a 4-in. spacing, you’d solve the problem.” Fewer bolts lead to less drilling, a lot less erection time, and fewer bolt-related injuries.

The right connection strategy also can help reduce fabrication costs by allowing for single-station fabrication: that is, the fab shop needn’t tie up a bridge crane to move a beam to another station, like from the beam line to welding. The soft-ware color-codes members to help the connection engineer identify the num-ber of required workstations. One color might signify members that need only go to the punch and drill line (a single-sta-tion fabrication), while another color shows components that go through the beam line plus welding (a two-station fabrication).

“Say you have a welded shear plate [requiring the welding station],” Leder-man said. “You might try a single-angle bolted-bolted connection.” That simple connection change eliminates costly material movement on the fl oor.



Still, just swapping out a connection may or may not make sense, mainly be-cause of the give-and-take nature of the construction value chain. A small savings in fabrication can lead to serious cost overruns in erection due to more on-site bolting, welding, insuffi cient erector aids—the list goes on.

This is why early data analytics and the computing power behind it are so important. “No matter the building’s size, the software iterates connections for the entire structure,” Lederman said. “It will try diff erent bolt diameters. It will try single-angle connections, shear plate connections, extended shear plate connections, double-angle welded connections, bolted double angles, and more. It will then output a report, with the cost and bolt quantities, so fabricators can do an analysis of what joint confi guration makes the most sense for the entire project.”

The ability to weigh all the trade-off s has far-reaching implications. Consider a job that requires hundreds of copes, a costly operation for a structural fabri-cator that copes manually. “But the only way to get rid of coped beams is to use a welded extended shear plate,” Leder-man said, “where the plate is pulled out of the girder. But when you do that, it can get more expensive. You might need more columns of bolts [in a connection], or the plates might get so thick that you need double-pass welds.” With so many unknowns, connection engineers take the conventional route, keep the coping requirement, and use conventional shear plate connections.

Data analytics, however, changes this situation. “You can do this data analysis in estimating. With software, you can run the entire building with extended shear plates, and it will show the exact plate thickness, the number of bolts, the weld sizes,” Lederman explained. “With this early data, everyone can make a decision regarding the trade-off between elimi-nating hundreds of copes versus using extended shear plates.”

If the software shows that extended shear plates are indeed possible and ef-fi cient, the erector’s job becomes much easier. “If you have extended shear plate connections, that’s the fastest erection for any erector, which means they can do more picks in less time. And if you have fewer bolts for the erector to install, that saves time and decreases costs.”

BIM ImplicationsLederman described a current project involving hollow structural sections. Before the job got to the fabricator, he worked with the engineer to produce a model with all the gussets in it. Hav-ing all this data upfront helps the ideals behind building information modeling (BIM) come to fruition. “The model al-lowed us to do a lot of BIM coordina-tion for MEP [mechanical, electrical, and plumbing], so everyone can start to improve the situation and save a lot of eff ort downstream.”

When designing connections, Qnect usually retrieves load information in one of three ways: the uniform design load

(UDL) factors on the engineering draw-ings; a load table provided by the engi-neer; or loads indicated on the design drawings, which can be put into the 3D model.

“Currently we are able to take loads right from the engineering software,” Lederman said. “Today we’re converting design drawings into the Tekla models with the loads, installing the connections with 100% detailing. Engineers can then observe any issues and improve their de-signs. And we can do that many times be-fore plunging into the fast-moving river [of the construction value chain].”

On Steel Day in September 2019, AISC announced its initiative to cut in half the time it takes to design and construct a building by 2025. “When AISC an-nounced this, some people asked, ‘Is this crazy?’” Lederman said. “But that’s the wrong question to ask. The real question is, how would you do it? It starts with technology.”


Qnect, www.qnect.com

This view provides web reinforcement awareness.



http://www.qnect.com


Fabricators & Manufacturers Association, Intl. www.fmamfg.org . . . . . . . . . . . . . . . . . 9

Industrial Magnetics www.magnetics.com . . . . . . . . . . . . . 7

Infra-Metals www.infra-metals.com . . . . . . . . . . 20

Miller Electric www.millerwelds.com . . . . . . . . . . 19

O’Brien Steel Service www.obriensteel.com . . . . . . . . . . . 14

Soitaab www.soitaabusa.com . . . . . . . . . . . . 3

Voortman www.voortman.net . . . . . . . . . . . . . . . 2

ad index

STRUCTURAL FABRICATION PRODUCT showcaseRobotic welding system automates nozzle welding process

Pemamek Ltd. has introduced Pema ro-botic welding technology for dynamic, one-off production in heavy industry, shipbuilding, and offshore applications. The robotic welding systems include WeldControl offline programming for user-friendliness and flexible production.

One of the company’s latest develop-ments is a complete robotic welding sys-tem for pressure vessel nozzles, which automates the nozzle welding process. Traditionally the process is done manu-ally because of the multipass nature of the weld, which includes many starts, stops, and changes of position. The au-tomation reduces defect rates while sav-ing manual welding hours, according to the company.Pemamek www.pemamek.com

CNC cutting machines, software designed for digitization

Messer Cutting Systems offers CNC cutting machines and software systems to help users drive and transform their digital strategies.

One key component of digitization is paperless production. Machine opera-tors, nesting engineers, and other staff running production tickets through the factory is wasteful and limits agility in production. Another equally important component is the connected machine; when machines have the capability to cultivate and share relevant data and are a part of the digital environment, the full benefits of digitization can be leveraged.Messer Cutting Systems us.messer-cutting.com

Machine offers multiple plate processing functions in one system

Kinetic Cutting Systems’ machines pro-vide plasma and oxyfuel cutting, milling, drilling, and tapping for plate processing with one system. They combine speed and accuracy with time-saving features for efficiency, the manufacturer says.

Companies can quickly load programs, organize nests, cut parts, mill, drill and tap holes, and load finished parts onto multiple pallets with a single machine. Kinetic Cutting Systems www.kineticusa.com

Discs remove slag, burrs from castings, heavy weldments

Superior Abrasives LLC has introduced ALPHA-KUT quick-change discs for re-moving burrs, sharp edges, and slag and shaping the workpiece in a single step. They comprise triangular, preci-sion-formed abrasive grains that exhibit the continually self-sharpening proper-ties and wear characteristics of ceramics, reports the company.

The discs are suitable for heavy mate-rial removal or hardened materials, such as castings, large parts, large welds in in-accessible areas, weld and seam removal and blending, leveling, and rough shap-ing. They are available in 36 grit in 11/2, 2, and 3 in. dia. with military-grade nylon type R button attachments. Superior Abrasives LLC www.superiorabrasives.com

Dust collector reduces compressed air usage

The Gold Series X-Flo in-dustrial dust collector from Camfil Air Pollution Control can reduce compressed air consumption up to 70% be-cause it provides more air-flow and usable filter media,

according to the company. The increased airflow helps clean filter cartridges thor-oughly with each pulse, enabling the system to pulse-clean less frequently.

The dust collector is designed in indi-vidual modules that handle airflows up to 6,000 CFM using four filter cartridges. Camfil Air Pollution Control www.camfilapc.com



http://www.magnetics.com

http://www.infra-metals.com

http://www.millerwelds.com

http://www.obriensteel.com

http://www.soitaabusa.com


http://www.pemamek.com

http://us.messer-cutting.com

http://www.kineticusa.com

http://www.superiorabrasives.com

http://www.camfilapc.com


http://millerwelds.com/arcreach


http://www.infra-metals.com

http://www.deltasteel.com

incl. INCH scale

6"

9" 7"

20"

Ø 2"

incl. INCH scale

1x US280030.XD7 8x US280610.N 4x US280630.N 4x US280648.1.N 16x US280510

4x US280410.N 6x US280420.N 4x US280110.N 2x US280162.N 1x US283999

135°

was $9,774

US 11-2020 | 11-15-2020 thru 01-14-2021

OUR WELDING TABLES ARE NOW AVAILABLE IN INCHES

SIEGMUND® IMPERIAL SERIESWELDING TABLES

$8,799Item No. US288030.XD7

Special Promotion

Exemplary structure. Accessories for Bundle are shown below.

System 28 – Imperial SeriesSiegmund® Welding TableProfessional Extreme 8.7 - 4'x8' Bundleincluding the following accessories

2

Quantum (USA), Charlotte, NC

Siegmund® (Germany)

Siegmund® is the world leader in the manufacturing of precision Welding Tables and Fixturing Accessories. Together with Quantum Machinery Group, we want to provide the best service for our customers nationwide. As the official USA Importer and Seller of Siegmund® Welding Tables and Fixtures, Quantum Machinery has opened a BRAND NEW Facility in Charlotte, North Carolina (USA).

Siegmund® Headquarters Germany

• Largest manufacturer of welding tables with a dealer network in more than 50 countries

• Large team of developers and on-going contact with our customers

Showroom and Stock in Charlotte, North Carolina, USA

• Over 20,000 sqft. Siegmund® display showroom• 38,000 sqft. of warehouse stocking space• With approximately 1,500 Siegmund® welding and clamping tables and over 100,000 tools and

accessories we can accommodate just about every request

THE LARGEST SIEGMUND® INVENTORY LOCATED IN CHARLOTTE, NORTH CAROLINA

Extremely Fast Shipping With Thousands of Siegmund® Welding Tables and Accessories In-Stock, you can get your new Siegmund® Welding Tables and Accessories when you want it and when you need it.

Award-Winning Support

Our team is here for you from 8:00 a.m. to 8:00 p.m. ESTWhether you need welding table advice or if you need a quote. You can always reach us at

(704) 703-9400

Or by email: [email protected] are offering introductory prices for our new Imperial Series

that you will not find anywhere else.

Prices quoted in U.S.D., excl. sales taxes, packing and transport costs.


http://www.siegmund.com

3

System 28 – Imperial Series4' x 8' (48" x 96")

System 28 – Imperial SeriesSurface hardness approx. 450 – 850 Vickers with Plasma nitration

Siegmund® Headquarters Germany

• Modular, compatible, flexible, individual – a welding and clamping system designed to suit all your applications• Special solutions according to customer requirements• Superior corrosion resistance and extended lifetime with Siegmund® plasma nitration• Significantly less adhesion of weld spatter• Retention of surface flatness with Siegmund® Professional Extreme 8.7 tables even after years of heavy use• On-going product development from field experience and customer feedback

THE HARDEST WELDING TABLESNOW AVAILABLE IN INCHES

THE LARGEST SIEGMUND® INVENTORY LOCATED IN CHARLOTTE, NORTH CAROLINA

Boreholes distance / Diagonal grid

2"

4"

Table weight approx. 2,227 lbs

Material thicknessapprox. 15/16" to 1-1/16"

INCH scale engraved on the surface

• Extraordinary hardness due to specially developed alloys for Siegmund® Professional Extreme Imperial Series welding tables exclusive to Siegmund®

• Improved protection against rust, scratches and weld spatter

• Surface-hardened accessories available

For your next project!

max. recommended total load 13,200 lbs


4

WELDING TABLE MATERIALS

The materials used are fundamental to the high level of hardness and long service life.

With a Siegmund® table, you will experience long term savings, thanks to the high level of precision engineering, as well as the consistent superior quality.

Exceptional Hardness and an extremely long service life: Our best selling weld table style is the Professional Extreme 8.7

Shows the improvement of the properties in the last few years.

Side surface of Professional Extreme 8.7 is made of specific basic material S355J2+N incl. plasma nitriding and BAR-coating.

SIEGMUND® PROFESSIONAL EXTREME 8.7with Plasma nitration

OTHERNORMAL STANDARDwithout Plasma nitration

Hardness in Vickers Basic hardness approx. 280 – 340 VickersSurface hardness approx. 450 – 850 Vickers Basic hardness approx. 165 – 220 Vickers

Material

Basic hardness Surface hardness Impact-proof Scratch-proof Protection against weld spatter Corrosion resistance Point load Flatness Maintenance of the flatness under heavy use Life span

BAR-Coating - Iron nitride Transient region

Through-hardened tool steel out of special alloy Siegmund® X8.7

Transient region - Iron nitride BAR-Coating

www.siegmund.com/Vhardness

WATCH THIS EXPLOSIVE VIDEO

Specific base material S355J2+N

*

*

With our evaluation, we would like to make it easier for you to compare the different materials and to support you in selecting the right welding table.

The strongest, most durable Welding Tables ever made.Now available in metric and inches.

http://www.siegmund.com/Vhardness


A welding table from Siegmund® can save up to 40%

of your production time!

Calculate for yourself!

Thanks to the high accuracy of the Siegmund® welding and clamping tables you can work much faster and more precise with reliable lower fabrication errors.

Within a very short time you can arrange many applications with the Siegmund® modular system. This reduces set-up times and saves storage space and costs.

SAMPLE CALCULATION:

Hypothetical costs for fabricator/welder per year incl. additional expenses: $60,000

$24,000

$240,000

The savings potential is around 40 % during the production of prototypes with high down times.

that equals

A realistic life span of 10 years on a table system is equivalent to a cost savings of:

Shows the improvement of the properties in the last few years.

Side surface of Professional Extreme 8.7 is made of specific basic material S355J2+N incl. plasma nitriding and BAR-coating.

6

System 28 (1-1/10" = 28 mm)

FOR HEAVY-DUTY APPLICATIONS – TOP OF THE LINE

MATERIAL

Hardened tool steel X8.7, plasma nitrided and BAR-coated

1. INCH scale engraved on the surface2. Borehole Ø 28 mm (1-1/10")

Boreholes with radius 1/10"Material thickness approx. 15/16" – 1-1/16"

3. Radius 1/10" on table edges and 1/4" corners4. Height of table side 7-7/8", borehole in diagonal grid5. Boreholes on the surface in diagonal grid 6. Bottom structure reinforced ribbing

For the most versatile solution to your welding needs, the System 28 is ideal.

Whether your project is small or large, with the standard legs that are included with your Siegmund® table, you can load approx. 4,400 lbs. per leg. Using our accessories, you can firmly hold-down in place applications that are small in size, to parts that are large and heavy with unmatched ease. Spacing between the boreholes is 4".

PROFESSIONAL EXTREME 8.7NEW NEW

System 28

System 28 – Imperial Series

6.5.

3. 4.

1. 2.

7

System 16 (5/8" = 16 mm)

FOR FINER DETAILED FIXTURING APPLICATIONS

MATERIAL

Hardened tool steel X8.7, plasma nitrided and BAR-coated

1. INCH scale engraved on the surface 2. Borehole Ø 16 mm (5/8") Boreholes with radius 1/16" Material thickness approx. 7/16" – 1/2"3. Radius 1/10" on table edges and 1/4" corners 4. Height of table side 3-15/16", borehole in diagonal grid 5. Boreholes on the surface 2" x 2" grid 6. Bottom structure reinforced ribbing

For simple applications with lower weight capacities, in comparison to

the Siegmund® System 28 tables. Each standard leg can support up to approx. 2,200 lbs. With the 2" standard borehole spacing, you can easily clamp even the smallest of parts.

PROFESSIONAL EXTREME 8.7NEW

System 16


1. 2.

3. 4.

5. 6.

8

1

3-3/

4"12"

2" – 6-1/2"

12"

90°/120°

Ø 2"

24"

6"

9" 7"

System 28 (1-1/10" = 28 mm)


FOR HEAVY-DUTY APPLICATIONS – TOP OF THE LINE

WELDING TABLES

Clamp Clamp Prism Bolt Stop Stop Stop Squareincl. INCH scale

Squareincl. INCH scale



Tool Cart

Material nitrided nitrided burnished burnished nitrided nitrided nitrided nitrided nitrided nitrided nitrided powder coatedItem No. US280610.N US280630.N US280645.1 US280510 US280410.N US280420.N US280430.N US280110.N US280152.N US280162.N US280134+36.N US280910Set 1: US283100 4 x 8 x 2 x 4 x 2 x $1,549Set 2: US283200 6 x 2 x 4 x 12 x 4 x 6 x 2 x 4 x 2 x 2 x $3,659Set 3: US283300 8 x 4 x 4 x 16 x 4 x 6 x 2 x 4 x 2 x 2 x 1 x + 1 x 1 x $5,889

TABLES 4' x 5' (48" x 60") 4' x 8' (48" x 96") 5' x 10' (60" x 120")

Item No. US280035.XD7 US280030.XD7 US280040.XD7Weight approx. 1,448 lbs approx. 2,227 lbs approx. 3,288 lbsLegs 4 6 6

PRICE $4,399 $5,639 $7,999

Maximum recommended static total load with 4 legs 8,800 lbs based on even load distribution. (Data only for leg standard equipment)

TABLE LEGS

SETS

Item No. US280858.X US280877.XX US280876.XX 1 US280879.XX 1

Capacity per table leg 4,400 lbs 4,400 lbs 1,760 lbs 1,760 lbsLeg height 28" 22" – 36" 28" 22" – 30"Table height 36" 30" – 44" 36" 30" – 38"Fine adjustment 2" 2" 13/16" 13/16"Surcharge per leg included $100 $130 $163

Stan

dard

equ

ipm

ent

Heig

ht a

djus

tabl

e

Cast

or, l

ocki

ng b

rake

Heig

ht a

djus

tabl

e,

cast

or, l

ocki

ng b

rake

Note castor: Not recommended for the 5’ x 10’ welding table. In order to use castors on a 4’ x 8’ welding table, you will need to use a 4 leg (instead of 6 leg) with castors configuration.

ACCESSORIES-SET US283999 (Free in all sets)

US280402.N Eccentric Stop US280852.1 Hex wrench US280820 Brush US000940 Oilstone US000911 Sample CleanBasicUS000921 Sample Anti-SpatterUS280920 Burner Holder Value: $167

Borehole Ø 1-1/10" Boreholes in diagonal gridHeight of table side 7-7/8"

Material thickness approx. 15/16" – 1-1/16"Grid dimension 4" x 4"



9

12" 20

"

35-7/16"

40"

24"

12x US28061024x US280510

16x US2805608x US280645.1

8x US280420.N

2x US280430.N8x US280110.N4x US280162.N1x US280134.N + 1x US280136.N

20"

24"

7" 24"

48"

2x US280374.P

7-1/16"

7-1/16"

212"

48"

96"

60"

9"





Tool Cart

Material nitrided nitrided burnished burnished nitrided nitrided nitrided nitrided nitrided nitrided nitrided powder coatedItem No. US280610.N US280630.N US280645.1 US280510 US280410.N US280420.N US280430.N US280110.N US280152.N US280162.N US280134+36.N US280910Set 1: US283100 4 x 8 x 2 x 4 x 2 x $1,549Set 2: US283200 6 x 2 x 4 x 12 x 4 x 6 x 2 x 4 x 2 x 2 x $3,659Set 3: US283300 8 x 4 x 4 x 16 x 4 x 6 x 2 x 4 x 2 x 2 x 1 x + 1 x 1 x $5,889

Value: $167

inclusive 2 drawers with suitable mounting.

$599

Item No. US280900.1

Sub Table Box

Special Promotion

was $845

additional offer

Hardened tool steel X8.7, plasma nitrided and BAR-coated Boreholes in diagonal grid

$17,769was $19,734Item No. US288035.XD7

Siegmund® Welding Table – Professional Extreme 8.7 including the following Expansion Bundle

2x 4' x 5' (48" x 60")

Max. load capacity per drawer approx. 110 lbs.

Surcharge for Table Legs forSquare U-Shape

$146Item No. US281858.X

6x US280604

including Accessories-Set 1x US283999

2x Standard leg US280858.X to support the U-Shapes as table extension

Exemplary structure. Accessories for Bundle are shown below.



10

1

2-1/

16"

7-11

/16"

1-3/8" – 5"

90°/120°

Ø 2"

5" 12

"

3-5/

8"

3-1/

8"

360°

7-11

/16"

System 16 (5/8" = 16 mm)


FOR FINER DETAIL FIXTURING APPLICATIONS

WELDING TABLES





Tool Cart

Material burnished / nitrided burnished nitrided burnished nitrided nitrided nitrided nitrided nitrided nitrided nitrided powder coatedItem No. US160610 US160630 US160645.1.N US160510 US160410.N US160420.N US160425.N US160110.N US160162.N US160164.N US160134+36.N US160910Set 1: US163100 4 x 8 x 2 x 4 x 2 x $849Set 2: US163200 6 x 2 x 4 x 12 x 4 x 6 x 2 x 4 x 2 x 2 x $2,209Set 3: US163300 8 x 4 x 4 x 16 x 4 x 6 x 2 x 4 x 2 x 2 x 1 x + 1 x 1 x $3,609

TABLES 4' x 5' (48" x 60") 4' x 8' (48" x 96") 5' x 10' (60" x 120")

Item No. US160035.X7 US160030.X7 US160040.X7Weight approx. 726 lbs approx. 1,151 lbs approx. 1,725 lbsLegs 4 6 6

PRICE $2,819 $4,539 $6,499

Maximum recommended static total load with 4 legs 4,400 lbs based on even load distribution. (Data only for leg standard equipment)

TABLE LEGS

SETS

Item No. US160858.X US160877.XX US160876.XX 1 US160879.XX 1

Capacity per table leg 2,200 lbs 2,200 lbs 440 lbs 440 lbsLeg height 32" 22" – 38" 32" 24" – 36"Table height 36" 26" – 42" 36" 28" – 40"Fine adjustment 1-5 /8" 1-5 /8" 1-3/16" 1-3/16"Surcharge per leg included $73 $81 $119

Stan

dard

equ

ipm

ent

Heig

ht a

djus

tabl

e

Cast

or, l

ocki

ng b

rake

Heig

ht a

djus

tabl

e,

cast

or, l

ocki

ng b

rake

Note castor: Not recommended for welding tables with 6 table legs.

ACCESSORIES-SET US163999 (Free in all sets)

US160402.N Eccentric Stop US160852 Hex wrench US160820 Brush US000940 Oilstone US000911 Sample CleanBasicUS000921 Sample Anti-SpatterUS160920 Burner Holder

Borehole Ø 5/8" Boreholes on the surface 2" x 2" grid

Boreholes on the table side in diagonal grid Height of table side 3-15/16"

Material thickness approx. 7/16" – 1/2"

Value: $138



11

26-5

/8"

22-1/16"

12" 20

"

24"

1x US160900.14x US160630

8x US160645.1.N4x US160403.N

8x US160410.N

16x US160510

8x US160740

8x US160110.N

2x US160162.N

6x US160420.N

8x US160610

2x US160164.N

7-1/16"

7-1/16"

5"

3-5/

8"

12"

20"

3-1/

8"





Tool Cart

Material burnished / nitrided burnished nitrided burnished nitrided nitrided nitrided nitrided nitrided nitrided nitrided powder coatedItem No. US160610 US160630 US160645.1.N US160510 US160410.N US160420.N US160425.N US160110.N US160162.N US160164.N US160134+36.N US160910Set 1: US163100 4 x 8 x 2 x 4 x 2 x $849Set 2: US163200 6 x 2 x 4 x 12 x 4 x 6 x 2 x 4 x 2 x 2 x $2,209Set 3: US163300 8 x 4 x 4 x 16 x 4 x 6 x 2 x 4 x 2 x 2 x 1 x + 1 x 1 x $3,609

TABLES 4' x 5' (48" x 60") 4' x 8' (48" x 96") 5' x 10' (60" x 120")

Item No. US160035.X7 US160030.X7 US160040.X7Weight approx. 726 lbs approx. 1,151 lbs approx. 1,725 lbsLegs 4 6 6

PRICE $2,819 $4,539 $6,499

US160402.N Eccentric Stop US160852 Hex wrench US160820 Brush US000940 Oilstone US000911 Sample CleanBasicUS000921 Sample Anti-SpatterUS160920 Burner Holder

Siegmund® Welding Table – Professional Extreme 8.7 including the following accessories

5' x 10' (60" x 120")Hardened tool steel X8.7, plasma nitrided and BAR-coated Boreholes on the surface 2" x 2" grid

$9,899was $10,998Item No. US168040.X7

Special Promotion

inclusive 2 drawers with suitable mounting.

$599

Item No. US160900.1

Sub Table Box

was $845

additional offer

Max. load capacity per drawer approx. 110 lbs.

including Accessories-Set 1x US163999

Value: $138



12 = Scratch-proof = Welding spatter protection = Corrosion protection

US280512

a

bd

a

bd

a

bd

ACCESSORIES

US280401.N US280402.N US280403.N

US280401.N Eccentric Stop Ø 2-3/8" - nitrided $27in situations with limited space, infinite twistingØ: MS: (d) Weight: 2-3/8" 1" 0.93 lbs

US280402.N Eccentric Stop Ø 2-3/8" with M10 thread - nitrided $32for ground connection, infinite twistingØ: MS: (d) Weight: 2-3/8" 1" 0.90 lbs

US280403.N Eccentric Stop Ø 4" - nitrided $32also serves as support surface, infinite twistingØ: MS: (d) Weight: 4" 1" 3.09 lbs

MS=Material thickness;

US280410.N Universal Stop 6" L - nitrided $46

Length: (a) Width: (b) MS: (d) VB: Weight: 6" 1-15/16" 1" 4" 1.72 lbs

US280410.N US280420.N

US280420.N Universal Stop 9" L - nitrided $74combinable with prisms and adaptersLength: (a) Width: (b) MS: (d) VB: Weight: 9" 1-15/16" 1" 4" 3.07 lbs

US280430.N

US280430.N Universal Stop 24" S - nitrided $945 system drill holesLength: (a) Width: (b) MS: (d) VB: Weight: 24" 3-15/16" 1" 8" 21.37 lbs

US280512 Fast Clamping Bolt long - burnished $83for clamping 3 components, with screw top, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 4-3/4" 1-1/10" 49,400 lbf 18 lbf·ft 5,600 lbf 1.43 lbs

US280510

US280510 Fast Clamping Bolt short - burnished $65for clamping 2 components, with screw top, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 3-3/4" 1-1/10" 49,400 lbf 18 lbf·ft 5,600 lbf 1.20 lbs

MS=Material thickness; VB=Adjusting range


13= Scratch-proof = Welding spatter protection = Corrosion protection = Scale = Aluminum

US280532 US280533 US280561 US280540US280560.N US280571 US280573

US280740 US280740.1 US280740.2


US280532 Universal Bolt, Comfort short - burnished $67for clamping 2 components, Clamping range 1-3/4" – 2-1/16", CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 4" 1-1/10" 44,900 lbf 18 lbf·ft 5,600 lbf 1.32 lbs

US280533 Universal Bolt, Comfort long - burnished $84for clamping 3 components, Clamping range 2-3/4" – 3-1/16", CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 5" 1-1/10" 44,900 lbf 18 lbf·ft 5,600 lbf 1.54 lbs

US280540 Positioning Bolt - burnished $18substitutes a second clamping bolt cost-effectively, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 2-3/4" 1-1/10" - - - 0.93 lbs

US280561 Connecting Bolt long - burnished $34for connecting 3 components, with hexagon socket, to connect tables and U-squares, not suitable for oblong holes, fixed long-term connectionLength: (a) Ø: SK: AM: ZK: Weight: 3" 1-1/10" 44,900 lbf 18 lbf·ft 2,200 lbf 0.58 lbs

US280560.N Connecting Bolt short - nitrided $27for connecting 2 components, with hexagon socket, to connect tables and U-squares, not suitable for oblong holes, fixed long-term connectionLength: (a) Ø: SK: AM: ZK: Weight: 2" 1-1/10" 44,900 lbf 18 lbf·ft 2,200 lbf 0.46 lbs

US280571 Fast Clamping Bolt adjustable without slot short - burnished $72for clamping 2 components, with screw top, clamping of customized laser cut profiles, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 4-1/2" 1-1/10" 49,400 lbf 18 lbf·ft 5,600 lbf 1.57 lbs

US280573 Fast Clamping Bolt adjustable without slot long - burnished $89for clamping 3 components, with screw top, clamping of customized laser cut profiles, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 5-1/2" 1-1/10" 49,400 lbf 18 lbf·ft 5,600 lbf 1.83 lbs

SK=Shearing Force; AM=Tightening Torque Steel; ZK=Tensile Force; Clamping torque dependent on material.

US280740 Magnetic Clamping Bolt 68 - Aluminum $34Length of Shaft 1", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 2-11/16" 1-1/10" 0.20 lbs

US280740.1 Magnetic Clamping Bolt 93 - Aluminum $40Length of Shaft 2", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 3-11/16" 1-1/10" 0.29 lbs

US280740.2 Magnetic Clamping Bolt 118 - Aluminum $46Length of Shaft 3", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 4-5/8" 1-1/10" 0.35 lbs


14 = Scratch-proof = Welding spatter protection = Corrosion protection = Aluminum

US280645.1.A US280648.1.N US280648.1.A US280652.1 US280650 US280650.AUS280645.1

90°/120°

US280649.3US280822 US280821

90°/120°

c c c

135°

c

135° 157°

c c c

120° 120°

c

a

ACCESSORIES

US280648.1.N Prism Ø 2" 135° with screwed-in collar - nitrided $35M16 thread for e.g. prism extensions Item No. US280649, for pipes up to Ø 3"Height: (c) Ø: Weight: 13/16" 2" 0.44 lbs

US280648.1.A Prism Ø 2" 135° with screwed-in collar - Aluminum $43M16 thread for e.g. prism extensions Item No. US280649, for pipes up to Ø 3"Height: (c) Ø: Weight: 13/16" 2" 0.15 lbs

US280645.1.A Vario Prism Ø 2" 90° / 120° with screwed-in collar - Aluminum $46M16 thread for e.g. prism extensions Item No. US280649, for round and square pipes up to Ø 2"Height: (c) Ø: Weight: 13/16" 2" 0.15 lbs

US280652.1 Prism Ø 4-3/4" 157° with screwed-in collar - burnished / nitrided $67M16 thread for e.g. prism extensions Item No. US280649, for pipes up to Ø 15"Height: (c) Ø: Weight: 1-3/16" 4-3/4" 3.75 lbs

US280650 Duo Prism Ø 1-5/8" - burnished / nitrided $26for Arbor with Trapezoid thread 3/4" x 5/32", compatible with 1-1/10" bore holes and clampsHeight: (c) Ø: Weight: 1-3/8" 1-5/8" 0.33 lbs

US280650.A Duo Prism Ø 1-5/8" - Aluminum $29for Arbor with Trapezoid thread 3/4" x 5/32", compatible with 1-1/10" bore holes and clampsHeight: (c) Ø: Weight: 1-3/8" 1-5/8" 0.11 lbs

US280645.1 Vario Prism Ø 2" 90° / 120° with screwed-in collar - burnished / nitrided $40M16 thread for e.g. prism extensions Item No. US280649, for round and square pipes up to Ø 2"Height: (c) Ø: Weight: 13/16" 2" 0.44 lbs

US280649.3 Prism Extension 6" - burnished $31compatible with prisms, support set US280821 and screw support US280822Length: (a) Ø: Weight: 6" 1-1/10" 1.52 lbs

US280822 Screw Support Ø 3-1/8" - burnished $100vernier adjustment height in a range of 3" – 4-5/16", combinable with support set US280821 and prism extensionsHeight: (c) Ø: Weight: 3 – 4-5/16" 3-1/8" 5.07 lbs

US280821 Set of Supports 11 pieces - burnished $67compensation of 1/32" – 4" height difference, with M10 threadLength: (a) Ø: Weight: 5" 2" 4.30 lbs

Find more Prism Extensions (Length 1", 2", 4") on our website.

Find more Prisms in Polyamide on our website.


15= Scratch-proof = Welding spatter protection = Corrosion protection

US280374.P

US280705 US280710 US280715 US280715.1 US280715.2 US280715.3

dc

cd

dc

dc

c

a

b


US280362.P 24" 8" 7-7/8" 1" 175 lbs $779US280374.P 48" 8" 7-7/8" 1" 318 lbs $1,279US280386.P 72" 8" 7-7/8" 1" 468 lbs $1,699US280391.P 96" 8" 7-7/8" 1" 618 lbs $2,193

US280356.P 12" 8" 7-7/8" 1" 93 lbs $605

Square U-Shape 8/8 - Plasma nitridedwith diagonal grid, as table extension and vertical superstructure, to connect tables (with connecting bolt US280560.N), for heavy components, from 24" with mounting holes for table legs, from 36" support through table leg required

Length: (a) Width: (b) Height: (c) MS: (d) Weight:

US280705 Vertical Toggle Clamp with Adapter $53Adapter US280715, combinable with stopsmaximum load Weight: 400 lbf 1.61 lbs

US280710 Horizontal Toggle Clamp with Adapter $65Adapter US280715, combinable with stopsmaximum load Weight: 560 lbf 1.57 lbs

US280715 Adapter with Hole Pattern Ø 2" / 5/8" - burnished $21for Toggle Clamp, for System 28Height: (c) Ø: MS: (d) Weight: 1-3/16" 2" 5/8" 0.66 lbs

US280715.1 Adapter with Hole Pattern Ø 2" / 1-5/8" - burnished $26for Toggle Clamp, for System 28Height: (c) Ø: MS: (d) Weight: 2-3/16" 2" 1-5/8" 1.23 lbs

US280715.2 Adapter with Hole Pattern Ø 2" / 2-3/4" - burnished $29for Toggle Clamp, for System 28Height: (c) Ø: MS: (d) Weight: 3-3/8" 2" 2-3/4" 2.20 lbs

US280715.3 Adapter with Hole Pattern Ø 2" / 4" - burnished $32for Toggle Clamp, for System 28Height: (c) Ø: MS: (d) Weight: 4-1/2" 2" 4" 3.28 lbs




16 = Scratch-proof = Welding spatter protection = Corrosion protection = Scale

US280124.N US280126.N

US280657.1.N

c

ba

d

ba

c

ba

c

da

c

b

da

c

ba

c

b b

c

a

cc

b

a

ACCESSORIES

US280110.N Stop and Clamping Square 7" L - nitrided $122drill hole / oblong hole, incl. INCH scaleLength: (a) Width: (b) Height: (c) MS: (d) Weight: 7" 1-15/16" 7" 1" 4.35 lbs

US280124.N Stop and Clamping Square 12" GK left - nitrided $305stop on left, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 11-1/4" 3-3/4" 12" 1" 53.18 lbs

US280126.N Stop and Clamping Square 12" GK right - nitrided $305stop on right, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 11-1/4" 3-3/4" 12" 1" 53.18 lbs

US280152.N Stop and Clamping Square 12" G - nitrided $189stop on left, incl. INCH scale, usable as table extension, material: GGG40Length: (a) Width: (b) Height: (c) MS: (d) Weight: 7-7/8" 2-15/16" 12" 1" 15.02 lbs

US280162.N Stop and Clamping Square 20" G - nitrided $246stop on left, incl. INCH scale, usable as table extension, material: GGG40Length: (a) Width: (b) Height: (c) MS: (d) Weight: 7-7/8" 2-15/16" 20" 1" 20.62 lbs

US280110.N US280152.N US280162.N US280134.N US280136.N

US280134.N Stop and Clamping Square 24" GK left - nitrided $480stop on left, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 15-3/8" 3-3/4" 24" 1" 59.18 lbs

US280136.N Stop and Clamping Square 24" GK right - nitrided $480stop on right, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 15-3/8" 3-3/4" 24" 1" 59.18 lbs

US280820

US280820 Brush with protecting cover $26for cleaning bore holesØ: Weight: 1-3/16" 0.13 lbs

US280852.1

US280852.1 Hex wrench 6 $19yellowWeight: 0.20 lbs

US280910 Tool Cart - varnished $879Max. total weight 525 lbsLength: (a) Width: (b) Height: (c) Weight: 25-9/16" 35-7/16" 40" 110.23 lbs

US280920

US280920 Burner Holder - burnished $38can be positioned in bore holeLength: (a) Width: (b) Height: (c) Weight: - - 7-7/8" 1.10 lbs

US280910


17= Scratch-proof = Welding spatter protection = Corrosion protection = Polyamide

US280604 US280608.N US280615.N

US280660 US280660.E US280660.PAUS280657.1.N US280658.E US280659.PA

c

b

c

c

b

c

c

b


US280610.N

US280610.N Professional Screw Clamp - nitrided $99interchangeable prism, Ball diameter spindle 5/8"maximum load Width: (b) Height: (c) Weight: 1,125 lbf 8-2/3" 12-3/16" 5.95 lbs

US280615.N Professional Fast Tension Clamp - nitrided $125

maximum load Width: (b) Height: (c) Weight: 1,125 lbf 10-5/6" 12-1/5" 4.40 lbs

US280604 Pipe Clamp Universal - burnished $99interchangeable prism, Ball diameter spindle 5/8", clamping at an angle of +/- 42°, fastening with an adjusting ringmaximum load Width: (b) Height: (c) Weight: 675 lbf 10-7/16" 9-5/6" 5.06 lbs

US280608.N Basic Pipe Clamp 90° - nitrided $65interchangeable prism, Ball diameter spindle 5/8", clamping at an angle of 90°, steplessly rotatable from 0°-360°, fastening with an adjusting ringmaximum load Width: (b) Height: (c) Weight: 675 lbf - 9" 3.08 lbs

US280630.N Professional Screw Clamp 45°/90° - nitrided $92interchangeable prism, Ball diameter spindle 5/8", steplessly rotatable from 0°-360°maximum load Width: (b) Height: (c) Weight: 1,125 lbf - 12-3/16" 5.07 lbs

US280657.1.N Prism for Screw Clamps - nitrided $13for Arbor with Trapezoid thread 3/4" x 5/32"Height: (c) Ø: Weight: 15/16" 1-5/8" 0.20 lbs

US280658.E Prism for Screw Clamps - Stainless Steel $18for Arbor with Trapezoid thread 3/4" x 5/32", for scratch-resistant surfaces (rust prevention)Height: (c) Ø: Weight: 13/16" 1-5/8" 0.22 lbs

US280659.PA Prism for Screw Clamps - Polyamide $15for Arbor with Trapezoid thread 3/4" x 5/32", for scratch-sensitive surfacesHeight: (c) Ø: Weight: 15/16" 1-5/8" 0.02 lbs

US280660 Pressure Ball for Screw Clamps - burnished / nitrided $13for Arbor with Trapezoid thread 3/4" x 5/32", for clamping in corners or groovesHeight: (c) Ø: Weight: 13/16" 1-3/8" 0.15 lbs

US280660.E Pressure Ball for Screw Clamps - Stainless Steel $18for Arbor with Trapezoid thread 3/4" x 5/32", for scratch-resistant surfaces (rust prevention), for clamping in corners or groovesHeight: (c) Ø: Weight: 13/16" 1-3/8" 0.15 lbs

US280660.PA Pressure Ball for Screw Clamps - Polyamide $15for Arbor with Trapezoid thread 3/4" x 5/32", for scratch-sensitive surfaces, for clamping in corners or groovesHeight: (c) Ø: Weight: 13/16" 1-3/8" 0.02 lbs

US280630.N

http://US280660.PA

http://US280659.PA

http://US280659.PA

http://US280660.PA



US160401.N US160403.N

US160512US160510

US160402.N

US160410.N US160420.N US160425.N

a

bd

a

bd

a

bd

ACCESSORIES

US160401.N Eccentric Stop Ø 1-3/4" - nitrided $21 in situations with limited space, infinite twistingØ: MS: (d) Weight: 1-3/4" 1/2" 0.29 lbs

US160403.N Eccentric Stop Ø 2-15/16" - nitrided $26also serves as support surface, infinite twistingØ: MS: (d) Weight: 2-15/16" 1/2" 0.86 lbs


US160402.N Eccentric Stop Ø 2-15/16" with M10 thread - nitrided $27for ground connection, infinite twistingØ: MS: (d) Weight: 2-15/16" 1/2" 0.84 lbs

US160410.N Universal Stop 3-1/8" L - nitrided $42

Length: (a) Width: (b) MS: (d) VB: Weight: 3-1/8" 1-3/16" 1/2" 2" 0.27 lbs

US160420.N Universal Stop 5" L - nitrided $38combinable with prisms and adaptersLength: (a) Width: (b) MS: (d) VB: Weight: 5" 1-3/16" 1/2" 2" 0.51 lbs

US160425.N Universal Stop 12" M - nitrided $627 system bore holesLength: (a) Width: (b) MS: (d) VB: Weight: 12" 1-15/16" 1/2" 4" 2.41 lbs

US160512 Fast Clamping Bolt long - burnished $56 for clamping 3 components, with screw top, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 2-9/16" 5/8" 12,365 lbf 7 lbf·ft 2,250 lbf 0.22 lbs

US160510 Fast Clamping Bolt short - burnished $28 for clamping 2 components, with screw top, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 2-1/16" 5/8" 12,365 lbf 7 lbf·ft 2,250 lbf 0.18 lbs

MS=Material thickness; VB=Adjusting range


19= Scratch-proof = Welding spatter protection = Corrosion protection = Scale = Aluminum

US160740 US160740.1 US160740.2

US160532 US160533 US160540US160561 US160571 US160573US160560.N


US160740 Magnetic Clamping Bolt 34 - Aluminum $19Length of Shaft 1/2", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 1-5/16" 5/8" 0.04 lbs

US160740.1 Magnetic Clamping Bolt 46 - Aluminum $23Length of Shaft 15/16", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 1-13/16" 5/8" 0.07 lbs

US160740.2 Magnetic Clamping Bolt 58 - Aluminum $26Length of Shaft 1-7/16", clamping without the use of tools, suitable for pressure-sensitive parts or when counterholding is not possibleLength: (a) Ø: Weight: 2-5/16" 5/8" 0.09 lbs

US160540 Positioning Bolt - burnished $15 substitutes a second clamping bolt cost-effectively, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 1-1/2" 5/8" - - - 0.15 lbs

US160561 Connecting Bolt long - burnished $29 for connecting 3 components, with hexagon socket, to connect tables and U-squares, not suitable for oblong holes, fixed long-term connectionLength: (a) Ø: SK: AM: ZK: Weight: 1-7/16" 5/8" 11,240 lbf 11 lbf·ft 900 lbf 0.11 lbs

US160532 Universal Bolt short - burnished $29 for clamping 2 components, Clamping range 7/8" – 1-1/10", CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 2-5/16" 5/8" 11,240 lbf 7 lbf·ft 2,250 lbf 0.24 lbs

US160533 Universal Bolt long - burnished $59 for clamping 3 components, Clamping range 1-11/32" – 1-5/8", CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 2-13/16" 5/8" 11,240 lbf 7 lbf·ft 2,250 lbf 0.26 lbs

US160571 Fast Clamping Bolt adjustable without slot short - burnished $53 for connecting 2 components, with screw top, clamping of customized laser cut profiles, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 3-1/16" 5/8" 12,365 lbf 7 lbf·ft 2,250 lbf 0.29 lbs

US160573 Fast Clamping Bolt adjustable without slot long - burnished $62 for connecting 3 components, with screw top, clamping of customized laser cut profiles, CANNOT be used for connecting tables and U-shaped squaresLength: (a) Ø: SK: AM: ZK: Weight: 3-9/16" 5/8" 12,365 lbf 7 lbf·ft 2,250 lbf 0.33 lbs

SK=Shearing Force; AM=Tightening Torque Steel; ZK=Tensile Force; Clamping torque dependent on material.

US160560.N Connecting Bolt short - nitrided $24 for connecting 2 components, with hexagon socket, to connect tables and U-squares, not suitable for oblong holes, fixed long-term connectionLength: (a) Ø: SK: AM: ZK: Weight: 1" 5/8" 11,240 lbf 11 lbf·ft 900 lbf 0.07 lbs



US160645.1.N US160652.1

US160649.2 US160821 US160822

US160650

US160705 US160710 US160715

cd

a

120°

c

90°/120°

c

120°

c

c

ACCESSORIES

US160705 Vertical Toggle Clamp with Adapter $54Adapter US160715, combinable with stopsmaximum load Weight: 400 lbf 2.10 lbs

US160710 Horizontal Toggle Clamp with Adapter $59 Adapter US160715, combinable with stopsmaximum load Weight: 560 lbf 2.00 lbs

US160715 Adapter with Hole Pattern Ø 1-7/8" / 5/8" - burnished $19 for Toggle Clamp, for System 16Height: (c) Ø: MS: (d) Weight: 7/8" 1-7/8" 5/8" 0.44 lbs

US160650 Duo Prism Ø 1" - burnished / nitrided $16 for Arbor with Trapezoid thread 1/2" x 1/8", without O-RingHeight: (c) Ø: Weight: 3/4" 1" 0.09 lbs

US160652.1 Prism Ø 3-1/8" 120° with screwed-in collar - burnished / nitrided $54 M10 thread for e.g. prism extensions Item No. US160649, for pipes up to Ø 4-3/4"Height: (c) Ø: Weight: 1-1/8" 3-1/8" 1.67 lbs

US160649.2 Prism Extension 4" - burnished $31 compatible with prisms, support set US160821 and screw support US160822Length: (a) Ø: Weight: 4" 5/8" 0.33 lbs

US160821 Set of Supports 7 pieces - burnished $51 compensation of 1/32" – 2-3/8" height difference, with M10 threadHeight: (c) Ø: Weight: 2-9/16" 1" 0.37 lbs

US160822 Screw Support Ø 1-15/16" - burnished $45 vernier adjustment height in a range of 2-5/32" – 3", combinable with support set US160821 and prism extensionHeight: (c) Ø: Weight: 2-3/16" – 2-15/16" 1-15/16" 1.57 lbs

Find more Prism Extensions (Length 3/8", 2") on our website.

Find Prisms in Aluminum and Polyamide on our website.

US160645.1.N Vario Prism Ø 2" 90° / 120° with screwed-in collar ‐ nitrided $50M10 thread for e.g. prism extensions Item No. US160649, for round and square pipes up to Ø 3"Höhe: (c) Ø: Gewicht: 13/16" 2" 0.46 lbs



21= Scratch-proof = Welding spatter protection = Corrosion protection = Scale

US160124.N US160126.NUS160110.N US160134.N US160136.N US160162.N US160164.N

US160374.P

c

ba

d

b a

c

ba

c

a

c

b

da

c

b a

c

bb

c

ad

c

a

b


US160124.N Stop and Clamping Square 12" GK left - nitrided $149stop on left, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 5-13/16" 1-15/16" 12" 1/2" 7.21 lbs

US160126.N Stop and Clamping Square 12" GK right - nitrided $149 stop on right, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 5-13/16" 1-15/16" 12" 1/2" 7.21 lbs


US160356.P 12" 4" 3-15/16" 1/2" 20 lbs $523US160362.P 24" 4" 3-15/16" 1/2" 38 lbs $836US160374.P 48" 4" 3-15/16" 1/2" 73 lbs $919

Square U-Shape 4/4 - Plasma nitridedwith diagonal grid, as table extension and vertical superstructure, to connect tables (with connecting bolt US160560.N), for heavy components, from 24" with mounting holes for table legs, from 36" support through table leg required

Length: (a) Width: (b) Height: (c) MS: (d) Weight:

US160386.P 72" 4" 3-15/16" 1/2" 109 lbs $1,355

US160110.N Stop and Clamping Square 3-5/8" L - nitrided $69 drill hole / oblong hole, incl. INCH scaleLength: (a) Width: (b) Height: (c) MS: (d) Weight: 3-5/8" 1-13/16" 3-5/8" 1/2" 0.64 lbs

US160134.N Stop and Clamping Square 24" GK left - nitrided $227stop on left, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 8-13/16" 1-15/16" 24" 1/2" 15.48 lbs

US160136.N Stop and Clamping Square 24" GK right - nitrided $227stop on right, incl. INCH scale, usable as table extension, for heavy components, material: GGG40, order in pairs recommendedLength: (a) Width: (b) Height: (c) MS: (d) Weight: 8-13/16" 1-15/16" 24" 1/2" 15.48 lbs

US160162.N Stop and Clamping Square 12" G - nitrided $110stop on left, incl. INCH scale, usable as table extension, material: GGG40Length: (a) Width: (b) Height: (c) MS: (d) Weight: 5-7/8" 1-13/16" 12" 1/2" 5.53 lbs

US160164.N Stop and Clamping Square 20" G - nitrided $151stop on left, incl. INCH scale, usable as table extension, material: GGG40Length: (a) Width: (b) Height: (c) MS: (d) Weight: 7-11/16" 1-13/16" 20" 1/2" 9.97 lbs



22 = Polyamide

US160606US160604 US160620US160610 US160630

US160656 US160656.E US160660 US160660.E US160660.PAUS160656.PA

c

b

c

c

b

c

b

c

b

ACCESSORIES

US160656 Prism for Screw Clamps - burnished / nitrided $12 for Arbor with Trapezoid thread 1/2" x 1/8"Height: (c) Ø: Weight: 9/16" 1" 0.04 lbs

US160656.E Prism for Screw Clamps - Stainless Steel $16 for Arbor with Trapezoid thread 1/2" x 1/8", for scratch-resistant surfaces (rust prevention)Height: (c) Ø: Weight: 9/16" 1" 0.04 lbs

US160604 Pipe Clamp Universal - burnished $51 interchangeable prism, ball diameter spindle 5/16", clamping at an angle of +/- 42°, fastening with an adjusting ringmaximum load Width: (b) Height: (c) Weight: 135 lbf 6-1/2" 5-7/8" 1.76 lbs

US160606 Professional Fast Tension Clamp - burnished $106 recommended only for plasma nitrided welding tablesmaximum load Width: (b) Height: (c) Weight: 562 lbf 5-3/16" 5-7/8" 1.98 lbs

US160620 Basic Screw Clamp - burnished $65 interchangeable prism, ball diameter spindle 5/16"maximum load Width: (b) Height: (c) Weight: 562 lbf 5-1/16" 7-7/8" 2.09 lbs

US160610 Professional Screw Clamp - burnished / nitrided $51interchangeable prism, ball diameter spindle 5/16"maximum load Width: (b) Height: (c) Weight: 562 lbf 6-7/16" 7-7/8" 2.65 lbs

US160630 Professional Screw Clamp 45°/90° - burnished $78interchangeable prism, ball diameter spindle 5/16", steplessly rotatable from 0°-360°maximum load Width: (b) Height: (c) Weight: 562 lbf - 7-7/8" 1.65 lbs

US160660 Pressure Ball for Screw Clamps - burnished $12 for Arbor with Trapezoid thread 1/2" x 1/8", for clamping in corners or groovesHeight: (c) Ø: Weight: 1/2" 13/16" 0.04 lbs

US160660.E Pressure Ball for Screw Clamps - Stainless Steel $16 for Arbor with Trapezoid thread 1/2" x 1/8", for scratch-resistant surfaces (rust prevention), for clamping in corners or groovesHeight: (c) Ø: Weight: 1/2" 13/16" 0.04 lbs

US160660.PA Pressure Ball for Screw Clamps - Polyamide $13 for Arbor with Trapezoid thread 1/2" x 1/8", for scratch-sensitive surfaces, for clamping in corners or groovesHeight: (c) Ø: Weight: 1/2" 13/16" 0.02 lbs

US160656.PA Prism for Screw Clamps - Polyamide $12 for Arbor with Trapezoid thread 1/2" x 1/8", for scratch-sensitive surfacesHeight: (c) Ø: Weight: 9/16" 1" 0.02 lbs

http://US160660.PA

http://US160656.PA

http://US160660.PA

http://US160656.PA


23

b

US160910 US160920 US160820 US160852

c

c

a

HOUSTEX in Houston, Texas A Manufacturing Technology Series EventFebruary 23-25, 2021 For more information please check the tradeshow website: www.houstexonline.com

Producer:

Bernd Siegmund GmbH 180 Landsberger StrasseOberottmarshausen, Germany 86507Phone: +49 (8203) 96070

E-Mail: [email protected]

Official USA Head Importer:

All prices are in U.S.D., quoted ex works, excl. sales taxes, packing and freight. Technical changes and release are reserved. Our General Business Terms apply. Subject to price changes and printing errors. All texts, pictures and design elements are copyrighted by the Bernd Siegmund GmbH. No part of this flyer may be edited analogously or digital or in another mode, may be multiplicated or published out of the flyer without written approval of the legal owner. Offenses are prosecuted. © 2020 Bernd Siegmund GmbH

Quantum Machinery Group 7110 Expo Drive, Suite D Charlotte, North Carolina 28269 Phone: (704) 703-9400 E-Mail: [email protected]

You can choose to Opt-Out of receiving future mailings by calling (704) 703-9400 or you may Opt-Out in writing to us at:Quantum Machinery Group · 7110 Expo Drive, Suite D · Attn: Marketing Department · Charlotte, NC 28269If you are writing to us, please include your company name, your full name, address and specify that you are not interested in receiving any promotional material.

Tradeshows:


US160910 Tool Cart - varnished $727 Max. total weight 525 lbsLength: (a) Width: (b) Height: (c) Weight: 21-7/8" 22-1/16" 26-5/8" 48 lbs

US160920 Burner Holder - burnished $29 can be positioned in bore holeLength: (a) Width: (b) Height: (c) Weight: - - 7-7/8" 0.60 lbs

US160820 Brush with protecting cover $21for cleaning bore holesØ: Weight: 11/16" 0.11 lbs

US160852 Hex wrench 4 $15 yellowØ: Weight: - 0.13 lbs

Find more practical examples from a wide range of application areas and sectors on our website: www.siegmund.com/practice

Find more Accessories on our website.

http://www.houstexonline.com




http://www.weldingtables.com

http://www.siegmund.com/practice


Phone (704) 703 - 9400

8xStop

US160420.N

4x Clamp

US160610

4x Square

US160162.N

12x Bolt

US160510

1x Accessories-Set

US163999

5"

12"

7-11

/16"

1-3/8" – 5"

incl. INCH scale

Quantum Machinery Group The Official USA Head Importer and Seller of Siegmund Welding Tables and Fixtures

OFFICIAL USA HEAD IMPORTER: Quantum Machinery Group 7110 Expo Drive, Suite D I Charlotte, North Carolina 28269 I Phone (704) 703-9400 I E-Mail: [email protected] I www.weldingtables.com

ORDER NOW!

3' x 4' (36" x 48")

$1,999was $3,521Item No. US168125.X7

1x US160025.X7Hardened tool steel X8.7, plasma nitridedBorehole Ø 5/8", Weight approx. 486 lbsBoreholes on the surface 2" x 2" gridINCH scale engraved on the surface

LIMITED QUANTITY: Only 200 Bundles of 3' x 4' Imperial System are available at this introductory bundle price thru 01-14-2021.

AUTUMN SALE TO CELEBRATE THE NEW SIEGMUND® IMPERIAL SERIES WELDING TABLESINCLUDING ACCESSORIES

Find your local dealer:www.weldingtables.com/dealers

7110 Expo Drive, Suite D · Charlotte, North Carolina 28269 · [email protected]

2"


System 16 – Imperial SeriesSiegmund® Welding TableProfessional Extreme 8.7 - 3'x4' Bundleincluding the following accessories

Table Size 3' x 4' (36" x 48")


http://www.weldingtables.com

http://www.weldingtables.com/dealers


The Fabricator - December 2020 - PMI LLC

Documents