The official publication of the

AUGUST 2019 | VOL. 49 NO. 8 Fabricators & Manufacturers Association ®

www.thefabricator.com
An official publication of

Kloeckner Metals
rethinks the
supply
chain

64 Metal Fab Solutions takes

collaboration to the next level

68 What high-powered fiber lasers

mean for a fab shop

82 A new approach
to forming louvers

August19FAB_Cover.indd 2 7/25/19 4:34 PM

 THE CAPITAL

AT BOOTH 2019
Capital Machine has been steadily growing other regions. Believers’ of THE CAPITAL
since 1984 with periodic expansions across DIFFERENCE, they urged Capital to assemble
the southern United States. Based in Florida, a solid team in this region. In addition to the
the company operates in 12 states with 5 Sales personnel noted below, Capital also
Technology Centers in Atlanta, Dallas added 2 resident Service Engineers in the
and Tampa. Carolinas with another 7 Technicians within
a few hours from north Florida and Georgia.
From the beginning, Capital built a reputation
on representing leading manufacturers from Please join us and our subsidiary,
around the world and by providing value- Capital Robotics, at booth number 2019
added services through a well-trained and at SOUTHTEC to experience the latest
professional staff. in Robotic Welding, Advanced Precision
Bending, Waterjet Cutting and cost-effective
Today, Capital employs 22 Field Service solutions for your metal fabricating needs.
Engineers, 5 Robotic Welding Specialists,
Application Engineers and a highly- Avoid the rush by getting signed-up early,
experienced management group. you can register by visting:
capitalmachine.events
Capital’s recent expansion to the
Carolina’s and Virginia was prompted by
the manufacturers Capital supports in

Let us introduce you to your local Capital Team:

Shaun Reiff Chris Gilmore Dewey Thomas

Branch Manager Sales Engineer Sales Engineer
Carolinas & Virginia Western Virginia & West North Carolina West South Carolina

Stay current with all things Capital Machine by

bookmarking our website:
www.capitalmachine.com│(800) 635-7777
David Scurlock Peter Baldauf
You can also follow us on:
Sales Engineer Sales Engineer
Central & East Virginia Eastern Carolinas
 THE FUSION ARC

AT BOOTH 2019
Capital Robotics is the leading distributor of and produce low-cost, simple fixtures in a
Robotic Welding Cells and Systems in the matter of hours. Additionally, Fusion Arc
south with over 600 installations. Fusion incorporates the industries’ most advanced
Arc is the designation for our family of welding power supply and user-friendly
pre-engineered Cells available in several pendant control making the entire package
configurations and easily customizable. uniquely flexible and user-friendly.

Every cell is built on a common-based Finally, all Fusion Arc Cells include the
platform, with four pockets under each industries’ most comprehensive training
facet allowing for easy placement. Our pre- program and service support from Capital’s 5
engineered systems provide a safe, fully Welding Specialist and 22 Service Engineers.
enclosed environment that remains functional, Be sure to take a closer look at The Fusion
flexible and very cost-effective. Arc ADVANTAGE.

Capital Robotics has hundreds of customers Avoid the rush by getting signed-up early,
achieving remarkable return-on-investments, you can register by visting:
even on low-volume production quantities. capitalmachine.events
Our capabilities include software to design

robotics
Precision Robotic Welding Equipment

Stay current with all things Capital Robotics by

bookmarking our website:
www.capitalrobotics.com│(800) 635-7777
You can also follow us on:
Aug19FAB_FrontAds.indd 2 7/24/19 12:21 PM
Aug19FAB_FrontAds.indd 3 7/24/19 12:21 PM
Aug19FAB_FrontAds.indd 4 7/24/19 10:44 PM
Aug19FAB_FrontAds.indd 5 7/24/19 10:44 PM
 TABLE OF CONTENTS
COVER STORY »

60 Going vertical
Ramping up its fabrication
capabilities and building
strategic partnerships, Kloeckner Metals
Corp. is taking a novel approach to the metal
fabrication supply chain.
Cover photo courtesy of
Kloeckner Metals Corp., Roswell, Ga.

the fabricator
64
FEATURES »

64
Fabricating better
together
Wisconsin-based Metal Fab
Solutions is part of a village of companies
®
that are taking collaboration to the next level.
AUGUST 2019
68 What high-powered
fiber lasers mean for
a fabricating shop
Vol. 49 No. 8
With fiber laser cutting machines available
with 12- and 15-kW power sources, what does
this mean for metal fabricators? They can
cut thick and cut it fast. But that’s just the
82 A new approach to
forming louvers
Red Dot Corp., a manufacturer
of mobile HVAC units and components for
beginning of the story.
heavy-duty commercial and military vehicles, EXPERTISE »
found new efficiencies with a new punching

70 Clever racking design

boosts lifelong powder
coating coverage
Lifetime Products powder coats 100,000
tool.

84
Plasma cutting:
Then and now
54 Precision Matters
CAD jockey Gerald Davis
describes how he distributes
files to end users of his CAD work.
Plenty of metal fabricators rely
metal parts per day. Trying to keep up with

56
on an older plasma cutting machine for their Continuous
those production levels while maintaining
the quality standards required to make
mechanized cutting. They could get much
more efficiency out of the effort if they
48 Improvement
Everyone resists change to some
recreational products that last a lifetime is
would only consider modern plasma cutting degree, but some never stop resisting. That
no picnic.
technology and options. MANAGEMENT » creates a problem that can’t be ignored.

72 Pipe welding
and the cobot
One challenge with pipe welding
automation is that once a cycle starts,
86
How to drill 232 holes
in 2-inch titanium
wing spars
42 Biz Talk
Companies around the world are
rethinking the metal fabrication
58 Bending Basics
A reader has trouble forming an
odd part with unparallel bend
When it came time to reassemble a disas-
an operator usually can’t account for lines. A new bend sequence with the right
sembled jumbo jet for some sort of huge supply chain to find new ways to compete.
unexpected variations in root opening, the gauging could be the answer.
party platform, the people in charge of the

44
bevel angle, or roundness. A new category of Around Washington
task needed a tool to drill through titanium
robots, however, has changed the equation: Sen. Gary Peters, D-Mich., wants
wing spars. Luckily, they found the right
the collaborative robot, or cobot. to create a National Institute of
tool to ensure that the party went on as
Manufacturing to bring federal manufactur-

76 [GET SOCIAL]
Serious welding scheduled.
ing-related programs into one office.
in seconds
Connect with The FABRICATOR

46
Imagine a resistance spot weld, Steel News
finished in less than a second. Now imagine Previously announced steel price
a large bridge weld occurring in a similar hikes have resulted in a slight The FABRICATOR
amount of time. increase after months of decline. Many steel

80
buyers wonder if this price increase is only
Where folding fits
temporary, however. @TheFabricator_
in the job shop Magazine
Folding machines can handle

48
Chief Concerns
large sheets, produce forms quickly, and Manufacturers can’t wait for
don’t require multiple tooling changeovers skilled labor to show up on their
@Fabricating
like a press brake does. Instead of adding doorsteps. They have to be proactive and
another 10-foot press brake, a shop might cultivate their own talent pools. Libertyville, The FABRICATOR
want to consider this alternative bending
technology.
86 Ill.-based Laser Precision has done just that
and was recently honored for its efforts.
Magazine

6 The FABRICATOR AUGUST 2019

Aug19FAB_Contents.indd 6 7/25/19 4:08 PM

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

“Our bending setups

have increased
400% per day.”
— Jeff Elliott

Productivity. Precision. 24/7.

Superior Equipment Solutions (SES) began in 2001 in a 44,000 sq. ft.
facility. Rapid and consistent growth resulted in SES moving to a 100,000
Jeff Bernstein, CEO and Jeff Elliott, COO sq. ft. location in 2017. Today, the California-based company is headquar-
of Superior Equipment Solutions tered in the City of Industry — manufacturing luxury commercial and
residential food service appliances. Looking to leverage industry-leading
technology as a means of maximizing manufacturing flexibility and
productivity, SES partnered with AMADA to configure the optimal
blank-to-bend solution consisting of:

To process medium-sized parts • EG 6013 AR Robotic Bending System: The ideal,

in a variety of lot sizes SES compact and high-speed solution for small, complex
purchased an HG 1003 ARs —
parts — eliminating the need for human operation
a fully-integrated robotic bend-
ing system with a 7-axis robot, and the associated risk of dealing with difficult-to-
automatic gripper changer and handle small parts.
automatic tool changer. • HG 1003 ARs Fully-Integrated Robotic
Bending System: The combined forces of an ul-
tra-precise press brake equipped with an Automatic
Tool Changer (ATC) and a 7-axis robot to achieve
maximum productivity and unattended processing.
• ACIES 2515 AJ Punch/Fiber Laser Combination:
Incorporates the power of a 33-ton, multi-function
turret punch press with the unlimited flexibility of a
4kW fiber laser.

Jeff Elliott, COO at Superior Equipment Solutions reflects on the

success of AMADA’s integrated blank-to-bend solution. “Automatic tool
changes provided by the ACIES and both of the robotic bending systems not
only speed setup, they have completely eliminated tool damage and the asso-
ciated imperfections in finished parts. The EG AR’s multiple part load/unload
stations allow us to easily introduce rush jobs in the middle of a production
run — maximizing our bending versatility. AMADA continues to provide SES
with optimal solutions that resolve our specific manufacturing challenges.
That’s value-added partnership at its best.”

The ACIES 2515 AJ achieves continuous processing

through automated tool changes and automated
material handling — including single part removal
Stay In Touch With What’s Next.
and stacking.

August_2019_FAB_SES_ad.indd 1 7/8/19 11:52

Aug19FAB_Contents.indd 7 7/24/19 12:23 AM
PM
 TABLE OF CONTENTS
FMA:
IN THE KNOW »

50 An invitation from
foundation leadership

51
NAM announces FMA
as one of the best
associations to work for

52
The FABRICATOR®’s
Technology Summit
heads to Denver

53
Fabrinomics®: When a
boom cycle really isn’t
a boom cycle

DEPARTMENTS »

10
From the

the fabricator
Editor-in-Chief
The sun can generate more [GET SOCIAL]
than heat. It can help manufacturers
Connect with The FABRICATOR
generate their own energy, perhaps even
enough to give back to the grid.
The FABRICATOR

11
®
Calendar
of Events
@TheFabricator_ AUGUST 2019
Magazine
14 Readers’
Forum
@Fabricating
Vol. 49 No. 8

16 Industry
News The FABRICATOR
Magazine

96 Classified
Advertising
COMING IN
WHAT’S
ONLINE?
97 SEPTEMBER»
Advertisers
Index
Improve your shop’s
98 THEFABRICATOR.COM »

98 Back Page quality efforts.

Warrior StoryField gives Learn how product life cycle management TECHNOLOGY » Fighting manufacturing
complacency in IoT
veterans, their families, and tools and enterprise resource planning
implementations.

32
civilians the chance to connect and heal software can help to streamline quality
Product Highlights
assurance efforts. Implementing internet of things technology
through metal sculpture. • Power source designed for
in a manufacturing plant is a daunting task.
manual steel welding
Make complex press brake Industry consultant Bill Frahm describes why
setups less so. • Tube/pipe welding machine delivers full proper planning, training, and data integrity
Offline programming and simulation can are needed to fully unlock the potential of
power output over range of product sizes
help to speed up complex stage-bend setups the industrial internet of things.

34
that would have taken too much time to Applications
figure out previously. • Automatic nesting and part Managing chronic pain
labeling help increase manufac- with Stimwave wireless relief
What’s keeping you turer’s efficiency, accuracy technology.
up at night?
For years fabricator Josh Welton has
34 More fabricators this year are worried about
the potential for material price hikes, but
• Zinc phosphate metal finishing line
improves part turnaround time for precision
endured chronic pain because of a rare
arm ligament complication. He recently
the majority still worry about finding the machining company underwent a trial Stimwave procedure
right skilled workers to help them grow.
to help manage his discomfort.
BUYERS’ GUIDES»
36
Technology Spotlight
Europeans have used laser weld-
ing in high-value manufacturing U.S. manufacturing growth hits

90
Forming & Fabricating ®
three-year low in June.
2019 Ventilation System environments for years. In the U.S. the tech-
nology has proven useful in repairing tooling ISM’s June Report on Business® registered
Buyers’ Guide© its lowest PMI, 51.7 percent, since October
for high-volume manufacturing. Could more
widespread use in job shops be next? 2016 and a 4.3 percent drop below the

94
Forming & Fabricating® year’s average. The manufacturing growth

38
2019 Gas Metal Arc slowdown in sectors like fabricated metal
Welding Power Source Product News
products has been mostly blamed on volatile
Buyers’ Guide© tariff tensions.

8 The FABRICATOR AUGUST 2019

Aug19FAB_Contents.indd 8 7/25/19 4:08 PM

Aug19FAB_Contents.indd 9 7/24/19 12:23 PM
 FROM THE EDITOR-IN-CHIEF

Making the sun work for you

Manufacturers probably don’t realize that their flat roofs
are perfect for solar panel installation

Read more from Dan Davis at

www.thefabricator.com/author/dan-davis

T
he forecast of possible 100-degree days all of the sun’s energy for a maximum amount of the 2005 Energy Policy Act, has helped to cre-
in mid-July in the Chicago area might time, which is not the case for panels attached ate 200,000 U.S. jobs and added $140 billion in
have been more newsworthy but for to smaller, angled roofs. Also, the fabrication private sector investment.
the fact that successive days of more than facility had a southern exposure, which further Meanwhile, many on Capitol Hill believe the
90-degree temperatures is plenty hot enough maximized hours of sunlight. incentive tax credit has done its job and don’t
already. At some point it doesn’t matter much By the end of 2018, the company had installed see the need to renew it. Today a company can
anymore. 925 solar modules with a 302-kW production ca- claim a 30 percent tax credit for installing solar
Of course, working in the heat is much differ- pacity. Drury said the goal is to generate approxi- panels; if the current policy is not renewed, the
ent from simply being in the heat. Anyone who mately 105 percent of its power, with the extra tax credit drops to 26 percent in 2020 and ulti-
works outside or in a shop with air-conditioning being fed back into the grid, which can result mately settles at 10 percent in 2022, but only for
can tell you that. But that’s why it’s called work, in revenue from solar renewable energy certifi- utility and commercial projects. Any tax credit
and for most manufacturers, a hot day on the cates (SREC) purchased on the utility market and for residential installations would be completely
job is nothing out of the ordinary. monthly credits directly from the electric utility. eliminated by 2022.
Shapiro & Duncan, a mechanical contractor, Checking an app on his mobile phone, Drury If metal fabricators are interested in harness-
doesn’t necessarily think like that anymore. The was able to see that Shapiro & Duncan’s solar ing the power of the sun, they probably need to
sun is working for them now. panels had produced more than 30 mW of elec- act now. The sun is setting on this opportunity.
With a new roof needed on its 51,000-square- tricity in April and consumption was only 25 mW. For those who are worried about rainy or
foot fabrication facility in Landover, Md., the It had exported 5 mW into the SREC market. cloudy days, they don’t need to be. A company
company committed to having solar roof panels “We’re going to save close to $50,000 per like Shapiro & Duncan is still attached to the grid.
installed at the same time. year,” Drury said. After taking into account all When it can’t produce its own or not enough
“It made sense to put the solar panels up there of the federal and state taxes, which knocked power, it draws power from its local electricity
with the tax incentives, and electricity is not get- a substantial amount off of the approximately supplier. For the most part, it hopes to be ex-
ting any cheaper,” said Mark Drury, Shapiro & $665,000 investment, the company hopes to porting power back to the grid.
Duncan’s vice president, business development. see its ROI achieved in six years. “If you’re a business owner, you should be
“So the motivation was to do the right thing for The timing of Shapiro & Duncan’s investment investing in your company, not something like
the environment, save some money, and earn was fortuitous, because one of the most impor- Wall Street,” Drury said. “It might be nice to play
some good PR in the long run.” tant tax incentives helping to fuel investment in with stocks and keep track of the ticker on your
The mechanical contractor had some knowl- solar panels is not likely to be renewed by the computer screen, but if you have the money, in-
edge of solar panel installations, having been in- Trump administration. Even though the Solar vest in your company. I think the returns you get
volved in some customers’ projects in the past, Energy Industries Association (SEIA) and near- are going to be much better.”
Drury said. It also had confidence in its roofing ly 1,000 companies from across the U.S. solar That’s the bright advice from a fabricator that
contractor and Aurora Energy, the commercial industry are calling on Congress to extend the sees the light.
solar project developer. Section 48 and Section 25D solar investment tax
In addition, the building’s flat roof was perfect credits, the calls might be falling on deaf ears.
for the solar farm. The panels are able to soak in SEIA contends the tax credit, which was part of

FMA OFFICERS FMA DIRECTORS Phil Kooima FMA’S CERTIFIED EDUCATION CENTERS
Chairman of the Board Kooima Co.
James R. (Rob) Bohn Jr. FMA Certified Education Centers (CEC) are community
William “Jeff ” Jeffery Nema Enclosures Jay Phillips and technical colleges, trade schools, and universities that
IRMCO Manufacturing Corp. Valley Iron Inc. specialize in training adults for careers in the metal forming,
First Vice Chairman Sarah Richards fabricating, processing, and machining sectors. They offer
Mike Cattelino
Gregg Simpson Jones Metal Inc. coursework for local students year-round and serve as host
Fox Valley Technical College
Ohio Laser LLC locations for many types of FMA professional development
Stephen Ford James Rogowski programs as requested. A council of members convene six
Second Vice Chairman TRUMPF Inc.
William Isaac Lapham-Hickey Steel Corp. times a year to plan and execute special programs on worker
MC Machinery Systems/ Lori Tapani training for educators and human resource managers from
Andy Gross Wyoming Machine Inc. companies of all sizes.
Mitsubishi Laser Alliance Steel LLC
Secretary/Treasurer Lisa Wertzbaugher To learn more about FMA’s CEC program and view a list of
Carlos Mendizabal-Perez Brian Havlovic Wertzbaugher Services/
Kawasaki Motors Mfg. Corp. USA the current member schools, visit www.fmanet.org/mem-
Industrias Selbor SA de CV Wertzbaugher Consulting
bership/certified-education-center.
Immediate Past Jason Hillenbrand President & CEO
Chairman of the Board Amada America Inc. Edward Youdell To discover how your local community or technical college
Lyle Menke Frank Joy Fabricators & Manufacturers can become a member, call 888-394-4362 or send an
Peddinghaus Corp. GE/Global Nuclear Fuel Association International email to [email protected].

10 The FABRICATOR AUGUST 2019

August19FAB_Editor.indd 10 7/24/19 12:25 PM

 CALENDAR OF EVENTS JOIN US FOR THIS FREE WEBINAR
Brought to you by thefabricator.com
GOLF4MFG NBT Open 3rd Trade Fair for Deburring
Aug. 19—West Chicago, Ill. Technologies and Precision
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FabCast: How to Manage Historically tied to welding applications since their introduction
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Oct. 15-17—Indianapolis
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The FABRICATOR®’s
Presenter:
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Oct. 1-2—Denver Nov. 11-14—Chicago CHARLES ADAMS
Fabricators & Manufacturers Assn. FABTECH Event Partners Arc Welding Laboratory Engineer
888-394-4362 888-394-4362 KUKA
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Metalstamping Assn. Fabricators & Manufacturers Assn. Arc TechCenter at its location in Shelby Township, MI.
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Made in America 2019 and test welding programs. He was also responsible for weld procedure
Oct. 3-6—Indianapolis Submit your industry event development and collecting data on continuum for the marketing team.

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https://madeinamerica.com [email protected].

Register today for this free webinar!

AUGUST 2019 The FABRICATOR 11 Visit www.thefabricator.com/webcast

AUGUST19FAB_Calendar.indd 11 KukaWebcastHTAug19FAB.indd 1 7/24/19 9:13

7/24/19 12:28AM
PM
 AMADA’s new Collimation System provides infinite mode and diameter control
combinations — AN INDUSTRY FIRST.

Collimation
System

➤
Variable Beam
Control Unit

Unmatched Cutting Versatility

Efficient Processing of Thin Materials and Thick Plate

9kW Configuration

June_2019_Fabricator_ENSIS_ad.indd All Pages

AUGUST19FAB_Calendar.indd 12 7/24/19 12:28 PM
 Thin-To-Thick. No Setup.
Continuous processing of thin materials and thick
plate without a cutting lens change or manual setup.
AMADA’s ENSIS fiber laser technology utilizes a proprietary and Key Evolution Factors:
highly-innovative resonator to automatically change the beam mode • Now available in 6kW and 9kW
to accommodate whatever material and thickness being processed. • Addition of collimation system expands ENSIS cut quality
Now, the latest evolution adds another dimension with an innovative and capabilities
collimation system to automatically control beam diameter and • Collimation mechanism does not limit access to cutting lens
beam configuration for unprecedented productivity. or head maintenance
To keep pace with the unmatched power and productivity of the • Infinite mode and diameter control combination is an
ENSIS Series, it’s essential to pair it with automated material handling industry first
such as the AMS 3015 CL (Cycle Loader). Designed and built in Brea, • 1-second clean pierce in 1" plate
California, the AMS CL’s modular design allows fabricators to easily • Up to a 66% reduction in process time when compared to
expand their automation capabilities as future needs evolve. conventional fiber lasers at the same wattage

ENSIS 3015 Fiber Laser

with AMS 3015 CL

AMADA AMERICA, INC. To learn more about how you can Stay In Touch With What’s Next.
leverage ENSIS technology
180 Amada Court • Schaumburg, IL 60173
to achieve unprecedented productivity,
www.amada.com/america
contact AMADA today.
877-262-3287

5/8/19 10:21
AUGUST19FAB_Calendar.indd 13 7/24/19 12:28 AM
PM
 READERS’ FORUM
Surviving in a Volatile Market some low-cost producers like Nucor and Steel welder. I bought it off Craigslist for $150. It was
Those of us in manufacturing are all too familiar Dynamics will emerge with better market share in like-new condition. The gent I bought it from
with cost pressure, but in today’s hypercompeti- and healthier margins. As global raw material used it only once. (It even had the hand-held
tive global economy the squeeze is tighter and prices have increased and tariffs remain in place, face shield with it.)
the stakes are higher than ever before. For com- recycled scrap metal has been readily available at I was a new student in my local college’s weld-
panies doing business in a cutthroat global mar- a low cost for U.S. producers. Scrap metal pric- ing program and had only taken an oxyacetylene
ketplace that moves at the speed of light, market es also are susceptible to fluctuation, but aren’t course up to that time. But I needed to do some
events ripple through an industry in the blink of nearly as vulnerable as foreign raw materials sub- sheet metal welding on my truck. Because I didn’t
an eye, and even the smallest misstep or mis- ject to the ever-changing global market. know anyone who could do it, I figured I could
calculation can be catastrophic. To exacerbate What has become increasingly clear in light of do it myself. I bought the little flux-core MIG ma-
this volatility, market-shifting events that are what’s happening around us is something most chine and taught myself how to weld with it.
beyond our control, like natural disasters and industry insiders have known for some time, but Since then I have completed the welding pro-
political chess moves, are occurring at a dizzying feels more critical than ever: Manufacturing is gram I was enrolled in, which had an emphasis
frequency. So how do businesses insulate them- the cornerstone of business, and every decision in TIG welding. I have since purchased an AC/DC
selves and stay ahead in a time of inevitable vola- surrounding it is critical. In a complex global en- TIG machine. However, I still use that little flux-
tility? Low-cost manufacturing is a great place to vironment, missteps are always costly, and often core MIG for a lot of stuff. Just recently I used
start, but the market shows no mercy for mis- catastrophic. When mistakes do happen or we’re it to fabricate a decorative railing for my front
takes perceived to be a result of corner-cutting. forced to endure market events beyond our con- porch. It runs off 110 VAC only but is so handy.
To illustrate this point, let’s take a look at what’s trol, companies built on lean, responsible, and I’ve repaired a quarter panel on my truck and a
happening in the steel industry. The American adaptable manufacturing will make it out alive. mower deck for a friend, just to name two things.
steel sector has been particularly volatile since Joe Morgan One doesn’t have to have the most expensive
President Trump slapped tariffs on foreign met- CEO machine on the market to get good results. If
Square Deal Machining Inc.
als shortly after taking office. The U.S. relies on Marathon, N.Y. one practices to learn the machine’s limits and
steel imports to meet demand, so tariffs have capabilities and learns to manipulate the set-
a big impact on domestic prices. To make mat- tings for each job, one can see very satisfactory
My First Welding Power Source
ters worse, foreign steel is made with iron ore results even on the most basic of machines.
from Brazil and Australia, where prices are up 45 Editor’s Note: The June 2019 “Welding Wire” Rob Newcomer
percent this year because of supply problems. e-newsletter referenced a story (“Indiana fab- Seattle
Based on these factors, we’d expect to see do- ricator, childhood business grow up together,” I took welding in vocational school. My father
mestic steel prices on a steep upward trajectory, The WELDER, May/June 2019, p. 17) about Chase was in business with the trades of metal spin-
but we’ve seen the exact opposite; prices have McCombs, owner of McCombs Fabrication, and ning and machining.
trended consistently downward for nearly a year. his first welding power source, which helped him I was intrigued with welding and all the
Analysts at Bank of America Merrill Lynch believe launch his business. The following are some of building you could do if you had this discipline
this shift to be the start of “Steelmageddon,” an the stories fabricators shared about their first mastered. My father knew nothing of welding,
industry purge caused by an oversupply of steel welding machines. so I thought it would be a good addition to our
commodities that will last several years, slashing Read the article about Chase McCombs and family business.
prices and eliminating inefficient producers. his first TIG machine. It was a very enjoyable A friend of my father’s gave me a welder his
So, who will remain standing when the dust set- story to read. father made from a transformer and plans from
tles from Steelmageddon? Merrill Lynch believes In response to your question, my first welding Popular Mechanics. This machine got me started,
the upheaval will be treacherous but predicts machine was a Lincoln Electric Handy Core MIG but was crude and maybe dangerous!

Publication Staff Digital Editor: Advertising Sales

the fabricator
®
Gareth Sleger,
President & CEO, [email protected] Associate Publisher:
FMA Communications Inc.: Jim Gorzek
Published by: Edward Youdell Senior Copy Editor: [email protected]
FMA Communications Inc., 2135 Point Blvd., Elgin, IL 60123 Teresa Chartos 815-227-8269
815-399-8700 | www.thefabricator.com Group Publisher: Graphic Designers: Senior Account Representatives:
Dave Brambert Mary Mincemoyer, Janell Drolsum, Sean Smith
Margaret Clark, Jennifer Paulson [email protected]
Statement of Policy Editor-in-Chief:
Media Coordinator:
815-227-8265
As the official publication of the Fabricators & Manu­fac­turers Associa­tion, International, The FABRICATOR
Dan Davis, [email protected]
Rose Merlino Mike Lacny
recognizes the need and importance of dis­seminating information about modern metal forming and fab­
ricating techni­ques, machinery, tooling and man­age­ment concepts for the metal fabricator. The policy of the Senior Editor: Director of Circulation: [email protected]
publisher and this journal is to be non­partisan, favoring no one product or com­pany. The representations of Tim Heston, Kim Bottomley 815-227-8264
fact and opinions expressed in the articles are those of the author and are not necessarily endorsed by the [email protected]
publisher and this journal. By including information on new products, new literature, news of the industry, Circulation Manager: Phil Arndt
articles, etc., this impartiality is strived for and extends to the mention of trade names. Unless product Brenda Wilson [email protected]
ident­ification makes the reference unavoidable, the generic name is used. We acknowledge that on occasion
The Tube & Pipe Journal Editor: 815-227-8267
there may be oversights and errors; the editors regret such oversights and re-emphasize their policy to be Eric Lundin, [email protected] Data Processing Specialist:
impartial at all times. The publisher reserves the right to refuse advertising deemed in­appropriate for pub- Kelly Palmer Amy Hudson
lication in The FABRICATOR, in­cluding ads for classes of products and services not considered of significant STAMPING Journal Editor: [email protected]
interest to the readership. “The FABRICATOR” is a service mark and a trade­mark of the Fabricators & Manu- Kate Bachman, Data Verification Specialist: 815-227-8237
facturers Association, International, and is used, under license, by FMA Communi­cations Inc. Standard Rate
[email protected] Rhonda Fletcher
& Data Service lists our advertising rates in Section 88. Consult SRDS or our current rate card for full rates Michael Scott
and data. Publications of FMA Communications Inc. maintain a policy of keeping editorial and advertising Senior Fulfillment Specialist: [email protected]
separate to ensure editorial integrity that most benefits our readership. Editorial content, including feature The WELDER Editor: Anna Peacock 815-227-8271
articles and press releases, is determined solely by the publisher. Editorial content cannot be purchased, nor Amanda Carlson,
can it be used as a benefit of advertising dollars spent. Editorial is free-of-charge, subject to space availability, Web Designer:
[email protected] Classified Advertising
and open to all interested parties that submit items meeting our editorial style and format as determined Sherry Young John Mathews
by the publisher. Note: Some photographs printed in this publication may be taken with safety equipment
removed for photo­graphic purposes. However, in actual operation, it is recommended that correct safety Contributing Editor: Senior Web Developer: [email protected]
procedures and equipment be utilized. Amy Nickel, [email protected] Mike Kunzelman 815-227-8219

14 The FABRICATOR AUGUST 2019

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 My brother Jack had a fender bender on a car my father insured. The car
was drivable, so he had my brother take me to the farm store and buy a
Lincoln Electric AC/DC 115/125 arc welder in 1980. This was a great machine
for the money and is plugged in my garage today. When my brother, now
60, visits, he always checks to see how my welder is doing.
Michael G. Finn
Metal Form Manager
Floturn Inc.
Fairfield, Ohio

So during high school and after graduation I had

welding jobs. I was never without a job. Most were in
gas metal arc welding (GMAW) production, but I
realized I liked gas tungsten arc welding (GTAW) better
and pursued a career in that welding process.
—Craig Srba

Here is my welding equipment story. I think you’ll find it interesting.

I took welding classes during high school at a trade school just to learn
how to be able to weld, not to make it a career. As a kid I saw my father
gas welding, brazing, and using lead to fill in dents in car panels. I thought it
was neat that he could do those things while most people couldn’t.
What also drove my interest in welding was that my older brother
would always challenge me in building miniature model cars to race
each other with. His joining skills included soldering, and my only joining
skill was with tape! He always beat me. My cars just fell apart, and that
scenario had to change.
So during high school and after graduation I had welding jobs. I was never
without a job. Most were in gas metal arc welding (GMAW) production, but
I realized I liked gas tungsten arc welding (GTAW) better and pursued a
career in that welding process. After a few years of that, I desired more
of a challenge and got the bug to start my own business in welding and
brazing, but specializing in GTAW.
So I purchased a GTAW machine; a GMAW machine; a plasma cutter;
a spot welder; and a bunch of grinders, clamps, and other hand tools for
about $12,000. Because of the multitude of material types, thicknesses,
and joint geometries that came my way on a regular basis, the need to be
able to change GTAW torch sizes quickly became paramount to maintain
successful business operations.
So out of that need, I invented the first Versa-Tig™ System in 1989,
which allows you to connect multiple GTAW torches to a single power
source and then safely select the proper torch for each welding situation
in one second, no tools required. I quickly learned that other welding
facilities had the same need as mine. So I patented the system and added
that production line to the business portfolio of welding and consulting.
Now, 40 some years later, I’m looking forward to retirement and passing
Versa-Tig System manufacturing on to another company that can recognize
its value. I’m grateful for the career path I chose in welding and feel very
satisfied to have been able to contribute new and useful equipment to the
welding industry in the process. It is amazing now that I look back at it and
realize that welding school and a $12K investment in welding equipment
would set me up for a great career in welding.
By the way, since I learned how to weld, my brother has never challenged
me to another miniature model car race again!
Craig Srba
President
Stainless Design Inc.
Westerville, Ohio

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 INDUSTRY NEWS
Manufacturing remains the largest employer Morgan Chase & Co. details how the industry migrated in 35 states,” said Anthony P. Car-
in only two states, says new Georgetown from a hotbed in the Northeast to hubs in the Mid- nevale, lead author of the report
University report west and Southeast by the early 2000s. “The Way We and CEW director.
The transformation of the U.S. manufacturing econ- Were: The Changing Geography of US Manufacturing Manufacturing’s ascent began in
omy from 1947 to 2016 is characterized by major de- from 1940 to 2016” reveals that Indiana and Wisconsin the 1800s, as the U.S. transformed
clines in employment in favor of major increases in are the only states where manufacturing remains the from an agrarian to an industrial
production capability—a loss of 3 million jobs but a largest source of employment today. economy. By 1940, 23 percent of
boost of $4 trillion in economic output. New research “Despite the fact that manufacturing is the largest workers were employed in manu-
from the Georgetown University Center on Education employer in only two states, it still is the top provider facturing. Industry employment was
and the Workforce (CEW) in partnership with JP- of good jobs for workers without a bachelor’s degree concentrated in 15 northeastern,
Mid-Atlantic, and Great Lakes states.
By the beginning of the millen-
nium, the share of workers in man-
ufacturing had fallen to less than
15 percent, and by 2016 it hovered
at 10 percent. Meanwhile, employ-
ment in services grew from 21 to 55
percent between 1940 and 2016.
As the economy shifted from
manufacturing to services during
the 20th century, the geography
of manufacturing shifted to the
southeastern and central states,
where labor costs were lower and
subsidies were more attractive to
industry. As of 2000, it was the
largest employer in 18 states, in-
cluding seven southeastern states:
Alabama, Arkansas, Kentucky, Mis-
sissippi, North Carolina, South Car-
olina, and Tennessee. However, by
2016, the industry had fallen from
the ranks as a top employer.
The status of manufacturing in
the U.S. economy has evolved be-
cause of three connected trends:
1. A decline in share of economic
output as the role of services in the
economy grew.
2. A decline in share of the work-
force as the industry adopted au-
tomation and encountered intensi-
fied international competition.
3. A rise in output per worker
that has allowed manufacturing to
increase its overall output.
Increased foreign trade and off-
shoring have also contributed to
steep manufacturing job losses,
especially after 2000. “Manufac-
turing’s employment base shrank
even further after China joined the
World Trade Organization in 2001,”
Carnevale said.
Despite the sector’s national de-
cline, continued industrial strength
in Indiana and Wisconsin reflects
the enduring legacy of manufac-
turing in the Midwest. For the full
report, visit cew.georgetown.edu/
manufacturingstates.
16 The FABRICATOR AUGUST 2019

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 Half of manufacturers panies with $500 million or more in annual revenues. Manufacturers also are mixed on how the expansion
experienced data breaches Overall, 63 percent of respondents are preparing for of e-commerce has benefited or hurt their operations.
in past year, report finds the possibility of a recession. Forty-nine percent of the companies surveyed said
Manufacturers face a barrage of cy- Despite the current economic boom, there are no- they use e-commerce to sell their products. Of these,
bersecurity threats today, and half table challenges on the horizon fueling concern of a 39 percent said sales from e-commerce have exceeded
of companies have fallen victim to downturn. Uncertainty surrounding global trade policy their expectations, while 37 percent said sales have
at least one data breach during the continues to hover over the industry. Nearly 40 per- been disappointing.
past 12 months, according to the cent of respondents expect trade developments to Further, labor challenges remain an impediment
“2019 Manufacturing and Distribu- have a positive impact on their companies, while 35 to growth. When asked to identify obstacles to inno-
tion Report” from Chicago-based percent said they expect a negative impact. (continued on page 18)
professional services firm Sikich.
Of the 50 percent of respondents
who said their companies experi-
enced data breaches, 11 percent
said they had “major” breaches.
Still, executives believe their com-
panies can thwart attacks. A ma-
jority (54 percent) said they are
“extremely” or “very” confident
in the ability of their companies to
prevent or minimize the impact of
data breaches.
The report found that many
manufacturers—especially
those with revenues under $500
million—neglect key cybersecurity
preparedness efforts. Overall, less
than 40 percent of these smaller
companies perform cyber audits
(38 percent), penetration testing
(33 percent), security assessments
of vendors (32 percent), and
phishing exercises on employees
(31 percent).
Though a majority of respon-
dents have automated in some way
production processes and machin-
ing, assembly, and packaging, only
about a third said they have “ex-
tensively” automated these areas.
Notably, even fewer manufacturers
maximize their use of the most ad-
vanced technologies. For example,
24 percent use robotics extensive-
ly, while 23 percent say the same
about 3D printing and additive
manufacturing. Only 34 percent of
companies use the industrial inter-
net of things extensively, though
that number rises to 57 percent for
manufacturers with revenues of
$500 million or greater.
Amid a decadelong economic ex-
pansion, manufacturers are bullish
but still preparing for a downturn.
Only 27 percent of the executives
surveyed believe it is “extremely”
or “very likely” that the U.S. econo-
my will enter a recession in the next
12 months. However, that number
rises to 49 percent among com-

AUGUST 2019 The FABRICATOR 17

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 INDUSTRY NEWS
(continued from page 17) that thrive in the years ahead will be the ones that em-
vation, 53 percent of respondents cited “finding and brace advanced technology and proactively take steps
retaining the talent needed” as “extremely” or “very” to fortify their operations against cybersecurity, labor,
challenging. and economic challenges.”
“Despite a long run of impressive economic growth, To view the full report, visit https://www.sikich.com/
manufacturers face challenges related to rapid chang- md-report/.
es in the industry, geopolitical uncertainty, and the
The Apprentice School at Newport News
prospect of an eventual economic downturn,” said
Shipbuilding marks 100th anniversary
Jerry Murphy, partner-in-charge of Sikich’s manufac- News, Va., marked its 100th anni-
turing and distribution practice. “The manufacturers The Apprentice School at Huntington Ingalls Indus-
versary on July 1.
tries’ Newport News Shipbuilding division, Newport
The school opened at the end of
World War I to recruit, train, and
develop shipbuilders. Today the
curriculum includes advanced digi-
tal shipbuilding concepts and tech-
nology to support the company’s
integration of digital technology
across the shipyard.
In its history, the school has pro-
duced more than 10,800 graduates
who have designed and built ships
for the U.S. Navy. It accepts about
225 apprentices per year, offering
four- to eight-year, tuition-free ap-
prenticeships in 19 trades and eight
optional advanced programs. Ap-
prentices work a 40-hour week and
are paid for all work, including time
spent in academic classes.
Lincoln Electric completes
purchase of controlling stake
in Askaynak
Cleveland-based Lincoln Electric
Holdings Inc. has completed the
purchase of the controlling stake
of Kaynak Tekniği Sanayi ve Ticaret
A.Ş. (Askaynak).
Askaynak, located in Turkey, is
a supplier and manufacturer of
welding consumables, arc weld-
ing equipment, plasma and oxyfuel
cutting equipment, and robotic
welding systems.
Moran Iron Works receives
$564,000 DoT grant for new
equipment
Onaway, Mich.-based Moran Iron
Works has been awarded a $564,000
grant through the U.S. Department
of Transportation Maritime Admin-
istration’s Small Shipyard Grant pro-
gram. The funds will be used toward
the purchase of a PythonX CNC
plasma cutting system.
The company offers shipyard
building and large metal fabrication
for power plants, locks and dams,
and large industrial businesses.

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Aug19FAB_IndustryNews.indd 19 7/24/19 10:54 PM
 INDUSTRY NEWS
Trace-A-Matic awarded Project Excellence lead applicant in collaboration with Ohio Tech- Dielectric Mfg. to build new headquarters
Challenge Coin by U.S. Army Net (OTN) and the Ohio Manufacturers’ Asso-
ciation (OMA), collectively known as the Ohio
Manufacturing Workforce Partnership (OMWP).
The funding will play a vital role in helping
Ohio address the workforce shortage and skills
gap affecting manufacturing, as manufacturers
across the state have repeatedly cited work-
force as their top issue of concern. With the Dielectric Mfg. has announced plans to expand
grant funds, OMWP will upskill 5,000 Ohioans its metal and plastic parts production capac-
over the next four years through Industry Rec- ity with a new plant and headquarters. The
ognized Apprenticeship Programs, an earn-and- 100,000-sq.-ft. facility in Germantown, Wis.,
Trace-A-Matic Corp., Brookfield, Wis., has re- learn model recently authorized by the DOL. will replace the company’s existing location in
ceived a Challenge Coin medallion, presented by The stated goals of the DOL initiative are to nearby Menomonee Falls, Wis. The building is
U.S. Army Col. Chuck Worshim, program man- accelerate the expansion of apprenticeships to expected to be completed in spring 2020.
ager for cruise missile defense systems at the new industry sectors reliant on H-1B visas, pro- The company machines and fabricates metal
U.S. Army’s Program Executive Office of Missiles mote the large-scale expansion of apprentice- and plastic components and assemblies for in-
and Space. ships, and increase apprenticeship opportuni- dustries including health care equipment, aero-
The company machines precision parts and ties for all Americans. space, defense industry vehicles and vessels,
assemblies for manufacturers in the aerospace, OMWP’s project will focus on career path- food processing, power distribution, and agri-
defense, food processing, heavy equipment, ways in advanced manufacturing with an eye to-
culture.
medical equipment, mining, oil and gas, pharma- ward technological advances, including Industry
The building will include space for offices, pro-
ceutical, power generation, transportation, and 4.0 and cybersecurity. To date, the partnership
duction, quality control, and warehousing. The
general industrial markets. has secured commitments from Ohio manu-
company’s facilities in Waupaca, Wis. (which
facturers to train 2,315 apprentices. OMA and
operates as Centerline Machine), and Lake Mills,
Ohio Manufacturing Workforce Partnership its industry sector partnership network will be
awarded $12 million apprenticeship grant Iowa, will remain operational.
conducting outreach and education to bring in-
The U.S. Department of Labor (DOL) has an- dustry-recognized apprenticeship opportunities Solar Atmospheres adds all-metal
nounced the recipients of its Scaling Appren- to additional Ohio manufacturers, while OTN hot zone furnace
ticeship Through Sector-Based Strategies grant. continues to develop innovative and accelerated Solar Atmospheres has installed an all-metal hot
The grant includes a $12 million award to Ohio’s training models at community colleges, universi- zone vacuum furnace at its facility in Souderton,
Lorain County Community College (LCCC), the ties, and Ohio Technical Centers. Pa. This is the company’s third such furnace in-

Aug19FAB_IndustryNews.indd 20 7/24/19 10:54 PM

 Shipments of extruded products to domes- tomotive markets. It offers short-run production,
tic markets increased across all sectors in 2018. prototypes, model shop work, and custom-fabri-
Building and construction continues to be the cated products, as well as products that require
largest market sector for extruded products, reverse engineering or print development.
with shipments of 2.12 billion lbs. in 2018. Trans-
portation is the second-largest market sector at Alfa Laval opens plant in Oklahoma
1.82 billion lbs. Auto and light truck is the princi- Alfa Laval, a Sweden-based supplier of heat
pal growth market for extruded products, and transfer, separation, and fluid-handling technol-
shipments to this sector have grown by more ogies, has opened a 60,000-sq.-ft. spiral heat ex-
than 72 percent since 2006. changer manufacturing center in Broken Arrow,
stallation for its climate-controlled room. The Imports of extruded products into the U.S. Okla., creating 50 jobs.
additional furnace increases Solar’s capacity for and Canada, excluding cross-border trade, con- The company also has announced plans to ex-
processing sensitive materials such as PH stain- tinued to rise in 2018 and totaled 472 million pand its facilities in Richmond, Va., and Green-
less, nickel-chrome-based superalloys, titanium, lbs. Import penetration, which is measured as a wood, Ind.
and ferritic and austenitic stainless steels. share of domestic producer shipments less ex-
The placement of isolation valves, an all-met- ports, grew to 8.4 percent in 2018, compared to Ort Tool and Die announces
7.5 percent in 2017. Peak imports were recorded certification to API Q1
al moly/stainless steel hot zone, and a stainless
in 2010 at 488 million lbs. The top five source Erie, Mich.-based Ort Tool and Die, a manu-
steel chamber allow the furnace to attain the
countries for imports during 2018 were Mexico, facturer of custom machines, assemblies, and
level of cleanliness mandated by the aerospace
Vietnam, Malaysia, Indonesia, and China. various machine components, has announced
and medical markets, according to the company.
KSM Metal Fabrication its certification under American Petroleum In-
North American aluminum extrusion marks 40 years in business stitute (API) Q1. This certification is intended
industry hit record-high shipments in 2018 for companies that manufacture equipment or
KSM Metal Fabrication,
The Aluminum Extruders Council (AEC), Wau- Troy, Ohio, marks its 40th components of equipment used in oil and natu-
conda, Ill., and the Aluminum Association, Ar- anniversary in 2019. Found- ral gas production. This certification focuses on
lington, Va., report that the aluminum extrusion ed as Kerber Sheet Metal quality management systems and performance,
industry in the U.S. and Canada had record-high in 1979 by Dan Kerber, the as well as assisting companies with aligning qual-
shipments in 2018. Producer shipments totaled company originally was an ity with business strategy.
5.51 billion lbs. in 2018, which is 4.5 percent high- HVAC contractor. Ort Tool is a machine and fabrication shop
er than shipments in 2017 and 3.2 percent higher Today the renamed firm, led by Kerber’s daugh- that builds all its machine parts and assemblies
than shipments in 2006. This is the ninth con- ter, Kathy, is a fabricator of customized metal to blueprint. Capabilities include CNC machining,
secutive year of growth. parts for the aerospace, food equipment, and au- grinding, EDM, welding, assembly, and design.

Aug19FAB_IndustryNews.indd 21 7/24/19 10:54 PM

 INDUSTRY NEWS
Penn College faculty prep to teach A week after the spring semester ended, six welding spent three days in Agawam, Mass.,
electron beam welding faculty at Pennsylvania College of Technology in Wil- training with field engineers from
Jorge Alvarez, field liamsport, Pa., went back to school—as students. That Cambridge Vacuum Eng. (CVE) on
engineer for Cambridge
preparation will equip them to be pioneers this fall an electron beam welding machine.
Vacuum Eng., discusses
components of an when the college becomes the first U.S. educational in- CVE is scheduled to deliver a 60-kV
electron beam welder
stitution to feature an electron beam welding machine. unit to campus in late October.
with Penn College
Penn College faculty initiated
welding instructors Welding instructors Michael R. Allen, Aaron E. Bid-
(from left) Aaron E. the CVE relationship after meet-
dle, Ryan P. Good, Jacob B. Holland, Ty E. Rhinehart,
Biddle, Ty E. Rhinehart, ing company representatives a
and Ryan P. Good. along with Assistant Professor James N. Colton II,
few years ago at FABTECH®, North
America’s largest metal forming,
fabricating, welding, and finishing
event.
“The faculty had the foresight to
think how an electron beam weld-
er could create distinction for our
program,” said Loni N. Kline, vice
president for institutional advance-
ment. “Tony Slater took the oppor-
tunity to advocate within CVE that
it made a lot of sense to place this
equipment in our facility, so they
worked out a deal that made it pos-
sible for us to partner.”
Slater’s push for the partnership
followed a visit to Penn College and
the welding-related instructional
space in the Lycoming Engines
Metal Trades Center. A 35,000-sq.-
ft. expansion of the facility—fund-
ed in part by a $2 million grant
from the U.S. Department of Com-
merce’s Economic Development
Administration—will be completed
by August.
According to Slater, Penn College
will be the first learning establish-
ment in the U.S. and only the sec-
ond in the world to have an elec-
tron beam welder.
Penn College offers a bachelor’s
degree in welding and fabrication
engineering technology, an associ-
ate degree in welding technology,
an associate degree in metal fabri-
cation technology, and a certificate
in welding. For more information,
visit www.pct.edu/icet.
Spartan Motors launches
Detroit Truck Manufacturing
Spartan Motors Inc., Charlotte,
Mich., a provider of specialty vehi-
cle manufacturing and assembly for
the commercial and retail vehicle
industries and emergency-response
and RV markets, has launched De-
troit Truck Manufacturing™ (DTM).
Located in Madison Heights, Mich.,
this captive channel supplier will

22 The FABRICATOR AUGUST 2019

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 provide fabricated aluminum cabs HL Precision, Hi-Grade Welding partner Both companies will continue to operate individually
for Spartan’s firetrucks, as well as to form H3 Manufacturing Group while seeking ways to work together collaboratively. HL
the cab and chassis products it sup- HL Precision Mfg. Precision offers CNC machining, assembly, and paint
plies to more than 40 OEM fire- LLC, with facilities and powder coating capabilities, while Hi-Grade pro-
truck manufacturers. vides laser cutting, fabrication, and complex welding.
in Champaign and
“In addition to producing cabs de-
Fisher, Ill., and Scha- The combined companies will serve the aerospace/
signed for final-stage manufactur-
umburg, Ill.-based defense, medical devices, power transmission, auto-
ing, this initiative further protects
Hi-Grade Welding & Mfg. LLC have combined to form a mated retail, life sciences, and public transportation
Spartan from potential supplier dis-
ruptions in our changing economic common parent company known as H3 Mfg. Group LLC. markets.
climate,” said Daryl Adams, presi-
dent/CEO of Spartan Motors.
This initiative will further Spar-
tan’s vertical integration strategy
for efficiencies and savings and re-
sult in reduced material costs and
freight savings.
Navistar to expand in Alabama
Navistar has announced plans for a
$125 million expansion of its truck
and bus manufacturing operations
in Huntsville, Ala., adding 145 new
jobs.
The project will allow the produc-
tion of big-bore powertrains devel-
oped under Navistar’s partnership
with Volkswagen commercial truck
subsidiary Traton.
Pemamek’s shipbuilding event
gathers more than 130
maritime professionals

Pemamek held its Modern Ship-

building Summit 2019 in Finland
June 11-12, 2019. The event attract-
ed more than 130 maritime profes-
sionals from 20 countries and 56
companies.
The two-day summit included
presentations from shipyards such
as Germany-based MV Werften and
U.S.-based Ingalls Shipbuilding, as
well as welding, cutting, and pro-
duction technology providers such
as Pemamek, Lincoln Electric, Davi,
HGG, Hexagon, and Microstep. The
event also offered live demonstra-
tions of such equipment as the Pema
one-sided welding station with the
laser-hybrid process and integrated
milling, Pema T-beam welding line,
and Pema VRWP-X2 robot welding
station for micropanels.

AUGUST 2019 The FABRICATOR 23

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 INDUSTRY NEWS
FMA announces winner of 2019 Frank A. DiPietro 2019 Frank A. DiPietro Award. Ream, an internationally ies and components. The award is
Award Recipient recognized expert in industrial lasers, process develop- given annually at ALAW to a per-
Fabricators & Manufac- ment and analysis, and manufacturing systems design son most exemplifying the vision,
turers Association Intl., and performance, is a pioneer in the development of spirit, and determination DiPietro
Elgin, Ill., has named Stan laser materials processing technologies. demonstrated in bringing laser and
Ream as the winner of its robotics technology to transporta-
The award was established by FMA in 2017 in
tion manufacturing.
Stan Ream, EWI, Frank A. memory of Advanced Laser Applications Workshop
DiPietro Award recipient, In the 1970s Ream began partici-
(ALAW) founder Frank A. DiPietro (1926-2016). DiPi-
with Jim Kenney, EMAG, pating in high-power laser welding
ALAW conference chair. etro was a great evangelist for laser welding car bod- development for the Air Force,
Navy, and NASA, and he has con-
tinued to contribute to a variety
of laser applications and produc-
tion implementations. Through
employment at Sciaky Inc., AVCO
Everett Research Laboratories, IIT
Research Institute, Battelle, Amada,
GE FANUC, Worthington Indus-
tries (TWB), and EWI, Ream has
gained a broad perspective on the
technological and marketing force
that has shaped the laser materi-
als processing world. A longtime
volunteer on the ALAW Steering
Committee, Ream carries on DiPi-
etro’s legacy today by promoting
the future of lasers and automation
in the industry.
S & B Modular Operations
opens module assembly bay in
Texas, adds pipe fabrication
S & B Modular Operations, a sub-
sidiary of S & B Engineers and Con-
structors Ltd., has announced the
installation of a covered module
assembly bay at its Baytown, Texas,
location. The existing 50,000 sq. ft.
of covered production space has
been converted to provide full pipe
fabrication services for both car-
bon steel and alloy pipe.
The new module assembly bay
provides an additional 24,000 sq.
ft. of covered assembly and pro-
duction space, as well as 4,480 sq.
ft. of additional office and storage
space.
Tramont Mfg. acquires
Compo Steel Products
Tramont Mfg., a Milwaukee-based
producer of diesel fuel tanks, en-
closures, trailer tanks, and walk-
ways for the standby power in-
dustry, has acquired Compo Steel
Products. Compo is continuing
operations as Motive Energy, a divi-
sion of Tramont Mfg., at its current
location less than a mile from Tra-
mont’s Milwaukee facility.

24 The FABRICATOR AUGUST 2019

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 Motive Energy’s product line in- Researchers capture microscopic manufacturing flaws via high-speed X-ray movies
cludes electrical enclosures for Microscopic defects problems if undetected, and the process of fixing these
multiple applications. The compa-
that occur in laser-based flaws can increase the time and cost of high-tech man-
ny produces precision components
manufacturing of metal ufacturing. But new research into the cause of these
for passenger and freight locomo-
parts can lead to big flaws could lead to a remedy.
tives and serves the above- and be-
Dr. Lianyi Chen, Missouri Researchers from Missouri University of Science and
low-ground mining equipment, al- S&T assistant professor of
ternative energy, utilities, military, Technology, Argonne National Laboratory, and the Uni-
mechanical and aerospace
and infrastructure industries. engineering. Photo by Sam versity of Utah created high-speed X-ray “movies” of
O’Keefe/Missouri S&T. (continued on page 26)
QComp announces
facility expansion
QComp Technologies, a robotic
systems integrator, has begun con-
struction of a 10,000-sq.-ft. ad-
dition to its production facility in
Greenville, Wis. The expansion is
scheduled for completion this fall.
The company is a provider of ro-
botic packaging systems, material
handling systems, and automation
line integration.
Maker Skills Academy
launches in California
Vocademy has opened the Maker
Skills Academy, a hands-on training
program that covers vocational, ca-
reer, and soft skills. The six-month
program is open to everyone over
the age of 16, with no prerequisite,
transcript, or GPA requirements.
It includes more than 90 classes,
such as 3D printing, CAD, laser cut-
ting and engraving, robotics and
automation, welding and fabrica-
tion, hand tools, and power tools.
Students have access to Vocade-
my’s Maker Labs prototyping facil-
ity every evening to practice their
skills, collaborate, create resumes,
and build capstone projects.
Bio Fab Technologies to expand,
move headquarters in Wisconsin
Kenosha, Wis.-based Bio Fab Tech-
nologies Inc. has announced plans
to move its headquarters to a new,
nearly 51,000-sq.-ft. office and cus-
tom stainless fabrication facility in
Pleasant Prairie, Wis.
The facility, which will produce
equipment for the food, beverage,
and pharmaceutical industries, is
expected to be operational by Feb-
ruary 2020. Plans call for future ex-
pansion of nearly 23,000 sq. ft. at
the new location.
The company, which currently
employs 39 people, expects the ex-
pansion to create five new jobs.
AUGUST 2019 The FABRICATOR 25

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 INDUSTRY NEWS
(continued from page 25) The researchers described their findings in a paper “The newly discovered mecha-
a manufacturing phenomenon known as laser spatter- titled “Bulk explosion induced metal spattering dur- nism will guide the development
ing. Laser spattering refers to the ejection of molten ing laser processing,” recently published in the journal of approaches to mitigate defect
metal from a pool heated by a high-power laser dur- Physical Review X. Using X-ray imaging, the research- formation in welds and additively
ing laser-based manufacturing processes, such as laser ers captured the spattering behavior of a titanium alloy manufactured parts,” said Dr. Li-
welding and laser-additive manufacturing. These laser anyi Chen, assistant professor of
Ti-6Al-4V during fabrication. Their microscopic movies
mechanical and aerospace engi-
manufacturing technologies are used to fabricate parts revealed “a novel mechanism of laser spattering—the
neering at Missouri S&T and one of
for use in a variety of industries, including aerospace, bulk explosion of a tongue-like protrusion” that forms
the paper’s corresponding authors.
automotive, health care, and construction. in one region of the metal.”
Chen collaborated with Dr. Tao
Sun’s team at Argonne National
Laboratory and Dr. Wenda Tan’s
team at the University of Utah on
the research. The group created
the images through the use of a
high-energy synchrotron X-ray at
Argonne National Lab, along with
image analysis and numerical simu-
lations. Researchers at the Argonne
facility employ X-ray scattering
techniques to study materials.
“The high penetration power of
hard X-rays and high resolutions
of the imaging technique enable
us, for the first time ever, to con-
nect the spattering behavior above
the surface with dynamics below
the surface and inside the titanium
sample,” Chen said.
Working with Chen on the re-
search is Qilin Guo, a PhD student
in mechanical engineering at Mis-
souri S&T.
Jorgensen Conveyors purchases
nearly $1 million worth of
new equipment
Jorgensen Con-
veyors, a suppli-
er of conveyor
and filtration
technology for
metalworking
and other indus-
trial applications in Mequon, Wis.,
has purchased and installed two
new machines from Bystronic Inc.
The machines—a 250-ton press
brake and 3-kW fiber laser—fea-
ture controls that integrate seam-
lessly with SOLIDWORKS® 3D CAD
software.
Report highlights senior steel
executives’ predictions for
steel and metal growth
Headwall Partners LLC, Greenwich,
Conn., an independent corporate
finance and strategic advisory firm
focused on the steel and metals
industry, has published the “Head-
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 wall 2019 Annual Steel & Metals Robinson Metal to expand in Wisconsin Murata Machinery to host Technology Showcase
Growth Survey.” The survey sum- De Pere, Wis.-based custom metal fabricator Robinson Murata Machinery USA will host its second Technology
marizes the perspectives of senior Metal has announced plans to invest $2.6 million in Showcase Sept. 19-20 at its Charlotte, N.C., facility. The
steel sector executives who have an existing manufacturing facility in Manitowoc, Wis. event will highlight Muratec automated turning centers
identified mergers and acquisitions The project is expected to create 94 jobs over the next and includes a private tour of company headquarters.
(M&A) as the key source of strate- three years. The event will include live demos, new technology
gic growth at their companies for previews, and one-on-one sessions with the company’s
The 112,000-sq.-ft. building will allow the company to
the next three years. engineers. To attend the event, contact Deandra Mik-
grow in three divisions: custom enclosures, pipe and
Peter J. Scott, founder and man- los, senior marketing specialist, at deandra.miklos@
vessel fabrication, and fabrication and machining.
aging partner of Headwall Partners, muratec-usa.com.
commented, “This year’s growth
survey indicates that the market is
primed for a meaningful uptick in
M&A. Senior sector executives in-
dicated optimism about near-term
growth at their companies as a re-
sult of the past and expected future
Trump administration policies.”
Thomas A. Danjczek, senior ad-
viser to Headwall Partners, added,
“The survey respondents were ex-
tremely positive regarding expect-
ed steel sector production volume,
pricing, and financial performance.”
Headwall conducted a detailed
survey of sector executives at the
chairman, CEO, and CFO levels to
assess how management teams
in the steel industry are pursuing
growth. Participating companies
represented a broad spectrum of
the industry’s subsectors, sizes,
and ownership structures. The sur-
vey focused on the policies of the
Trump administration, general ex-
pectations for economic and sec-
tor growth rates, and corporate
plans for strategic growth.
According to the survey, 90 per-
cent of respondents believe the
economic policies of the Trump
administration had a positive im-
pact on recent U.S. GDP growth.
Sixty-seven percent of respondents
believe these policies will have a
positive impact on 2019 GDP, down
from last year’s response.
Fifty-seven percent of respon-
dents are more optimistic about
the prospects for their companies’
financial performance over the
next three years than over the past
three years, also down from last
year’s survey. Eighty-six percent of
respondents expect their company
to be equally active or more active
in M&A over the next three years
than in the past three.
To view the complete results of
the survey, visit www.headwallpart-
ners.com/publication.
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 INDUSTRY NEWS
Supplier News The 285- by 216-in. press will weigh about 650,000 air or water. Beckwood will design
Beckwood Press Co., a St. Louis-based manufacturer lbs. when fully assembled and will be installed in a 6-ft.- a closed-loop pneumatic control
deep pit. The 160- by 160-in. bolsters will contain ma- system for the bulge forming op-
of hydraulic and servo-electric presses and automa-
chined t-slots for use with the quick die change system, eration, allowing Wabash National
tion systems, has been awarded a contract by Wabash
and a fully adjustable 8-point square gib-guidance sys- to form parts to specific dome
National Corp. to engineer and build a custom 3,500-
heights while using up to 750 PSI of
ton hydraulic bulge forming press. This machine will be tem will help ensure bed-to-ram parallelism through-
air pressure.
used to form stainless steel and aluminum tank heads out the stroke.
An automated quick die change
with diameters up to 156 in. for Wabash National’s tank To accommodate Wabash National’s existing tool-
system with chain-driven die
and silo business in Lafayette, Ind. ing, the press will be able to bulge form using either clamps and a bed trolley will be
included. The trolley will be able
to transport dies up to 30,000 lbs.
across a 30-ft. track via a push-but-
ton controls station.
Waunakee, Wis.-based Blade-
Serpent.com has launched as a
band saw blade e-commerce re-
source with a subscription-based

TECHNICAL TRAINING
option, providing blades through
scheduled delivery every two or

IS AVAILABLE THIS FALL four weeks.

The company has a proprietary
line of Hellbender™ metal cutting
Find dates, locations, and more on page 52. band saw blades, as well as an ex-
tensive selection of Lenox® metal
cutting band saw blades
supplied by a certified Lenox
weld center. Its products include
custom bimetal, carbon, and car-
bide band saw blades.
Fabrication Solutions & Tech-
nologies has announced the con-
struction of a new building in
Expert instructors of FMA Certificate Courses Longview, Texas. The company is the
will help develop and improve your employees’ North American representative for
critical skills on the shop floor. IMCAR steel fabricating and weld-
ing equipment, including plate rolls,
Precision Press Brake Coil Processing presses, and Vertical Systems for
Tank Production™. An open house
is being planned for early 2020.
Lantek, a provider of manufac-
Understand the principles Master the fundamentals of coil processing turing software for the sheet metal
of precision sheet metal bending with an understanding of the machines, and fabrication industrial sectors,
by learning techniques, calculations, processes, and tools of the trade. has entered into a collaborative
and equipment. agreement with the Basque Center
for Applied Mathematics (BCAM).
Laser Welding Technology Machine Tool Field Service Technician This international research center
currently has a workforce of more
than 90 high-level researchers who
work in different areas from data
Gain knowledge needed to build the Obtain the vital skills necessary for
science to mathematical modeling.
foundation for sound laser welding incoming machine installers and field The agreement reached by
design and process implementation. service repair technicians. both organizations focuses on
developing new models of applied
mathematics and algorithms that
will enable metal forming industries
to reach high levels of efficiency
Learn more | fmanet.org/certificate in their calculations. As a starting
point, the collaboration will explore
new avenues for approaching

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 parts nesting. Lantek’s goal is to SafanDarley North America LLC, a manufac- When fume extraction supplier ULT LLC entered
constantly improve its nesting turer of press brakes and shears for sheet metal and the U.S. market in early 2017, the company promised
methods, and this collaboration plate, has announced it will relocate its U.S. facility to to plant a tree for every unit sold in the U.S. On May
will result in the development of an Waukesha, Wis. 17, 2019, ULT paid the transportation costs for 150 Mil-
advanced algorithm that achieves The new facility, to be opened in September 2019, waukee children to native plant seedlings at Mequon
the optimization of 2D nesting from will provide service, help desk support, parts, applica- Nature Preserve.
the different possible approaches, tions engineering, robotics support, technical sales, ULT LLC is a provider of fume extraction systems
says the company.
and administrative support for distributors and cus- for welding, lasers, and soldering; and dust-collection
Ocean Machinery, Fort Lauder-
tomers in the U.S., Canada, and Mexico. equipment for the filtration of gases, vapors, and odors.
dale, Fla., a provider of structural
steel fabricating machinery, has en-
tered into a partnership with AGT
Robotics to offer a compact auto-
mated welding robot to medium-
sized structural steel fabricators.
AGT Robotics offers automation
and industrial robotics for the met-
al fabrication market.
Metal fabrication equipment dis-
tributor On Point Solutions has
announced its exclusive distribu-
tion relationship with Faccin USA.
Italy-based Faccin manufactures
plate rolls, angle rolls, dished heads,
and specialty machines.
Faccin USA has sales and ser-
vice offices in Tallahassee, Fla., and
Fairhope, Ala.
On Point Solutions has sales of-
fices in Sheboygan, Waukesha, and
Wauwatosa, Wis.; Jonesboro, Ark.;
Nashville; and Fairhope, Ala.
Rockford Systems, a provider
of machine safeguarding and com-
bustion safety systems, now offers
a press safety inspection service,
which evaluates the mechanical
operation and safety compliance of
punch presses and press brakes.
The company’s inspectors visit
customers on-site. The visual in-
spection determines if part-rev-
olution punch presses and press
brakes and full-revolution punch
presses are in safe working order
according to OSHA regulations and
ANSI standards. This determination
follows a series of function tests in-
cluding press stop times, safety dis-
tance measurements, and inspec-
tion of safeguards and controls.
In addition, a visual mechani-
cal inspection assesses the proper
functioning of the press, condition
of press lockout/tagout devices,
safeguarding and controls, NFPA
79 electrical compliance, tooling or
dies and their setups, and any auxil-
iary safeguarding.
AUGUST 2019 The FABRICATOR 29

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 INDUSTRY NEWS
DeWys Mfg. to expand in Michigan Salvagnini to expand campus in Ohio Bystronic Canada hosts
Quebec Best Choice event
DeWys Mfg. Inc., a metal fabricating company
based in Marne, Mich., has announced plans for Mississauga, Ont.-based Bystronic Canada Ltd. re-
a nearly $7 million, 30,000-sq.-ft. expansion in cently presented one of its Best Choice events for
Wright Township, Mich. customers, OEMs, and shop owners in Quebec.
Held at EPP
The expansion is expected to create 41 jobs.
Metal, the seminar
Reibus Intl. acquires Metalmixx Salvagnini has broken ground for the expan- presented attend-
sion of its customer resource campus in Hamil- ees with new tech-
Atlanta-based Reibus Intl., an independent, web-
ton, Ohio. The expansion will encompass about nologies in laser
enabled marketplace for buying and selling in-
30,000 sq. ft. of space focused on the compa- cutting, bending,
dustrial metals, has acquired all of the assets of
ny’s machines, IoT utilization, service, and vir- automation, soft-
Blue Steel LLC, d/b/a Metalmixx, an online plat-
tual simulations. It will feature dedicated areas ware, and integra-
form that facilitates the purchase and sale of ex- tion, with a strong
for education, training, and design-for-manufac-
cess carbon steel. focus on equip-
turing concepts. The grand opening is scheduled
Reibus will transition Metalmixx customers to for Q1 2020. ment connectivity,
the Reibus platform, and Metalmixx will cease Salvagnini is a manufacturer of flexible sheet predictive main-
operations. metal processing systems, machines, process tenance, and smart factory. The event included
Reibus’ platform includes a proprietary data- software, and tooling for factory integration. a tour of EPP Metals, allowing attendees to see
base of industrial metals for sale on an indepen- Its product lines include punching and shearing, cutting, bending, and automation firsthand.
dent cloud-based platform, trade credit servic- automatic panel bending, fiber laser cutting sys- Bystronic is a worldwide supplier of press
es, freight services, and security and anonymity tems, as well as ASRS, robotic loading/unloading, brakes, lasers cutting systems, automation, and
for all transactions. conveying, and parts manipulation. software for processing sheet metal and tubes.

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 voestalpine eifeler Coatings Wendorff Bros. sells Steel Craft, Hartford Finishing, Capitol Stampings
opens California facility
Wendorff Bros. Co. Inc. has announced the sale of certifying, and logistics management. Hartford
voestalpine eif- Steel Craft Corp. and Hartford Finishing, both of Finishing is an industrial powder coater providing
eler Coatings
Hartford, Wis., along with Milwaukee-based Capitol e-coating, wet painting, assembly, batch work, and
has opened its
Stampings, to MiddleGround Capital of Lexington, Ky. blasting. Capitol Stampings offers metal forming
newest coat-
ings facility in Steel Craft offers laser cutting, punching, press and stamping capabilities that include custom metal
Walnut, Ca- brake forming, welding, machining, painting, stamping, custom tooling, robotic welding, resistance
lif., providing mechanical and electromechanical assembly, testing, welding, and split steel pulley technology.
PVD coatings
to manufacturers in the western
U.S. The plant is operated by EDRO
Eng., a division of voestalpine and a
supplier of custom mold bases, tool
steels, and nonferrous alloys.
The Walnut facility is equipped
with new PVD and sputtering coat-
ing systems and offers diamond-
like carbon coatings. The company
also has facilities in Ohio, Michigan,
Illinois, Mexico, and Canada.

Metalcraft to expand
in Wisconsin
Metalcraft, Mayville, Wis., has an-
nounced the addition of 100,000
sq. ft. to its metal fabrication facil-
ity in Beaver Dam, Wis.
Scheduled for completion in
summer 2020, the addition will
house a shipping and receiving
area, cold storage, and a paint line.

Mid Atlantic Machinery

adds northeast division
Harrisburg, Pa.-
based machine
tool distribu- INITIAL PINCH SHEET BENDING MACHINES
tor Mid Atlan-
tic Machinery
has opened a
northeast di-
(From left) Steve Tapply vision, North-
and Nick Tapply.
east Machinery
Sales, in Agawam, Mass., to cover
territory from New York to Maine.
• The B Series from WDM.
The new location, which in- • Over 40 years of experience with
cludes an office, demonstration 3 generations working in the business.
facility, and showroom, is led by • Built in USA with American components.

Steve Tapply, vice president, and • 30 gauge to 3/8” thick, 1’ to 12’ wide.
• Custom and built to order options available.
his son, Nick Tapply, regional terri-
tory manager. They have 40 years
Have a rolling question? Call and speak directly to the designer, engineer
of combined industry experience Waldemar Design & Machine LLC
and manufacturer of WDM machines, right in Tennessee, USA. 900 Highland Drive
at Marvel Saw, Jancy Eng., Erco- Spencer, TN 38585
931-946-8474, or
lina, and Nitto Kohki. 606-787-8474
The company distributes ma-
chines for structural and miscella-
neous fabricators, machine shops,
manufacturers, and precision sheet
metal fabricators.

AUGUST 2019 The FABRICATOR 31

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 TECHNOLOGY » PRODUCT HIGHLIGHTS
Power source designed System enables tailored properties
for manual steel welding in press-hardened components
Fronius USA LLC has launched AP&T has introduced a pat-
a new version of its TPS/i power ented system for partial press
source platform, the Steel Edi- hardening of structural parts
tion. Designed for manual steel for passenger cars. Temper-
welding, it offers characteristics Box® allows hard and soft
for standard and pulse welding, as zones to be combined in a sin-
well as a WPS package containing gle part. It can be integrated
welding procedure specifications with the company’s new and
that are certified in accordance existing Multi-Layer Furnace
with DIN EN 1090. and any other type of heat-
The modular system can be treating equipment.
customized for individual re- After being heated up to
quirements. Its processors en- 930 degrees C in a conven-
able it to analyze and control tional austenization furnace,
welding processes to help opti- the blank is moved to the
mize results in a variety of weld- TemperBox, where selected sections are blocked from radiation and
ing tasks on material thicknesses of 1 mm and greater. cooled down while the rest of the part is kept hot. The blank is subse-
The system’s new pulse controlled spray arc feature offers a smooth quently formed and quenched to produce the finished part.
transition from pulsed to spray arc to help minimize welding spatter. The result is a part with tailored properties, customized to the required
Fronius USA LLC, www.fronius.com performance of the component. The technology enables short cycle
times comparable to producing press-hardened components with mono-
lithic properties over the cross section. Postprocessing is simplified be-
cause specific areas of the component, such as flanges, can be kept soft,
enabling them to be punched or trimmed using conventional methods.
AP&T, aptgroup.com

Electric linear actuator

designed for pressing,
punching, joining
Tolomatic’s new RSX096P electric linear
actuator increases the force range of the
existing RSX product family to 40,000 lbf.
and is designed to be optimized for force
in the extend direction. The actuator is
suitable for metal forming and assembly
including pressing, punching, stamping, riv-
eting, fastening, and joining.
This press-model actuator is upgraded
with large tie rods and an optimized bear-
ing system, as well as a high-strength,
front-mounting flange. A standard antiro-
tate feature prevents the rod from rotat-
ing without external guidance. Rated IP67,
the actuator resists ingress from splashing
water and dusty environments. Type III hard-coat anodized aluminum
or zinc-plated steel adds to the heavy-duty construction. An extended
temperature range option is designed for outdoor applications.
The “Your Motor Here” feature allows for servomotors and gearboxes
up to 215-mm frame size. Additional features include an access port for
relubrication and a breather/purge port to prevent ingress into the ac-
tuator. The actuators are built to order with configurable strokes and
flexible mounting options.
Tolomatic, www.tolomatic.com

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 Tube/pipe welding machine delivers full
power output over range of product sizes
Thermatool offers the CFI high-frequency
(HF) welder, a solid-state tube and pipe
welding machine. With frequencies
from 150 to 800 kHz, the machine is
based on the company’s HF weld-
ing process, and the current-fed
inverter (CFI) design allows users
to weld almost any metal.
The machine uses the com-
pany’s patented AutoMatch™
power and frequency matching
and stabilization, which ensures full power output over a range of prod-
uct sizes. It also provides stable welding frequency, even with changes in
weld area setup, tube OD and wall thickness, and impeder material.
Caps protect pipes against corrosion The power set point is maintained within 0.5 percent, and fixed fre-
quency is maintained within 1.0 percent. Short-circuit-tolerant CFI tech-
Cortec offers CorroLogic® CorrPlug® heavy-wall black polyethylene pipe nology helps ensure reliable operation through coil arc-overs. The ma-
caps. They contain proprietary vapor-phase corrosion inhibitors to protect chine is available with traditional contact welder output and with dual
pipe threads, pipe ends, and other tubular objects from corrosion, mechan- induction/contact output for specific applications.
ical damage, and contamination during transit, handling, and storage.
Thermatool Corp., https://thermatool.com
In addition, VpCI®-337, VpCI pouches, or CorroLogic tube strips can be
used in combination with the caps to emit corrosion inhibitors that form
a protective molecular layer on the internal surfaces of pipe walls. The
caps keep the protective vapors from escaping.
The pipe caps are made to order in diameters from 0.25 to 64 in. They
protect carbon steel, stainless steel, copper, brass, and aluminum.
Cortec, www.cortecvci.com

Dot peen marker transfers tags from top

to eliminate jamming, scratching
The KwikMark Tag Master 3 uses dot peen technology to mark industrial
components permanently. The fully automatic feeder/marker was devel-
oped to increase production speed and eliminate the tag feeding problem
of tags escaping from the bottom of the magazine.
The tags are transferred from the top to eliminate jamming and
scratching. This also eliminates problems with thickness tolerance and
sharp edges, the company reports.
The machine’s display includes a batch counter, cycle timer, current
status, production history log, and percentage of completion information.
KwikMark Inc., www.kwikmark.com

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 TECHNOLOGY » APPLICATIONS
Automatic nesting and part labeling help increase
manufacturer’s efficiency, accuracy
“When a unit has been sold, we’ll see that and automatically generate a
list of parts in our ERP system, and a data file that we can use with Radan
will also be generated,” Reinke said. “This helps to eliminate the need to
manually input information, which saves time and reduces error.
“We just push a few buttons and Radan does all the heavy lifting. There
may be 18 nests for one project, and in a matter of 10 minutes, we can have
18 programs ready to send to the machine to cut out on a laser.”
Included in Reinke’s overarching mission for greater optimization at
GDTS is the reduction or elimination of manual input wherever possible.
As such, he is currently in the process of creating an automated system to
replace the manual labeling of parts that have been cut on the laser. “We
may have 10 nests for a single project, and they’re using a marker to write
a part number when it comes off the laser,” Reinke explained. “The manual
writing isn’t efficient and can be prone to error.”
The company is using the software’s ability to generate project reports
to create stickers that will eventually replace the need for manual labeling.
Once the software has nested everything, “I can go in on the project
Situation level and create a sticker layout that can be used to label each part. These
Cooling systems manufacturer Glen Dimplex Thermal Solutions (GDTS) can have an image of the part, the part number, a QR code, a serial num-
opened its doors more than 60 years ago with its Koolant Koolers brand ber—whatever other information that you want—to create a sticker for
chiller. Today the company, which employs about 200 staff, produces cus- each part for the project.
tom chillers for the aerospace, automotive, food and beverage process- “Trying to cut out several different models at once is the challenge, but
ing and packaging, medical imaging, and machine tooling industries—and we can nest several of our machines at once. Because of the stickers, we
even counts a microbrewery or two among its clients. can tag each part and there is a ton of information that is automatically
The company, which offers extensive design services, produces its own generated. It’s definitely going to be faster to apply a sticker, and it will
have a lot more information on it than what we have now.”
line of products and employs an in-house research and development team
In addition to reducing error, the new labeling process will make it easier
to assist clients and break new ground. “We are in a state of constant up-
for the company to increase the size of its nested batches. “This all adds
grade, including new technologies that keep us competitive,” said Manu-
up to better sheet utilization and laser time utilization,” explained Reinke,
facturing Engineer Zachary Reinke.
who estimates that material savings will be five to 10 sheets per week once
One of those upgrades was the installation of a fiber laser to update
the labeling process is at full force.
fabrication capabilities. The company began looking for a software system
for programming the laser. Radan/Hexagon Manufacturing Intelligence
www.radan.com
Resolution
GDTS chose Radan computer-aided manufacturing (CAM) software for
sheet metal. Reinke was hired following the implementation of the fiber
laser and software and tasked with optimizing production.
“Part of my job has been to get the laser and software up to production
quality,” he said. “There’s a really delicate balance and a really tight link be-
tween the laser and the software. So much of the potential of the expensive
piece of machinery is dependent upon on how well you use the software.”
The cooling systems manufacturer uses Radan’s automatic nesting capa-
bilities to generate efficient nests automatically that can be edited manu-
ally if needed.
“Almost all of what we do is customized in a lot of small ways, so the
benefit for us is in the automatic nesting,” said Reinke. “There is a lot of
flexibility for fine-tuning things when it comes to nesting.”
The automatic nesting works in conjunction with Radan MRP Essentials,
a material resources planning integration utility that enables nested proj-
ects to be generated automatically from a production schedule file.
GDTS uses an enterprise resources planning (ERP) system for produc-
tion control that tracks parts and generates bills of materials. That system
produces text files that MRP Essentials uses to initiate the creation of data
files, and Radan uses that data to load parts and part quantities, as well as
to generate batches of nests for each project.

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 Zinc phosphate metal finishing line improves part turnaround time
for precision machining company
This fine-grained zinc phosphating process is designed for iron and steel
components, which make up the majority of A.R. Machining’s present work.
Applied at 120 to 160 degrees F, the finish complies with MIL-DTL-16232G,
Type Z Classes 1, 2, and 3—important because the company is expanding
its work in the military sector. When sealed with a rust preventive, the fin-
ish has excellent corrosion resistance and provides antigalling protection
and break-in lubricity to critical working surfaces, which are advantageous
in certain military applications.
For extra corrosion protection, the Dri-Touch Plus IRP3 heavy-duty pro-
tective coating produces a robust film that is suitable for use on parts
for limited outside storage, into warehouses, and for certain battlefield
conditions. The product is an effective water displacer, with a self-healing,
soft waxy film with thick consistency and high moisture resistance. “The
combination process really improves the appearance of finished goods,”
reported Dobias, “with parts coming out a nice, uniform dark gray or black
depending on the material.”
The system comprises seven 220-gal.-capacity tanks with a 48- by 30-
by 35-ft. footprint. An overhead crane is positioned above the system to
handle large parts, which are up to 6 ft. long by 2 ft. in diameter, as well
as baskets of smaller parts. The tank line is equipped with an adjacent ion
exchange system, which purifies and recycles the system’s rinse waters.
The result is a closed-loop system that conserves water and makes no dis-
charge into the sewer system.
“With our new in-house system, we get same-day finishing. The cost is
Situation less than half compared to outside finishing and is improving as more work
A.R. Machining is a contract manufacturer in Hutto, Texas, specializing in is added. Just as important, we eliminated many hidden costs using out-
precision machining work for the aerospace, oil, gas, and semiconductor side finishing vendors, such as the extra part moves, packing and repacking
industries. With more than 50 highly trained employees, a 38,000-sq.-ft. parts, inventorying and inspecting parts when received, and unexpected
manufacturing facility, and more than 24 CNC mills and lathes with 4-axis delays on different part projects,” Dobias added.
capability, the company’s fast-turn prototype products include turnkey Birchwood Technologies
CNC production, part finishing, and mechanical assembly. www.birchwoodtechnologies.com
Original equipment manufacturers are demanding fast turnaround time
from their suppliers to bring their products to market faster, and A.R.
Machining’s customers are no exception. But without in-house finishing
capability, the company was hampered. “Using outside finishers took sev-
eral days and made it difficult to meet customer delivery requirements,”
reported Matthew Dobias, president.
“Our oil and gas customers required corrosion-protected parts and
just-in-time delivery,” Dobias continued. “These are large, down-hole steel
components that often are stored outdoors before installation, so they are
subject to corrosion. In our area, outside finishers are several hours away.
Turnaround time was a real problem. Also, their finishing tank sizes were
limited for our larger parts. We needed large capacity and ferrous metal
corrosion protection.”
As part of its continuous improvement mission, the company decided to
investigate in-house finishing options.

Resolution
“We knew about Birchwood Technologies and asked their area account
manager, Tom Ingersoll, for metal finishing input,” said Dobias. “Birch-
wood Technologies chemists performed several no-obligation, no-cost
test finishes on our sample parts in their lab. Tom recommended their
zinc phosphate process and showed us how their MicroLok® MZN and
Dri-Touch® Plus IRP3 process combination would answer our needs, so we
went with a new system.”

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 TECHNOLOGY » TECHNOLOGY SPOTLIGHT
Laser welding on the move
Technology for repairing tooling might prove useful for general metal fabricating
By Dan Davis Alpha Laser US believes that could change with laser

L
welding technology that is flexible enough for shops
aser welding is not something that many metal that value the ability to get new jobs up and running
fabricators think about because, honestly, they quickly. These laser welding units also are more af- » Alpha Laser US laser welding units can
don’t come across it that often. Welding lasers fordable than the high-powered units that are com- be moved to where the arm can reach its
welding position, even in deep or complex
can be found in a variety of manufacturing facilities monly found in car assembly plants. Wes Wheeler is molds.
across the globe, but they are not as ubiquitous as the the sales manager for Alpha Laser US. He also happens
press brake, for instance. to be the sales manager for Phoenix Laser Solutions, a company that uses pulsed laser
welding technology to repair tool-
ing of all kinds, from plastic injec-
tion to stamping. It has four loca-
tions: Cuyahoga Falls, Ohio; Blue
Springs, Mo.; Brookville, Ind.; and
its headquarters in Meadville, Pa.,
which at one time many considered
to be the plastic injection molding
capital of North America. Phoenix
Laser Solutions uses the German-
made Alpha Laser equipment, typi-
cally Nd:YAG lasers of at least 300
W. (Nd:YAG lasers get their name
from the crystal of neodymium-
doped yttrium aluminum garnet
that is used as the lasing medium.)
In recent years Phoenix set up a
sister company to sell and service
Alpha Laser products in the U.S.
“We just opened a shop in Indiana,
and a lot of people in that area have
never heard of laser welding, which
surprised me a bit. But it kind of
makes sense because there’s not
a lot of people doing it around
there,” Wheeler said. “So there
are segments of the U.S. where
everyone knows about it, and other
areas where people need to learn
about it. It’s definitely a chance to
grow the technology.”

The Portability of
Laser Welding
Phoenix uses the Nd:YAG pulsed
lasers, ranging in power from 300
to 500 W, for repairing tooling. The
Nd:YAG laser is better suited for
this type of work because it gener-
ates enough peak power to provide
a nice melt of the filler metal and
minimize dilution around the weld
pool, Wheeler said. (Alpha Laser
US machines can use up to 0.040-
in. welding wire, but traditionally
are more efficient and faster when
using wire that is 0.020 in. thick.)
The Nd:YAG laser also doesn’t over-
penetrate the base metal when the
welding process begins.

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 This type of laser is particularly New Opportunities pulses release high energy, but in a very short time peri-
useful for repairing tooling used for Wheeler said that at one time tooling repair represent- od, allowing the laser to melt the metals without infus-
something like rubber moldmaking. ed about 95 percent of Phoenix’s laser welding work. ing more energy than it needs to into the workpiece.)
These molds obviously can’t have Today that percentage has decreased as manufactur- In a nod to the flexibility needed in modern manu-
any inconsistencies in the tooling ers discover more applications where laser welding facturing settings, Alpha Laser US lasers also can be
surface because it could damage the used in automated applications.
might make sense.
rubber component being created. “The unit has programming software and can quick-
As an example, he described a scenario in which a
Alpha Laser US also has laser ly be set up to process a welding job that involves sev-
stainless steel container for the medical industry was
welding units powered by fiber eral pieces. Then you can jump from the production
fabricated using laser welding instead of GTAW. With a process back to a manual process if needed.”
laser technology, which relies on
fiber laser welding device, the manufacturer gets full- Editor-in-Chief Dan Davis can be reached at [email protected].
YAG-doped fiber optics to gener- HeckBM_3.375x4.875_Heck_BM_3.375x4.875 2/15/17 4:01 PM Page 1
penetration welds with less heat distortion. (The laser Alpha Laser US, www.alphalaser-us.com
ate the laser. The fiber lasers can

BEVEL-MILL®
provide more penetration and are
useful as a replacement in applica-
tions where gas tungsten arc weld-
ing (GTAW) is typically used. Model Model
Many metal fabricators are fa- 9000 PRO21-G

miliar with the reliability of fiber World’s Up to 10

laser power sources, in which mod- Largest feet per
minute
ules can be replaced quickly with
little worry of extended downtime.
Wheeler said that the Nd:YAG lasers HAND OPERATED POWER FEED
ultimately have some degradation PLATE BEVELERS BEVELERS
Bevel up to 13/16”
of the flash lamp over time, and at
that point more energy is needed to Model
deliver the same amount of power WS625 Model
BB27
that the unit was originally designed
to deliver. He also noted that fiber
laser technology costs more than
Nd: YAG technology. WELD BEAD
Of course, the welding applica- SHAVER BENCH TOP
tion determines what laser power Machines weld beads flush DEBURRING
to work piece. Precision finish chamfers.
source makes the most sense. It
also determines whether the tech- 800-886-5418
nology needs to be mobile. That’s Fax 810-632-6640
where Alpha Laser US stands out. www.heckind.net
Its ALFlak laser welding unit sits
on traction belts and can be moved
to where the arm can reach its
welding position, even in deep or
complex molds. Welding seams up
to 500 mm are possible without
relocation of the workpiece to be
welded, which can be a valuable
time-saver.
Your advantage: The laser weld-
ing process can be performed with-
out constant repositioning.
Wheeler recounted a recent
demonstration the company did
for a major automotive manufac-
turer. It was able to load the ALFlak
unit onto a van, drive to the plant,
unload the laser welding unit, ma-
neuver it about three-quarters of
a mile to the tooling area of the
plant, demonstrate the technology,
exit the plant, and drive back over
the course of a few hours. Of that
time, only about 15 minutes were
needed to get the power source up
and welding.

AUGUST 2019 The FABRICATOR 37

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 TECHNOLOGY » PRODUCT NEWS
Fiber laser with rotary index offers high-speed processing of flat, shaped materials Corrosion-inhibiting foam
The ENSIS 3015 The system uses a variable beam control unit that available in custom-
RI from Amada is automatically adjusts the laser beam’s properties to perforated rolls
equipped with a cut a variety of thin to thick materials without a lens Cortec® offers
3-kW fiber laser change. Optimal beam control enables the machine to custom per-
and an integrated process thin materials up to four times faster than a foration of its
rotary index located on one of three shuttle pallets, al- CO2 laser, the company reports. VpCI®-137 foam
lowing the operator to switch from flat sheet cutting to Amada America Inc. rolls. The rolls
tube or pipe cutting in as little as two min. www.amada.com/america can be perfo-
rated to the
desired sizes
for easy tear-off of individual piec-
es to be placed with metal parts in
shipping or storage for corrosion
protection. Minimum perforation
size is 4 by 4 in., with the maximum
size being the width and length of
the roll. Custom vertical perfora-
tions are available for users that
want side-by-side pieces to tear off
across the width of the roll.
The flexible packaging material
combines corrosion protection,
desiccant action, and antistatic ca-
pabilities in one step. Vapor-phase
corrosion inhibitors impregnated
throughout the foam’s polymeric
matrix diffuse into the enclosure,
forming a protective molecular
layer on the surface of the metal.
Cortec Corp.
www.cortecvci.com

Collector removes
ultrafine airborne
coolant mists
Camfil APC offers
the EM Expert
coolant mist col-
lector for appli-
cations that use
cooling lubricants
such as turning,
drilling, milling,
roughing, and
grinding. The collector, which sepa-
rates ultrafine coolant mists and
fumes, is available with an optional
HEPA final filter stage to collect
particulates less than 1 micron.
Quick-acting clamps allow sim-
plified filter cartridge changes that
require no tools. Filter cartridges
are accessed via the service doors,
and a transport trolley is available
for drip-free removal of the filter
cartridges.
Camfil APC
www.camfilapc.com

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 Tool rack stores frequently Wet dust collector redesigned Baffles create turbulence and divergent forces that
used shop tools Midwest Automation has introduced
cause the metal dust to settle to the bottom of the
a newly redesigned line of Niagara wet tank as sludge. A stainless steel secondary filter helps
Guardair Corp.
has developed dust collectors recently updated to clean prevent moisture-laden air or “mist” from entering the
the new Quick- or filter contaminated air in a variety of plant.
Select tool metal grinding, deburring, and sanding The wet dust collectors are available in three series
rack. Made of operations. Dust particles are separated with 15 models.
heavy-duty alu- from the air by mixing the contaminated Midwest Automation
minum, the rack includes an array air using water as a filtration media. www.midwestautomation.com
of slots and holes to organize fre-
quently used shop tools such as Al-
len wrenches, dead blow hammers,
screwdrivers, and safety air guns.
It also features a 13/4-in. hole lined
with a plastic bushing for storing
sensitive instruments such as tool-
holders and gauges.
Offering a slim profile, the rack is
available in two versions, with eight
holes for custom mounting or with
dual, high-strength magnets for
quick mounting on steel surfaces.
Guardair Corp.
www.guardair.com

CAD/CAM software
includes enhancements
to part unfolding

VISI 2020.0 CAD/CAM from Hexa-

gon Manufacturing Intelligence’s
Production Software business
helps improve mold and progres-
sive-die design processes and fea-
tures an enhanced Reverse module.
New part unfolding technology
lets the user work directly on the
original solid part without needing
to extract the model’s skin. Sheet
metal part recognition provides an
improved graphical representation
of the part analyzed by identifying
bends, planar faces, and features.
The software’s associativity with
the original model during the die
design process allows the original
part to be edited and changes to be
made automatically on the study of
the part. Also, the blank calculation
will completely unfold all the de-
tected features and coining faces.
Hexagon Manufacturing
Intelligence
www.hexagonmi.com/en-us

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 TECHNOLOGY » PRODUCT NEWS
Abrasives come in variety of small shapes, sizes Boundary lubricant pre-
Saint-Gobain Abrasives has on the abrasives adds durability. A coating on the grain/ vents metal-to-metal
introduced Norton Merit bond reduces friction for a greater grain-holding ability contact under high loads
Pink R928 flap wheels and for cool and fast cutting on hard-to-grind materials. Dillon Mfg. Inc. has
specialty abrasives for bev- The product line includes mini flap wheels, cartridge introduced HPG500,
eling, blending, cleaning/ rolls and tapered spiral rolls, square pads and cross a boundary lubricant
detailing, deburring, and finishing stainless steel and pads, and mounted points. that prevents metal-
other hard-to-grind materials. Norton | Saint-Gobain Abrasives to-metal contact under
For hard-to-reach applications, a poly-cotton backing www.nortonabrasives.com high-load and slow-
speed conditions for
either high-end manual chucks or
power chucks.
This all-purpose industrial lubri-
cant can be used in bearings, bush-
ings, slides, pivots, and tracks. It is
suitable for applications that re-
quire high lubricity, EP properties,
mechanical stability, rust and corro-
sion protection, water washout pro-
tection, and good oxidation stability.
Dillon Mfg. Inc.
www.dillonmfg.com

Synthetic stamping
fluids compatible
with various metals
IRMCO has introduced two new
synthetic, oil-free stamping fluids.
IRMCO FLUIDS® 323-00K pro-
vides medium- to heavy-duty utility
on steels from 200 Mpa to 1 GPa
tensile strengths, 300 and 400 se-
ries stainless steels, and some 5000
and 6000 series aluminum alloys—
all without the use of chlorine- or
sulfur-containing additives. It can
be applied via roller or spray and
is compatible with conventional,
low-temperature, and TMC surface
treatment systems.
The fluid is suitable for automo-
tive support and framing struc-
tures and wheel stamping, provid-
ing tool protection and excellent
weld-through characteristics, the
company states.
IRMCO FLUIDS 109-00J is a
medium-duty stamping fluid suit-
able for appliance and automotive
framing stamping processes. It is
compatible with porcelain enamel-
ing and automotive e-coat surface
preparation. The fluid can be used
for light- to medium-duty stamp-
ing of enameling steel, steels with
tensile strengths from 200 to 600
MPa, and light-duty stamping of
stainless steels
IRMCO
www.irmco.com

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 Industrial storage Servo press offers smooth operation, high production rates
containers are highly Nidec Press & Automation has Eccentric wheels with double helical gearing help en-
customizable introduced the Arisa GS2 series sure smooth operation. The Desch planetary gearbox
Steel King In- servo press with capacities from reduces the drivetrain inertia for quicker acceleration
dustries Inc. 3,150 to 8,000 kN. The press’s and faster stopping times. Zero-clearance slide guiding
has intro-
precision kinematics allow fast helps improve die setup and operation.
duced a line
system response and high pro- Nidec Press & Automation
of rugged in-
dustrial storage containers for a duction rates, the company states. www.nidecpa.com
variety of heavy-duty storage appli-
cations such as sheet metal, steel
parts, and automotive parts.
The container can be made in
any size. Available designs include
round-corner corrugated steel
containers, heavy-duty rigid bulk
storage containers, “workingtain-
ers” that double space usage by
turning work areas into storage,
a stow gate container that adapts
easily to multiple configurations,
and a Hold ’n Fold design that can
be stored or staged for use on the
production floor.
Available features include half-
drop gates, fork stirrups, floor
runners, caster plates and casters,
crane eyes, crane lifting lugs, drains/
valves, fork pockets, rollover run-
ners, and universal stacking legs.
Steel King
www.steelking.com

Honing brushes available

in variety of diameters

Weiler Abrasives has introduced

CrossFlex™ honing brushes. Avail-
able in small, medium, and large
diameters and with heavy-duty op-
tions, these brushes provide a sur-
face finish free of metal burrs, the
manufacturer reports. They are
designed for manual or automated
use in automotive; marine; oil and
gas production; aerospace; and
tube, pump, and valve production
applications.
The brushes are available in 120,
180, 240, and 320 grit. Flexible ny-
lon stems distribute pressure even-
ly, self-centering within the part.
Weiler Abrasives Group
www.weilerabrasives.com

AUGUST 2019 The FABRICATOR 41

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 MANAGEMENT » BIZ TALK
Streamline the metal fabrication
supply chain
It’s a goal shared by fabricators around the world
Read more from Tim Heston at
www.thefabricator.com/author/tim-heston

By Tim Heston This business model isn’t entirely new. State-

I
side, a company called Xometry (xometry.com)
n April 2018 a team of enterprising individu- has developed a network of shops that began in
als decided to try a new business model for machining and 3D printing and now incorporates
the fabrication business. At first they thought metal fabrication. OEMs contact Xometry for a
they would simply play matchmaker. Their job. Xometry returns an instant quote, based
thinking went that the typical fab shop didn’t on historical data and, thanks to artificial intel-
have strong marketing platforms. Fab shops ligence (AI) technology, is perfected over time.
are everywhere, after all, but no one knows The details behind Xometry and Zetwerk are
they’re there. In the past 20 years metal fabrication quite different, but the overall idea is the same:
But eventually those enterprising individuals to connect a host of small, hidden job shops with
has been transformed by advanced
found they had to do more than matchmaking. OEMs and other large manufacturers and fabri-
machinery and software. Within the
They had to delve into project management. cators looking for more fabrication capacity.
Clients send them drawings; they find fab shops next 20 years the metal fabrication
Zetwerk and Xometry are just two examples of
with the right capabilities and available capac- industry might have some new,
a new kind of competitive edge: the streamlined
ity; they purchase the material; and they handle very different players. value chain in a world of highly variable demand.
the quality assurance. Far beyond simple match- In the broadest sense, companies are working
all the problems. With large projects, the prob-
making, they’re now offering a turnkey package. together differently to squeeze out waste.
lem was about execution. So we moved from just
Thing is, these individuals don’t live in the Consider Wisconsin-based The Village Compa-
being a marketplace to becoming a platform. We
United States. Srinath Ramakrishnan and Amrit nies (thevillage.bz). Featured in this issue, it’s an
no longer do the matchmaking. We do the com-
Acharya live in India. Their company is called organization of highly collaborative companies,
plete order. The network takes the order from
Zetwerk (www.zetwerk.com), and the launch including Metal Fab Solutions (MFS), a 3-year-
the clients, and all the orders that come through
could be a harbinger of the kind of supply chain old fab shop. The village is all about sharing re-
this network are owned by the network. We add
developments the industry might experience sources, from engineering to human resources
our project management and quality control
over the coming decades. and safety. A company might not need intense
teams that institute these processes across the
“We have built a network of more than 500 engineering work done all the time; it comes in
various workshops in our network.”
of the best fabrication shops throughout India,” waves. Spreading those waves across a larger
When a client seeking fab work submits a
said Sidhdharth Shah, Zetwerk’s head of ex- network of companies turns them into ripples.
request for quote (RFQ) online, Zetwerk en-
ports. “And we have onboarding teams who are gineers study the drawings, then match the Demand becomes more consistent, the value
continually looking out for new suppliers.” RFQ up with about five shops. They’re not se- chain more efficient.
The company offers what it calls a “manufac- lected randomly but instead are matched based In the past 20 years metal fabrication has
turing platform,” and as Shah’s job title implies, on their capabilities, location, and a variety of been transformed by advanced machinery and
Zetwerk is looking to compete across India and, other attributes. “Our team negotiates with related software. Two decades ago a laser op-
ultimately, on a global scale, including North suppliers and selects the best quotation,” Shah erator would look agog at a 12- or 15-kW fiber
America. “We’re also looking for U.S.-based fab- said. “It will not necessarily be the lowest price, laser cutting a nest at extraordinary speeds. A
ricators to collaborate with us to expand their either. The match is made based on who’s best bending operator might react similarly with the
interest.” Some U.S. fabricators partner with suited for the job, and the timeline and delivery incredibly complicated staged bending setups
plants in Mexico, and Shah said he sees a similar date they’re able to promise.” that software allows and the consistency and ac-
potential between Zetwerk and U.S. fabricators. Fabricators new to the program start with a curacy today’s brakes can achieve.
After a stint in the U.S., one of the company’s few projects. Those early projects give Zetwerk What will we stand agog over 20 years from
founders returned to India several years ago an idea of their capabilities, and the work ramps now? It’s hard to predict, but the industry might
looking for a problem that could be solved with up from there. Shah said that about 30 percent have some new, very different players. They
a technology platform. The other founder had of workshops in the network now get 70 per- could include various networks of shops that
family in the metal fabrication business. cent of their revenue from Zetwerk. “And about stay small but collaborate closely, with data
“We started as a pure matchmaking platform,” 25 fabricators now work exclusively for us,” he and algorithms driving out waste and better
Shah explained. “It’s a challenge in India for com- said, “because we’ve become a very predictable utilizing available capacity. Ultimately, they’ll
panies to find the right suppliers. These shops source of revenue for them. They don’t have aim to spread risk, smooth out demand vari-
aren’t online. You can’t just Google them. But to do any marketing; they just have to focus on ability, and streamline the value chain—locally
then we found that matchmaking doesn’t solve what they do best and leave the rest to us.” and globally.

42 The FABRICATOR AUGUST 2019

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Aug19FAB_BizTalk.indd 43 7/24/19 3:23 PM
 MANAGEMENT » AROUND WASHINGTON

Senator proposes new

high-level manufacturing institute
Such an office could help to centralize 58
scattered programs spread over 11 federal agencies
Read more from Stephen Barlas at
www.thefabricator.com/author/stephen-barlas

By Stephen Barlas America, Raleigh, N.C.; Rapid Advancement in Process Intensification De-

S
ployment Institute, New York; and REMADE (Reducing Embodied-energy
en. Gary Peters, D-Mich., probably has a bumpy road in front of and Decreasing Emissions), Rochester, N.Y. The NIST also funds other fed-
him if he wants to see his idea of a National Institute of Manufac- eral manufacturing programs such as the state-based Hollings Centers,
turing (NIM) enacted into law. Peters, who is up for re-election in also known as the Manufacturing Extension Partnership.
November, introduced his proposal in June, but there is no bill yet. There are also many lesser U.S.-administered manufacturing-related
Peters is waiting for input from interest groups and other senators be- programs, 58 scattered among 11 federal agencies, according to the Gov-
fore actually writing a bill. Maybe he could be criticized for not doing that ernment Accountability Office. Ostensibly, a NIM would impose order on
important spadework first, but that is a quibble. However, it is noteworthy that unwieldy mass of programs, eliminate duplication, and improve ef-
that the Alliance for American Manufacturing (AAM) called Peters’ pro- fectiveness.
posal “a very ambitious idea … and it’s not a bad one.” Peters’ NIM would
be led by a chief manufacturing officer who would report directly to the OSHA Considers Changes to Lockout/Tagout Standard
president. The Occupational Safety and Health Administration (OSHA) announced in
The AAM went on to say that it agrees with the “central thrust” of the mid-May via a request for information (RFI) that it is considering revising
proposal. But the AAM, which has labor union and manufacturing com- its lockout/tagout (LO/TO) standard to take recent technological advances
pany members, added that among the things that such an organization into account. The standard comes into play for users of metal cutting and
should encompass is a “clear role for labor in NIM decision-making; Buy other machinery.
America procurement rules in our manufacturing strategy; and plenty of The agency’s move comes three years after it issued a permanent vari-
attention paid to capital-intensive, trade-sensitive manufacturing sectors.” ance from the standard to a manufacturer of steel wire rod and coiled re-
There is, of course, already a major federal effort directed at advanced bar for grinding rolls on a roll mill. The OSHA variance allowed Nucor Steel
manufacturing: that would be Manufacturing USA, run by the National In- Connecticut Inc. to use a trapped key concept and monitor safety-rated
stitute of Standards and Technology (NIST), composed of 14 manufactur- power relays in combination with administrative procedures.
ing institutes around the country, all of which are involved in high-tech The LO/TO standard, established in 1989, currently requires that all haz-
manufacturing. They are Advanced Functional Fabrics of America, Cam- ardous energy from power sources and energy stored in the machine itself
bridge, Mass.; American Institute for Manufacturing Integrated Photonics, be controlled using energy isolating devices (EIDs) when an employee is
Rochester, N.Y.; America Makes (Additive Manufacturing), Youngstown, performing servicing or maintenance of a machine or equipment. OSHA’s
Ohio; Advanced Robotics for Manufacturing, Pittsburgh; BioFabUSA, Man- definition of an EID excludes push buttons, selector switches, and other
chester, N.H.; Clean Energy Smart Manufacturing Innovation Institute, Los control circuit-type devices. But technological advances since the stan-
Angeles; Institute for Advanced Composites Manufacturing Innovation, dard was issued in 1989 suggest that, at least in some circumstances, con-
Knoxville, Tenn.; Lightweight Innovations for Tomorrow, Detroit; Manufac- trol circuit-type devices may be at least as safe as EIDs.
turing times Digital, Chicago; NextFlex, San Jose, Calif.; National Institute The original LO/TO standard was influenced heavily by a consensus stan-
for Innovation in Manufacturing Biopharmaceuticals, Newark, Del.; Power dard issued by ANSI in 1982. ANSI reaffirmed that standard in 1988 and
1992. But ANSI issued a new consensus standard in 2016 that requires
that LO/TO “be used unless the user can demonstrate an alternative
method will provide effective protection for persons.” Before using
an alternative method, the employer is required to complete a prac-
ticability/justification analysis, a risk assessment, and other applicable
evaluations.
The trapped key system was designed to replace a locked-out EID
and to function similarly to a lockout device, in that only the employee
in possession of the key could restart the machine undergoing mainte-
nance. The single key was controlled through administrative group
lockout procedures.
Alliance for American Manufacturing, www.americanmanufacturing.org
Government Accountability Office, www.gao.gov
Manufacturing Extension Partnership, www.nist.gov/mep
Manufacturing USA, www.manufacturingusa.com
National Institute of Standards and Technology, www.nist.gov
Occupational Safety and Health Administration, www.osha.gov

44 The FABRICATOR AUGUST 2019

Aug19FAB_AroundDC.indd 44 7/24/19 3:27 PM

 FABTECH 2019
CHICAGO
NOV 11-14
REGISTER TODAY
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TECHNOLOGY & INNOVATION TO

TRANSFORM YOUR BUSINESS

Thank You to Our Platinum Sponsors

Aug19FAB_AroundDC.indd 45 7/24/19 3:27 PM

 MANAGEMENT » STEEL NEWS

Does the steel price upturn have legs?

Steel service centers aren’t rushing to raise prices

Visit www.steelmarketupdate.com
for more information

By John Packard and Tim Triplett Seventy percent of the manufacturers responding to SMU in the first

A
week of July (see Figure 2) reported that spot pricing from their distribu-
s of mid-July, after a yearlong downtrend, steel prices appeared tors continued to move lower—still a high percentage, but 23 percentage
to have finally turned around. Whether the uptrend has legs or
points fewer than reported in mid-June prior to the mill price increase
will be short-lived will reveal itself in the coming weeks.
announcements.
Mills and service centers suffered a serious margin squeeze in the past
SMU will be watching the green bars in these graphics carefully from
year as they watched steel prices, and the value of their inventories, de-
this point forward. For the mill price increases to gain traction, the distrib-
cline week after week. Last year’s jubilant announcements of mill expan-
utors need to begin raising spot prices to their customers. Earlier this year
sions and upgrades have given way to idled furnaces, capacity reductions,
the market experienced a “dead cat bounce.” (Even a dead cat will bounce
and questions about true steel demand.
The benchmark price for hot-rolled steel peaked at this time last year
at around $910/ton but declined by 40 percent in the second half of 2018
and first half of 2019 despite the Trump administration tariffs that limit the
competition domestic steelmakers face from imports.
Steel Market Update (SMU) data indicates hot-rolled prices appeared
to bottom out in the first week of July at around $520/ton, but then in-
creased by $30 following two $40 price increase announcements by the
major mills. The market may not accept the entire $80 increase right away,
but the mills seem to be collecting at least a portion of it, which means
higher prices for manufacturers and fabricators.

Steel Market Update Prices

SMU gathers real-time pricing data from steel buyers every week. The
price direction, as represented by SMU’s Price Momentum Indicator, had
been pointing “lower” for most of the past year. So it was a noteworthy
event when SMU moved its momentum indicator to “higher” on July 12.
At that time, according to SMU data, the benchmark price for hot-rolled » Figure 1
steel (FOB the mill, east of the Rockies) was averaging $550/ton ($27.50/ After months of holding the line on price increases, 18 percent of service centers
surveyed reveal that they are raising prices as of mid-July. Many industry observers
cwt), with lead times that had stretched a bit to three to five weeks. Cold-
wonder if this trend will continue or if it is short-lived.
rolled averaged $710/ton, with lead times of four to seven weeks. The price
for benchmark galvanized 0.060-inch G90 coil averaged $798/ton, with a
five- to seven-week lead time for spot orders.
Price momentum for plate steel continued to trend “lower,” with the
delivered price for plate averaging $780/ton ($39/cwt), with lead times of
three to six weeks.

Service Centers Supporting the Increase?

Other SMU market data supports the change in momentum. SMU sends
out a market trends questionnaire to steel buyers every two weeks, and
the shift in the pricing direction was evident in the last batch of returns. As
seen in the bars on the far right in Figure 1, just 24 percent of service cen-
ters said they were still reducing spot pricing for their customers, down
dramatically from 81 percent in the prior canvass. Perhaps the leading pre-
dictor of whether mill price hikes will “stick” is how much support they
get from service centers. The fact that the majority of service centers (58
percent) said they were still keeping prices the same, rather than raising
» Figure 2
them, suggests that many remained unconvinced the turnaround was yet Only a small percentage of manufacturers indicate that they have witnessed service
for real. centers charging more for steel.

46 The FABRICATOR AUGUST 2019

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 if dropped from a high enough dynamics in place as we did prior. • “Our only concern right now is a tour of the Nucor Steel Gallatin
height.) This can clearly be seen There doesn’t appear to be enough sustainability of current demand. Mill.
in the green bars during the latter reduction in domestic capacity or Things are solid today, but it just John Packard, president/CEO of Steel Market
portion of first-quarter 2019. Ser- imports to lower the supply enough seems like a bubble is due to burst.” Update, can be reached at john@steelmarket
vice center prices rose briefly, then update.com. Tim Triplett, executive editor for
to create any tightness. Many are Steel Market Update and the former editor-in-
receded. If the latest mill increases concerned that Canada and Mexico Upcoming Events chief for Metal Center News, can be reached at
receive the same tepid support, the Nearly 1,000 industry executives [email protected].
will become more aggressive to
long-awaited rebound for steel may are expected to show up for the
grab market share in a rising U.S.
suffer the same fate as that poor 2019 SMU Steel Summit Confer-
price environment. Scrap prices,
cliched kitty. ence, Aug. 26-28, in Atlanta. For
which typically rise in the fall, may
more information on the program, HOT COLD
help to keep a floor under prices. speakers, costs, and how to regis- ROLLED STEEL ROLLED STEEL
What’s the Market
But uncertainty in demand may be ter, visit www.steelmarketupdate.
Sentiment?
the biggest wildcard for the second com/events/steel-summit.
Opinions are split among steel
buyers on whether demand will be half and could tilt the market in On Oct. 8-9, Steel Market Update
sufficient to sustain higher steel either direction.” will conduct its next Steel 101: In-
prices in the second half. Some • “We think pricing will relax by troduction to Steel Making & Mar-
fear another bounce in which the October. I think we see $560-$580 ket Fundamentals workshop in Cin- WE MAKE
STEEL EASY.
turnaround proves only temporary. in Q4.” cinnati. This workshop will include
Here are some anonymous
responses about a temporary price PICKLED &
COATED STEEL
OILED STEEL
bounce that we received from steel
buyers:
• “Yes, I think this will be a dead
cat bounce with prices declining
again in the fourth quarter due
to lack of demand and mills with
available capacity.” PRE-PAINT STEEL STAINLESS STEEL
• “Yes [dead cat], but I don’t
know how much lower prices could
go. At $500, mills start to flip out,
both integrated mills and minis.
Scrap is going up or at least looks
that way for August.” In the complex world of
• “I do not feel the momentum manufacturing you need a supply
will continue. After a bump in partner that will keep your shop
pricing, I expect a pause in activity, running no matter the circumstance.
Alliance Steel is a steel supply and
and then perhaps a slow drift lower.
processing partner you can count
We may not test the lows seen in on to get it right. Call us and we’ll
June, but I do not think this current help develop a sourcing program
rally will last.” tailored to fit your needs, or help you
• “No dead cat bounce, in my navigate our vast inventory. Our coil
opinion. We cannot be the cheapest processing capabilities are sure to
support your requirements.
market in the world with no import
offers for long. Unless demand dips With competitive pricing, on-time
delivery and world-class service,
more, I see Q3 picking up a bit of
Alliance Steel makes it easy.
steam.”
• “As we adjust back up to a more
normal replacement cycle, then a
price bounce back to the mid-$500s
seems very reasonable. While
mills are targeting to get the price GETTING A QUOTE IS EASY.
back to $600/ton, I think that will CALL US AT 855.224.3604 OR
be a tall challenge. As the market VISIT ALLIANCESTEEL.NET
resettles, we’ll still have the same © 2017 - 2019 Alliance Steel.

AUGUST 2019 The FABRICATOR 47

August19FAB_SteelNews.indd 47 7/24/19 3:47 PM

 MANAGEMENT » CHIEF CONCERNS
» Welder Sean McCarley, left, reviews a job’s specifica-
tions with Welding Manager Chris McAteer.

and support education, college is not for every-

one and doesn’t guarantee success for myriad
reasons.
“One big reason is that when a lot of kids
graduate, they are saddled with huge sums of
student debt that puts them behind the eight
ball when it comes to getting established in soci-
ety. It’s taken a while but people are slowly start-
ing to recognize that this vast amount of school
indebtedness is a concern for society as well as
the individuals themselves.”

Building Its Own Skilled Workforce

Laser Precision, with about 160 employees, is
one of the small to midsized job shops dedicat-
ing resources to solve the workforce problem.
“Individual companies are getting more in-
volved in the effort for a couple of reasons. One
is that if we don’t have skilled, intelligent, reliable
people in place to carry our mission forward,
we won’t be able to satisfy our customers. The
second is that without those people it becomes
very difficult to evolve the manufacturing disci-
pline to support 21st century manufacturing in
general,” Adams said.
Kimberly Wimer, the company’s human re-
sources manager, spearheads the recruitment
efforts. She uses several avenues of community
outreach, many working with like-minded orga-
nizations, while continually seeking new oppor-
tunities to advance manufacturing in general
Reeling in a new generation and garner candidates for the organization.
“We have several lines in the water, but we
of metal fabricators need more because individuals in the skilled
trades comprise an aging population. Without
a proactive and engaged effort, we’re not going
Laser Precision promotes manufacturing to attract the students we need as they come
to attract new talent out of high school or the community college,”
Wimer said.
“We need to hedge our bet on the numbers,
By Sue Roberts About 18 months ago Jeff Adams, owner of open the search wider than other manufacturers,

A
Laser Precision in Libertyville, Ill., began invest- and create our own workforce. We do that by
ging, and inevitable retirement, of ing heavily in finding and educating individuals to bringing in people who have no experience and
industry’s skilled workforce has been ensure that his company can continue providing training them from the ground up. Many of our
an encroaching problem for several quality metal fabrication for its customers. skilled technicians and machine operators have
years. Technical advances and automation from “Our company realized that there was going
been homegrown within our facility,” she added.
OEMs have reduced the number of tradesmen to be a lot of heavy lifting to do to redefine man-
needed to accomplish many tasks and the ufacturing and metal fabrication as a viable ca-
reintroduction of vocational programs in some reer alternative for the generation entering the
high schools and community colleges is helping workforce. Young people and their parents need
to a certain extent, but the reality remains that to know that the industry has evolved to where
shop floors need an influx of qualified, trained there is no resemblance to what manufacturing
young adults. looked like just 20 years ago. Manufacturing has
Currently not enough young people are choos- gotten an undeserved, negative reputation for
ing industry as a career path to meet current and many years,” he said.
future workforce needs. Part of the problem lies “There has been a steady narrative proclaim- » Kimberly Wimer poses with Wyatt Balmes on
with a lack of information and understanding as ing that a four-year college degree is required Student Signing Day. Balmes was offered a position in
the company’s welding department upon high school
to what is involved in modern manufacturing for a young person to amount to anything in this graduation because of his involvement with the welding
and the opportunities it offers. world, and while we wholeheartedly endorse program at Lake County Tech Campus.

48 The FABRICATOR AUGUST 2019

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 Working With Others
The Lake County Workforce Ecosystem, a local
consortium comprising College of Lake County,
Lake County Tech Campus, Workforce Develop-
ment, and Lake County Partners, reached out to
Laser Precision to become involved in efforts to
bring employees to Lake County, Ill., businesses.
“Working with all these entities to track the
workforce, encouraging continuing education
for underskilled individuals, and going into local
area high schools and the college to promote
manufacturing are beginning to attract some
attention,” Wimer said. “We’ve also done some
work with the Illinois Department of Employ-
ment Security.”
Wimer described some of the outreach activi-
ties designed to draw young adults—as well as
established individuals—to industry and Laser
» Trainee Sean Duffin, left, and press brake operator Ian Doorey inspect a part.
Precision:
• Internship program in conjunction with
Lake County High Schools Tech Campus.
• Committee work with educational in- Seeing Results
stitutions. The company actively participates
Seniors attending welding classes at the Tech Dedication to increasing the number of young
on advisory committees at the College of Lake
Campus have the opportunity to work at the adults coming into the industrial job pipeline in
County and the Lake County Tech Campus. Input
company during their last semester and receive the Lake County area earned Laser Precision the
from manufacturing companies in the county
a job offer upon graduation. Four individuals 2019 Lake County Workforce Ecosystem Talent
aids in developing industrial programs and class
from this relatively new program have become Innovator Award. The organization was cited as
curriculum. “It is beneficial to us when potential
full-time employees thus far. “We thought that being a thought leader in workforce develop-
employees who have participated in these class-
if we show students the workplace before they ment and playing an instrumental role in shap-
es come to us with formal education in the skills
graduate, there is a greater chance of them con- ing strategies that will benefit Lake County and
we need.”
tinuing on in the manufacturing workforce and industry as a whole.
• School presentations. Time is spent visit-
perhaps pursuing further industrial training, ing local area high schools to talk with students, Former Illinois Gov. Bruce Rauner and several
such as working towards certificates and associ- teachers, and parents about the industrial edu- other dignitaries recognized the company’s ef-
ate degrees with a manufacturing focus.” cation programs available and encourage manu- fort with visits during its 2018 Manufacturing
• On-site job fairs. The Illinois Department facturing as a career. “We talk about the oppor- Day open house, which brought stakeholders to
of Employment Security (IDES) works with the tunities available in the area.” And the company the shop to discuss options and opportunities to
company to coordinate job fairs at its facility. provides extensive in-house training along with improve the manufacturing ecosystem in Illinois.
“IDES helps us advertise for our open positions reimbursement for further formal education Adams said that with efforts to reintroduce
and brings unemployed candidates and em- when an employee is working toward a certifi- today’s manufacturing and rekindle interest in
ployed candidates looking for new opportunities cate or degree. its career potential he fully expects that in two
to the fair. The candidates see the environment Even with all of these efforts, Wimer said, “we or three years high schools and community col-
and learn about career opportunities.” have to keep putting more lines in the water.” leges—at least in Lake County—will have enough
• Job shadows. Students from the Welding
interested students to begin offering vocational
and Machine Tool Trade programs at the College
programs again. But it’s not there yet.
of Lake County are invited to shadow an employee
“The onus is on us to provide the level of
to experience a typical working day and determine
training that gets young people up to speed
their interest levels in manufacturing positions.
quickly. We have the responsibility to provide a
“We work with the professors to bring students
clear picture of the opportunities that industry
on-site so they can learn more about what we do.
provides; the career alternatives available; and
It’s an opportunity for us to pitch Laser Precision
to the students who are looking to start their ca- a thorough, safe training environment so these
reer and continue with their education.” people succeed.
• Layoff events. Laser Precision has “A lot of our efforts have been successful be-
participated in a number of layoff events
» Dignitaries toured Laser Precision during its 2018 cause of our focus on raising awareness, provid-
Manufacturing Day event. Visiting the metal fabricator
sponsored by Lake County Workforce Develop- were (left to right) Ed Youdell, president and CEO of the
ing clarity, and then offering flexibility and op-
ment. These events introduce potential em- Fabricators & Manufacturers Association International; portunity. Our investment is bringing us
Dr. Lori Suddick, president of the College of Lake County; potential associates,” Adams said.
ployees to employers who are actively hiring. Jennifer Serino, director of Lake County Workforce
“We have been able to assist a number of people Development; Jeffrey Adams, president of Laser
Freelance writer Sue Roberts can be reached at
who were experiencing a layoff by providing them Precision; Bruce Rauner, former governor of Illinois;
Terry Weppler, mayor of Libertyville; Kevin Considine, [email protected].
with employment opportunities. This has been a president and CEO of Lake County Partners; and Daniel
successful method for attracting new talent.” McConchie, state senator for the 26th district of Illinois. Laser Precision, www.laserprecision.com

AUGUST 2019 The FABRICATOR 49

AUGUST19FAB_ChiefConcerns.indd 49 7/24/19 2:15 PM

 & Manufacturers Association, International ®
News and information from the Fabricators

An Invitation From
Foundation Leadership
I’m thrilled that for the first time, Nuts, Bolts & Thingamajigs® (NBT), the foundation
in the of the Fabricators & Manufacturers Association, International® (FMA), will host
an awards gala on October 24 in the Chicagoland area. The gala will celebrate
manufacturing, and NBT will recognize some of the industry’s finest contributors.
Proceeds from the gala will go to NBT’s summer manufacturing camp and
scholarship programs to encourage manufacturing’s next generation and help
Mike Cattelino ensure a future workforce of highly skilled and motivated professionals.
Nuts, Bolts & Thingamajigs Having hosted camps at my school, I have had the privilege of seeing many
Board Chair students discover a lifelong passion for creating things with their hands and identify
the educational pathways that can lead to prosperous manufacturing careers.
Fox Valley Technical
College Instructor I hope to see you at the gala,
Mike Cattelino

UPCOMING
EVENTS
Coming Soon…
Precision Press Brake
Certificate Course October 24, 2019
Sept. 19-20, 2019 | West Memphis, Ark.

Laser Welding Technology

Certificate Course
Nominate Industry Contributors
Sept. 24-26 | Wixom (Detroit), Mich.
NBT’s inaugural awards gala will
Looking Ahead… acknowledge individuals and companies
Coil Processing Certificate Course for their generosity and commitment
Oct. 1-2 | Elgin (Chicago), Ill. to ensuring a thriving manufacturing
The FABRICATOR's future. Since the foundation’s inception
Technology Summit more than 25 years ago, NBT has
Oct. 1-2 | Denver, Colo.
been committed to supporting the
industry’s workforce needs. Thanks
fmanet.org/calendar to the continued support of generous
888-394-4362 donors, the foundation has provided
over $1 million in scholarships and
over $1 million in camp grant funding,
impacting more than 6,000 students. Avanté Banquets & Conference Center • Fox River Grove, Ill.

One of the ways notable contributors can be honored for their part in reaching these remarkable milestones
is by receiving an award at the gala. Three prestigious awards will be presented: Power of Industry, Impact
on Industry, and Future of Industry. Nominations for award recipients are being accepted through August 31.

Thank You Join NBT and FMA for a delightful evening of stewardship and gratitude. For individual tickets, tables of
10, and sponsorship opportunities, contact Daunel Czarnecki at [email protected].
Corporate partner of
Presenting sponsor:
FMA membership

Learn more | Nominate | Purchase tickets | nbtfoundation.org/gala

50 The FABRICATOR AUGUST 2019

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 Your leading educational resource

NAM Announces
FMA as One of the
Best Associations to
Work For
For the second year in a row, FMA has been named one of the
“Best Manufacturing Associations to Work For” by the National
Association of Manufacturers’ (NAM) Council of Manufacturing
Associations (CMA). FMA will receive an award at the CMA’s
2019 Summer Leadership Conference in Charleston, South
Carolina, August 7-9, 2019.

The CMA has partnered with Best Companies Group, an independent research firm specializing in identifying great places
to work, to recognize manufacturing associations that go above and beyond for their employees.

“FMA is honored to be recognized, for two consecutive years, as one of the best manufacturing trade associations to work
for. We take great pride in the work we’re doing to contribute to the growth and sustainability of the metal processing, forming,
and fabricating industry,” said FMA President and CEO Ed Youdell. “This award represents the culture our employees have
created of living up to our organization’s core values of honesty, integrity, respect, trust, accountability, teamwork, innovation,
creativity, and open communication.”

Learn more about FMA | fmanet.org

Transform Your Business

at FABTECH 2019
World-class Education Programs Will Be
Featured in Chicago
FABTECH® is where the industry gathers to overcome challenges, share best practices, sharpen job skills, and discover the
latest innovations. Whichever way you want to transform your business, you’ll find it here. Network and collaborate with the
brightest minds in manufacturing and take a forward-thinking look into the latest trends and innovations, from additive and smart
manufacturing to automation and robotics — only at FABTECH.

FABTECH 2019 will deliver more than 170 sessions covering the hottest trends and advances in the industry. Expand your skill set
through expert-led presentations to experience real-life applications. With targeted technical, operational, economic, and managerial
topics, FABTECH education sessions will help you discover the solutions you need to improve productivity and increase profits.

FABTECH Education Program Highlights Include:

• Over 120 NEW sessions
• Laser welding, leadership skills, and development workshops
• 14 tracks including 3D/additive manufacturing, automation, and smart manufacturing

Learn more | fabtechexpo.com/education

AUGUST 2019 The FABRICATOR 51

Aug19FAB_FMAITK.indd 51 7/24/19 2:56 PM

 The FABRICATOR's Technology Summit
Heads to Denver
Gain a fresh perspective on your operation by reserving your spot for The FABRICATOR®'s Technology Summit in Denver, October
1-2. Through presentations and tours of local manufacturers, you'll learn about the industry’s latest technologies and best practices
in a noncompetitive environment.

Plus, experience unique networking opportunities at:

• The annual Beer on the Bus sponsored by Ncell
• An optional distillery tour and dinner at Leopold Bros.
• An optional private dinner at the historic Stanley Hotel in Estes Park, Colorado

Return to your shop with new ideas on how to better manufacture parts, improve flow, reduce bottlenecks, and resolve everyday
headaches with creative innovations.

Learn more | Register | fmanet.org/fts

Have Employees Earn an FMA Credential

Targeted Training Courses Are
Available This Fall
Your employees can improve their
performance on the shop floor with FMA
Certificate Courses. The courses are taught
by some of the industry’s best experts who
will help develop your employees’ technical
capabilities. Each course includes a brief
final exam, enabling participants to earn an
industry-recognized FMA certificate.

FMA Certificate Courses

Precision Press Brake Sept. 19-20 | West Memphis, Ark. Coil Processing Oct. 1-2 | Elgin (Chicago), Ill.
This two-day course teaches the principles behind quality sheet This two-day seminar teaches the theory of operation behind
metal bending and how to calculate accurate bend deductions, the slitting, leveling, shearing, and blanking processes with a
select the best tooling for the job, and determine the correct comprehensive overview of the coil slitting and leveling process.
V-die opening to avoid part distortion.
Machine Tool Field Service Technician Oct. 17-18 | Elgin
Laser Welding Technology Sept. 24-26 | Wixom (Detroit), Mich. (Chicago), Ill.
This three-day course in a lab setting teaches the crucial This two-day course provides interactive instruction that
fundamentals of the properties, advantages, and expanded teaches in-depth insights on job site safety, electrical
applications of the laser welding process. assessment, understanding hydraulics and gases, and more.

Learn more at fmanet.org/certifcate | Register by calling 888-394-4362

52 The FABRICATOR AUGUST 2019

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 Your leading educational resource

When a Boom Cycle

Really Isn’t a
Dr. Chris Kuehl
Author of Fabrinomics

Read more from Chris at Boom Cycle

fmanet.org/blog/author/ckuehl
By Dr. Chris Kuehl

We hear all manner of assertions regarding

the status of the economy and a wide range
of opinions regarding whether the news is
good or not so good. As with most things
in economics, much depends on one’s
perspective. Given that an election year is
looming, there is even more pressure to spin
the news to fit whatever narrative one wants
to pursue. However, there is one consistent
story: The U.S. is experiencing one of the
longest periods of economic growth in
modern history. This period of expansion has
thus far lasted nearly 10 years (the longest
period was from March 1991 to March 2001).

There have been two sets of reactions to

this development. The optimists assert that
this expansion is a sign that old patterns no
growth. The first is that most of this growth The second aspect of this boom to note
longer apply and there is no reason to think
period has been anemic. Coming out of a is that progress was not all that well
that this cycle will end anytime soon. The
recession is usually a rapid process — the distributed. Many sectors of the economy
pessimists assert that cycles die of old age,
economy goes down fast and rebounds have struggled and never really participated
and this one is about due. Others assert that
fast. That is the “V-shaped” recession. in the growth. The agricultural sector was a
past patterns matter very little as every cycle
A delay in recovery is represented by a net loser, and many retail sectors fell on hard
of boom and bust is different. This cycle was
“U-shaped” graph as the economy lingers times. Job growth has been solid, but the
in its eighth year when Trump took office and
in the doldrums for a while. This recovery majority of these jobs were in the lower-paid
has obviously continued.
has been described as a “check mark,” as service categories. Despite 10 years of a
A couple of factors have played a rather there was a swift decline followed by an boom cycle, wage gains were few, and most
unique role in this decade-long period of excruciatingly long recovery. people experienced income stagnation. The
point is that a boom cycle is subjective —
some see real benefits and some don’t.

THE U.S. IS EXPERIENCING ONE OF Fabrinomics is the exclusive newsletter

for FMA members. If you’d like more
THE LONGEST PERIODS OF ECONOMIC economic insights delivered straight to
your email, become an FMA member

GROWTH IN MODERN HISTORY. at fmanet.org/join. To ask a question of

Dr. Kuehl, send it to
[email protected].

AUGUST 2019 The FABRICATOR 53

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 EXPERTISE » PRECISION MATTERS

Tips for sharing revision-controlled files

File folders help with distribution of files for purchasing,
assembly, and engineering

Read more from Gerald Davis at

www.thefabricator.com/author/gerald-davis

By Gerald Davis member for P1 Group, he is involved with the Private Playground

R
CAD for complex structural projects. Revision With Shared Children
evision is an important aspect of the CAD The project folder is used for CAD work. Shared
is his thing. We appreciate having the P1 Group
job. The revision task includes archiving subfolders (children of the project) contain DXF
share these very granular ideas.
the prior design’s files and folders, creat- and PDF files for distribution and exchange with
Larsen agreed with that article’s suggestion
ing revised 3D models, producing final 2D draw- outside parties.
for including the revision level in PDF file names.
ings, and distributing files to interested parties. The files in subfolders are the master copies
“Interested parties” might include personnel Files that are distributed to others should be
of what has been released from the CAD depart-
in procurement, subcontracting, various fabri- clearly named.
ment to the outside world. The CAD files that
cation trades, the assembly line, marketing, and He also offered a few enhancements to what
were used to create those released PDFs are
end users. Each of those customers of CAD have the June article mentioned. He has a work flow
kept in the private project folder.
their preferred digital format. Some even have policy to use the date of release as the revision A recommended work flow for the revision
preferred methods of receipt, such as thumb level. Who needs “REV A1+” when “08_05_2019” task includes taking a snapshot (make a copy) of
drive, email, or shared drive. is unique and informative? the project folder (and its subfolders) to archive
Document control software may be attached Larsen explained: “The current date and file the version. The copied project folder is then
to the CAD system. CAD jockeys also recognize location are linked to update when the file is renamed to become the working folder for the
this as the vault or PDM (product data manage- opened. When the file is saved to PDF, that date next revision.
ment). The document control add-in to CAD al- becomes the revision. The date is also used to Larsen emphasized that the P1 Group’s folder
lows for recovery when prior art is changed ac- create the file name for the PDF.” system for file distribution is tailored to match
cidentally. The vault is used to archive versions In addition to date-as-the-revision, Larsen re- the needs of each project.
of the 3D models to establish a revision history gards location as an important aspect of CAD “The exact process that I follow is refined for
of the design. the work that we do (architectural metal). It
work flow. He uses Windows® File Explorer to
Access to the vault is restricted. A specific set seems that between our engineer, the general
manage a suite of project folders. In Figure 1 we
of CAD files—PDFs and STEP/IGS/DXF files— contractor, the architect of record, the owner,
see an example of his “flattened folder” system
need to be located for easy access. safety, and anybody else important to a project,
for a panel assembly.
Revision terminology used in this article: changes are going to happen. It is then our re-
• A build is a physical assembly. Often made in sponsibility to keep up and integrate change,” he
batches, each build has a revision that reflects said. “This usually means a new set of drawings
its version. every other day. It is our practice to have a work
• A version is the collection of revisions that flow that preserves and communicates ideas.”
represent the current design. The current design
is what is to be built. Unless there is a revision, An Organizational Playground
the current version is what was built last time. Figure 2 shows a slightly different approach to a
• A revision is a necessary change to a com- folder system for CAD file distribution. The fold-
ponent or its documentation that corrects some er MyCompany belongs to the CAD department.
defect or error. CAD personnel manage the folder, but it reflects
A vault is recommended for maintaining a safe the overall organization of the business.
and secure CAD database. Don’t CAD without MyCompany has subfolders for various cus-
PDM. Whether or not PDM is in use, the docu- tomers of CAD departments, such as assembly
ments distributed by the CAD department ben- and purchasing. The assembly department fold-
efit from thoughtful organization of the CAD de- er has drawings, photos, and procedures to put
partment’s file system. things together. Access to this folder is shared
with responsible personnel. These are the origi-
Distribution of Controlled Documents nal files used to make copies for distribution.
An episode of this column published in June » Figure 1 Delete something here and the CAD people get
(“Tips for document control when it comes to A folder system for files that are distributed to various grumpy.
CAD file revisions,” Precision Matters, The FAB- customers of the CAD department is shown. The working The CAD department folder has restricted
folder for CAD is private and includes PDFs that are
RICATOR, p. 66) caught the attention of reader pending release. Subfolders for DXF files and PDFs are access. Nothing here should be exposed to the
Jonah Larsen. As an architectural metals team shared with the outside world. outside world. Research and development, as

54 The FABRICATOR AUGUST 2019

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 JOIN US FOR THIS FREE WEBINAR
Brought to you by thefabricator.com

INTEGRATING
COLLABORATIVE ROBOTS
Date: Thursday, August 8, 2019
» Figure 2
Here is another approach to file distribution using private and shared folders. The
purchasing department shares subfolders for various fabrication trades; this allows
Time: 1 pm CST
PDFs and STEP files to be shared. The entire CAD department folder is exclusive for This event is
things that are changing. Like the purchasing department, the assembly department now available at
folder has released drawings for current production. Presented by: thefabricator.com/webcast
well as sustaining engineering, are going on in here. The local copy of CAD
files that are checked out of the vault resides here.
The CAD department folder has a history folder for all PDFs that have
been released. Copies of these files appear in the various trade folders.
The purchasing department folder is shared with personnel outside of
the CAD department. It has subfolders for each product line that is ser-
Universal Robots is the largest manufacturer of
viced by the purchasing department. Within each product line, subfolders
for various trades (machined, structural, sheet metal, and so forth) can be collaborative robots, one of the most exciting
found. These trade folders have copies of PDFs and matching STEP files developments in the robotics industry over the last
for distribution to fabricators. Quite often a link to such trade folders is
shared directly with subcontractors.
few decades. Collaborative bots – or cobots are safe
These two examples of file/folder systems for controlled distribution of to work and if they bump into you, they slow,
documents merely scratch the surface of possibilities. Another aspect of and they stop. Collaborative robots are changing
the revision task is annotation of change on the drawing. This involves revi-
sion tables, zones, revision symbols, the use of layers, and the use of color. the way the world manufactures, handles and
Stay tuned. assembles goods and makes life easier for
Gerald would love for you to send him your comments and questions. You are not alone, and the manufacturers. In our webinar, you will see how
problems you face often 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]. companies are integrating collaborative robots
into all kinds of processes: from welding, sanding
and assembly to material handling, inspection
and final pack-off.

JIM BERETTA
President,
Customer Attraction Marketing

The speaker for this webinar will be Jim Beretta, President of

Customer Attraction Marketing. Jim is a marketing consultant for
the automation and robotics industry. He is a moderator at industry
conferences, works in marketing strategy with robot companies,
robot integrators, end of arm tool manufacturers and advanced
manufacturers around the world. Jim comes from the automation
industry and worked as an application engineer then in sales of
complex automation systems and then finally in marketing for one
of North America’s largest robot automation firms. Jim graduated
from the University of Western Ontario, is based in Cambridge,
Ontario and loves everything that is automated.

Register today for this free webinar!

AUGUST 2019 The FABRICATOR 55 Visit www.thefabricator.com/webcast

August19FAB_PrecisionMatters.indd 55 UniversalRobotsHTAugust19FAB.indd 1 7/25/19

7/25/19 3:55
3:57 PM
PM
 EXPERTISE » CONTINUOUS IMPROVEMENT

Help Johnny climb aboard

the lean train
Your lean manufacturing effort depends on it
Read more from Jeff Sipes at
www.thefabricator.com/author/jeff-sipes

By Jeff Sipes really bust momentum, especially when they or underlying issues holding Johnny back, and

Y
come from a widely respected employee like uses examples relevant to Johnny’s situation
ou have been on your lean journey for Johnny. that can help him break through.
some time now. You have demonstrated Sometimes Johnny just hunkers down and Let’s assume you are not quite there yet with
results, gotten employees’ attention, does business as usual. The problem is that the Johnny. What do you do next? One technique
and have shown customers your company can
decisions he makes or the directions he provides might be to get him some outside exposure so
be reliable. Sounds like this is the way to go. All
are inconsistent with the direction the leader- he can see lean in action. Send Johnny to a con-
is well—except for one thing.
ship has set for the company. ference where he can attend education sessions,
You have a problem with Johnny, a longtime
As a result, employees take actions that don’t hear from industry peers, mingle with people
employee true to the company and respected,
support the lean journey. They fail to reduce from other companies who are on their own
maybe even revered, by the workforce. But he
batch sizes; keep a non-bottleneck operation lean journeys, and go on a plant tour that is part
just does not seem to be supportive of your
running when the bottleneck operation should of the conference. The FABTECH® annual expo-
company’s lean initiative. Even worse, Johnny is
be running; and accept the status quo with sup- sition and conference fits this bill, as does the
beginning to negatively influence some employ-
pliers instead of working with them to perform Fabricators & Manufacturers Association Annual
ees. You are concerned that Johnny might un-
in a way that’s consistent with your company’s Meeting. And there are lots of other regional and
dermine the positive changes that are taking the
direction. national conferences that provide exciting and
company in a new direction. What do you do?
Don’t get me wrong. Johnny is not a bad guy. compelling opportunities to learn.
Ways Johnny Might Resist He’s just not with the program and is showing no Another way to learn is through deep immer-
You’ve moved away from the traditional ways of signs of intending to get with the program. What sion. Send Johnny on a lean study trip. It might
manufacturing, with lots of inventory, a focus on do you do to get Johnny aboard the lean train? be a weeklong trip to visit multiple companies
efficiency, keeping the machines running, and a to see lean in action and interact with the host’s
top-down tell-the-people-what-to-do manage-
Ways to Overcome Resistance management team. These trips usually are open
One of the most important tenets of a lean or- to the public, so you can expect a variety of par-
ment style. You now have a more contemporary
way of running the business that focuses on ganization is respect for people. You understand ticipating companies. The debriefs following
throughput, maintaining high velocity, and in- what that means, but you still struggle when each plant visit are essential.
volving the workforce in problem-solving. Many dealing with Johnny. Although there are no You can choose a domestic study trip or an in-
people’s jobs have changed, and that’s uncom- cookie-cutter solutions, here are a few ways to ternational study trip. To make the deep immer-
fortable for those who were satisfied with the deal with Johnny in a respectful manner. sion most valuable, go along with Johnny so you
status quo. This can happen with people at any First, spend the time necessary to help Johnny can do some one-on-one coaching.
level, from the top floor to the shop floor. understand what lean is and how it helps manu- Finally, you might need to have a career de-
Let’s focus on Johnny, a high-level manager. facturing organizations be successful. Educa- velopment discussion. Help Johnny understand
Many employees look up to Johnny because of tion and training provide this baseline. Make that his participation in the lean journey is not
his long-term tenure, deep knowledge of the sure Johnny participates in internal training, negotiable. Let him know the company is going
business, and “being a great guy.” Johnny has and don’t allow the “I’m too busy to sit in that in this direction and that Johnny cannot be a
been skeptical of this lean thing from the begin- training” excuse. Johnny needs to know this is constraint to progress. Provide him with specific
ning. He is rarely overt in his resistance. Rather, a priority both for his development and for the examples of behaviors that are inconsistent with
his resistance seems to be quiet, behind the company’s deployment. Some of the education what you expect. Help him create a personal
scenes, and very low-key. But your employees focuses on leaders only, while other training plan to become a lean team player and leader.
are noticing. will be cross-functional and cross-level. Johnny This will be a frank and, most likely, uncomfort-
One form of resistance is the negative back- needs to be active in both. able discussion. But at this point it is a necessary
biting, a side comment here or a snide remark Johnny has questions and concerns, but he discussion both for Johnny and the company.
there. No long diatribes—just comments that get often has a hard time opening up in front of a
people’s attention. Johnny says the right things group. Here’s where one-on-one coaching can About Respect
when the boss or other key players are around, help. The coach could be his boss, a peer who I’ve described Johnny as being part of the man-
but back-peddles when they’re not around. gets it, your company trainer, or even someone agement team, but he could just as easily be a
This will never work. I don’t understand what from outside the company. This person listens department manager, production supervisor,
they think they are doing. Keep your head down to Johnny’s concerns about this “lean thing.” or a highly skilled welder. He could be anyone
until it passes. These and other comments can The coach tries to understand the root causes in your company. It really makes no difference.

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 Regardless, you’ve pursued various ways to get Johnny aboard the lean
train. But what if after all this work, focus, coaching, and training, Johnny
just refuses to get on board? You have been patient and respectful up to
this point. But he still is exhibiting those negative behaviors that others in
the company are picking up on.
If Johnny is in a position where he exerts either formal or informal in-
fluence on the company, then you have a quandary. Since you are serious
about the “respect for people” tenet on the lean journey, you are faced
with a decision about how to carry it out.
On the one hand, you could make the case that to be respectful of John-
ny, you have to keep trying to bring him along. On the other hand, you can
make the case that to be respectful to others in the company, you need
to deal with the Johnny situation to help preserve the paychecks all those
families are depending on—especially if Johnny is slowing momentum and
putting the company’s performance at risk.
At some point Johnny becomes a personnel issue. If Johnny sees that
you are really serious about this lean thing, he might just think that this
isn’t what he signed up for and leave the company. Alternatively, he might
continue to be the constraining factor and just go along for the ride. In this
case, you might need to terminate Johnny. This is difficult but sometimes
necessary. And, of course, termination is a last resort.
Does Johnny work at your company? If so, are you doing everything you
can to help Johnny get on board? Are you willing to invest in the train-
ing, lean study trips, or whatever else to develop Johnny? Finally, are you
willing to take the difficult actions necessary if Johnny just will not climb
aboard the lean train?
Getting Johnny on the train, or dealing with him when he won’t, is one of
the most difficult issues you will have to address as you continue your lean
journey. The best solution is to be respectful and develop Johnny so that
he willingly gets on board.
But when all else fails, you need to deal with the problem and respect the
efforts of everyone else. You have to take action with Johnny so that ev-
eryone else can thrive.
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 [email protected] or
Senior Editor Tim Heston at [email protected].   

AUGUST 2019 The FABRICATOR 57

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 EXPERTISE » BENDING BASICS

Gauging a new forming order

A new bend sequence makes all the difference

Read more from Steve Benson at

www.thefabricator.com/author/steve-benson

By Steve Benson the workpiece. You never get your piece truly
flat again, and you mar the workpiece. You’ll also
Question: I’ve been working on a challenging part weaken the flattened material along the bend
(see Figures 1 and 2) made of 3/16-inch-thick steel. line. It will be challenging to hit the bend in the
It has stiffeners on the left and right side that are same place, and when you do, you’ll start to see
90-degree downward flanges, along with four in- stress fractures on the outside bend radius.
ternal bends. Each of the four internal bend lines The bend line will shift to the weakest point,
run askew, unparallel to the blank edge. which won’t necessarily be straight down the
The center trapezoid shape created by the two
» Figure 1 bend line. You’ll end up with a flattened “W”
innermost bends should sit flat on the table, and The part in question has internal bend lines unparallel shape in the material. Some areas of the flat-
the tips of the triangle flukes should also touch to the blank edge. Per the shop drawing, the innermost
up-bends are bent to an internal angle of 150 degrees
tened bend line will thin and thus create weak
the table, so there is an 8- to 10-degree slope
(an external angle of 30 degrees), while the outer down- areas within the part.
downward from the back to the front (flukes in bends are formed to 152 degrees (external angle of 28 Even worse, you will not be able to hold any of
the front). I can form most of this part consis- degrees).
the desired dimensions. The flattening changes
tently, but I’m having trouble with the trapezoid
the flat dimensions and causes the bend deduc-
shape, which isn’t sitting flat and usually has
tion to change. The overall dimension will be
some wobble.
longer. Flattening and rebending the part will
I bend everything over a special commercial
weaken the bend and the integrity of the mate-
die with a 0.65-in. opening (see Figure 3), per-
rial will be gone. This could lead to part failure
forming each of the 90-degree stiffeners first. I
once the unit has been installed in the field.
bend the outer down-bend, then flip it over and
» Figure 2 While you may get away with rehitting on a
do the inner up-bend. I then do the same on the The stiffener flange on the edge requires a 90-degree few parts, you might cause the wobbling to get
other side (see Figure 4). The shop drawing tells downward bend.
worse. I know you don’t want to hear this, but
me to “bend down to 150 degrees” (30-degree
remaking the parts from new blanks is the cor-
external angle) for the inner bend and “bend up
rect course of action. It will save you a lot of un-
to 152 degrees” (28-degree external angle) for
necessary aggravation, especially when the diffi-
the outer bend.
culty cuts deep into your profit. Trust me on this
Unfortunately, after performing the outer
one; it is not worth the fight.
bend, I find it almost impossible to start the sec- » Figure 3
ond bend without the first bend contacting the This 0.65-in. die was
custom-made to form Perfecting Your Forming Order
die. So, I have to use another V die with a 0.65-in.
the part in question. Because you’re starting with the 90-degree
opening to get the second bend started.
down-bends for the stiffener flanges followed by
I now have about 60 of these pieces that are all
those innermost up-bends, you’re forcing your-
wobbly and not sitting flat, and I can’t figure out
self to bend off a downward flange, which puts
how to fix them. Should I flatten them out and
you below the plane that’s parallel to the top of
then rebend using a wider die? If I rebend them
the die. Reordering your bend sequence will help
all from a flat piece, could doing the inner bends
improve your process and should take care of
first make a difference and influence the trap-
the trapezoid’s wobbling problem and allow you
ezoid to sit flat, rather than be tilted backward?
to hold the other dimensions to the print.
Answer: Your thinking, for the most part, is right I would begin with the two innermost bends
on track. While the die you’re using is a contrib- and work my way out from there, finishing with
uting factor, one that you can correct for easily, the 90-degree bend. Specifically, I would start
your problem probably has more to do with your with the innermost up-bend; flip the part for the
bend sequence and the associated gauging. outer down-bend; then perform the 90-degree
Even under the best of circumstances, trying down-bend for your stiffener flange. After this,
» Figure 4
to flatten and rework a part rarely works out The reader’s bend sequence is the likely cause of the spin the part around to produce the same three
well and leads to badly marked-up sections on “wobble” of the center trapezoid shape. bends on the other side.

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 Gauging the Workpiece Bending Die Modification
Any variation in bend angle will change the part’s The die you’re using (see Figure 3) appears to be
relationship to the backgauges, causing the loca- a little overbuilt. If you still have clearance prob-
tion of the bend line to move from the position lems, forcing the first bend to open and chang-
that it should be. Considering this, how do you ing the part dynamic, you could easily afford to
develop a consistent gauging strategy so that all have material removed from both sides of the
the bends lines are in the same location, side to tool. Removing a portion for clearance should
side and bend to bend? not change the function or strength of the tool.
Your gauging strategy will depend on the type
of backgauge system you have. Modern multiaxis Mastery Through Practice and Patience
backgauge systems have stops that are agile and Forming order and gauging are always going
designed to work with the backgauge fingers out to be a practiced art that does take some time
of parallel. Figure 5
to learn and one that can only be acquired by
This part (different than the one in question) illustrates spending time at the press brake, by making mis-
laser stitching. The extra material on either side provides takes, and learning from them. These mistakes
Always remember, the press brake a flat gauging surface; once forming is complete, the
operator snaps off the microtabbed material.
can be costly, especially when you need to re-
remains one of the most make an entire order.
challenging machines to master In time, however, you should get pretty good
two laser-stitched lines on either side. The edges at it—that is if you don’t let the process of learn-
on the fab shop floor. ing frustrate you too much. Just keep in mind
should be parallel to the innermost bend line (for
the 150-degree angle); the outer laser-stitch line that there is a rather long learning curve to op-
Another option is to add breakaway material should be parallel to the outermost bend line erating a press brake efficiently and with finesse.
to gauge from, by having the additional material (for the 152-degree angle); and the inner laser- Always remember, the press brake remains one
cut to the same angle as the bend lines in the stitch line will be the edge of the formed part. of the most challenging machines to master on
workpiece (see Figure 5). (Note that I’m refer- You’d form the 150-degree bend first, then the fab shop floor.
ring to the angle of your bend lines in relation break away the material along the outermost Steve Benson is a member and former chair of the Pre-
to the blank edge, not the angles of the bends laser-stitched line, revealing an edge parallel to cision Sheet Metal Technology Council of the Fabrica-
themselves.) This extra material keeps the bend that 152-degree bend. After forming that bend, tors & Manufacturers Association International®. He is
the president of ASMA LLC, steve@theartofpressbrake.
line parallel to the gauges. Once you finish bend- you’d break the innermost laser-stitch line to com. Benson also conducts FMA’s Precision Press Brake
ing, you can remove the extra material. reveal the true blank edge, which you can use Certificate Program, which is held at locations across
Because of the two different angles of the four to gauge your 90-degree downward flange. Fi- the country. For more information, visit www.fmanet.
org/training, or call 888-394-4362. The author’s latest
internal bend lines, you will need two breakaway nally, you’d spin the part around and repeat the book, Bending Basics, is now available at the FMA book-
pieces. To make these, try cutting the blank with sequence on the other side. store, www.fmanet.org/store.

FAB_ad.indd 1 7/9/18 11:56 AM

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 One service
COVER center’s future
STORY in fabrication
and supply chain
management
By Tim Heston

I
t’s no secret that metal service centers have
boosted their fabrication capacity over the
years to meet the needs of OEM customers.
Although many haven’t trumpeted the fact,
most know that vertical integration is a reality
in some areas of the metal fabrication business.
Roswell, Ga.-based Kloeckner Metals Corp.
(KMC), whose German parent acquired

GOING
Namasco Corp. and Macsteel Service Centers
USA and merged the two under the KMC brand
in 2012, in recent years has been developing
a new approach to the U.S. metal fabrication

VERTICAL
market. Earlier this year the company rolled out
a formal communications effort on its website,
laying out the full scope of metal fabrication
services, from plate rolling and laser cutting
to stamping, punching, bending, welding,
assembly, and kitting.
“We’ve definitely been doing more with our
marketing efforts and promoting our fabricat-
ing services to grow that area of the business,”
said Steven Nghe, head of marketing and com-
munications. “If we can make the supply chain
more efficient, at the end of the day, it’s going
to be better for the customer.”
KMC’s strategy involves more than just an
expanded service offering, though. It’s a new
approach to the metal fabrication supply chain.

A New Approach
In 2015 KMC acquired American Fabricators Inc.
(AFI), a custom fabricator in Nashville, Tenn.,
and that AFI location remains the center of
KMC’s fabrication capabilities. But the company
is looking to build its fabrication capabilities at
other branches to meet the needs of local cus-
tomers, most of which are large OEMs.
Mark Zumbrun, director of fabrication, has
spearheaded the effort. He began his career at
Ryerson, then joined Edgecomb Metals more
than 25 years ago. Edgecomb became Macsteel,
which was acquired by KMC.
In recent years KMC has been sending out a
portion of its fabrication work to fab shops on

» Formed and welded parts are staged for downstream

processing at American Fabricators Inc. (AFI), which was
purchased by Kloeckner Metals Corp. (KMC) in 2015.

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 focus on that area. Are you running out of roll
forming capacity? We’ll then focus on that.
“And with many fearful that the boom of
2018 has turned into the bust of 2019, we have
companies that thought they would have larg-
er capex budgets than they have. But we have
them covered.”
Zumbrun added that local customer needs
also dictate how far downstream the manu-
facturing processes at a particular KMC plant
go. “Some plants can take it to a point. We can
punch it, laser it, bend it, and then we stop.
Other plants do welding, hardware insertion,
kitting, and line setting. And we’ve even done
private-label manufacturing, where a complet-
ed product went into a box that went to the
customer’s distribution center, who then sent
it to the final customer.”
» A laser finishes a cutting cycle at AFI.
a toll basis; the fab shops charge for the labor
and machine time, but they don’t own and so
don’t charge for the metal.
“This has helped small fab shops particularly
when it comes to working with large OEMs that
are increasingly difficult to penetrate,” Zum-
brun said, adding that fab shops that partner
with KMC are effectively “utilizing the KMC
sales team … The model we employ allows the
smaller fabricators to increase cash turnover
and cash flow, while focusing on their core
competency.
“Also, we have our money in metals. Instead
of sending you [a fabricator] just enough ma-
terial to run three or four days, with frequent
machine setups, we’re going to put enough » KMC has more than 45 branches across North America, each with varying levels of metals processing and
metal on your floor to satisfy the job’s produc- fabrication capacities that aim to meet local demand.
tion requirements for a full month. You set up, The arrangement also overcomes another
and you run a month’s worth of inventory. I’m common issue in custom fabrication: obsolete
then going to get it off your floor, and we’ll pay inventory. As Zumbrun explained, “We have
Vertical integration has been
you for it. And you didn’t tie up any money in contracts in place to deal with obsolescence, around for decades in metal
metal.” slow-moving inventory, and receivables issues.” fabrication, as each player
Integrating the Fabrication attempts to service customer
AFI has its own website and remains a brand, but needs in new ways.
it’s also integrated into a larger whole. It remains
a center of fabrication expertise at KMC, consid-
ering the talent it employs and the number of
machines (more than 35) it has on the floor. He added that company engineers—both in
As Zumbrun explained, the kind of fabrica- flat-roll cutting and leveling and in fabrication—
tion equipment KMC acquires at its more than collaborate to eliminate quality concerns. It’s all
45 North American branches hinges on the designed to eliminate the unexpected, and the
needs of the nearest OEM customers. Plants farther downstream the unexpected occurs,
near heavy-equipment OEMs are investing in the more expensive it can get. Say a job re-
8-kW fiber lasers, high-tonnage press brakes, quires laser cutting a sequence of long, skinny
and blasting equipment. KMC plants near, say, parts. The laser operator sets up the job, runs
HVAC OEMs focus on lighter-gauge fabrication. the sheet, and lo and behold, stress in the sheet
“We sit down and talk with our customers and is released, the part springs up and crashes into
ask where they need help over the next five the laser head.
» As director of fabrication, Mark Zumbrun leads years. Where is their capacity tapping out? Are As Zumbrun explained, KMC aims to elimi-
fabrication sales for both KMC and AFI. you running out of press capacity? Then we’ll nate these issues before any metal reaches the

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 laser. “We spend a lot of time on the front end
going through those types of scenarios. For
some products we might have to look into an-
other type of leveling. Other products might
not require it. Regardless, now we have experts
on both sides [coil processing and metal fabri-
cation], and there is no finger-pointing.”

Capacity Management
How much fabrication capacity an OEM builds
in-house—be it a comprehensive amount or next
to nothing—depends on the business model;
the nature and complexity of the work; the level,
type, and reliability of fabrication capacity in the
area; the demand cycle of the product; as well
as the company culture and available expertise.
No matter the situation, though, everyone
in the metal fabrication supply chain strives to
reduce risk. Relying too heavily on internal fab-
rication capacity—especially without building
» A roll forming job commences at a KMC branch.
relationships with outside partners that could
offer additional capacity when needed—could
in many cases introduce excessive risk. Ma-
chines might be busy during peak seasons but
sit idle during the slow months, and no manu-
facturer wants millions of dollars’ worth of
equipment sitting idle for long periods. And if
those machines can’t meet capacity demands
during busy times, an operation without out-
side partners runs up against a wall; it just can’t
produce any more. All this makes the metal fab-
rication supply chain a fluid thing.
“A lot of our fabrication work comes from
customers bumping up against capacity,” Zum-
brun said. “So we know for six months out of
the year they need us, and the other six months
they’re going to do the fabrication themselves.
That’s OK, and it’s all communicated upfront.”
The same can apply for KMC’s custom fabri-
» Coil is stored and ready for processing at a KMC branch. cation and stamping suppliers. KMC works to
keep its available capacity as flexible as possible.
Part of this strategy involves outsourcing some
capacity to custom fabricators and stampers,
many of which act as toll processors, charging
for the processing time and labor without own-
ing the metal.
What if a custom fabricator has a specific
technology or process that’s unique or requires
significant processing? “Say one of our [fabri-
cator] partners has a $10 part that’s $8 worth
of metal. We’re going to pay them the labor
[to fabricate the metal as a toll processor]. But
then there are some parts that are worth $2 of
metal and there’s $8 worth of value-add. In this
case, the fab shop will sell to the customer di-
rectly, and we’ll just sell them the metal.”

“We’re Not a Fab Shop”

Look at a bar chart depicting the revenue mix
of many job shops and you’ll likely see a narrow
» Material undergoes a leveling operation at a KMC branch.
head (the high-revenue work) and a long tail

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 of low-volume work. A typical job in turn makes [the fabricator] a better supplier to to shorten time to market, reduce price and increase
shop might have hundreds of cus- Kloeckner, because the shop has additional capacity.” quality for the ultimate customer, and reduce risk to
tomers, but just a handful provide make the business sustainable.
the majority of revenue. Smoothing the Ripples Zumbrun said he sees KMC’s place in all this as a
According to the annual “Finan- Vertical integration has been around for decades in supply chain manager. It can supply the metal as it al-
cial Ratios & Operational Bench- metal fabrication, as each player attempts to service ways has. But it can also grow in supply chain manage-
marking Survey” from the Fabrica- customer needs in new ways. Custom stampers get ment and, ultimately, work to smooth out the ripples
tors & Manufacturers Association, into custom fabrication and vice versa; fabricators of chaos caused by the unexpected.
around five customers make up have their own machine shops; sheet metal fabricators Senior Editor Tim Heston can be reached at [email protected].
more than 50 percent of shop rev-
delve into tube fabrication; metal service centers and Kloeckner Metals Corp., www.kloecknermetals.com
enue at the typical custom fabrica-
OEMs build up their own fabrication capability. All work American Fabricators Inc., www.americanfabricators.com
tor. Of course, high revenue con-
centration introduces risk. A shop
can grow on the backs of one or a
few large customers, then be left
out to dry when those large cus-
tomers change sourcing strategies.

» A series of cut and formed parts are

ready for sorting at a KMC branch

Especially since the last down-

turn, many fabricators have put a
renewed focus on diversification.
And according to Zumbrun, KMC’s
approach can give a fabricator an-
other avenue to achieve that di-
versification.
“We’re not a fab shop,” Zum-
brun said, clarifying that by “fab
shop” he means the small job shop
that thrives on low-volume work.
“We’re a parts manufacturer and
inventory control and supply part-
ner. We don’t want to make five
of this and four of that. We can’t
make any money on that. That
doesn’t fit our structure, so we’ll
steer all that business to our fabri-
cator partners.”
He described a typical scenario
in which a member of the KMC
sales team visits an OEM customer
or prospect and reviews a list of
part numbers. “That person might
see a list of 400 part numbers. We
can manage the top 300, but we
can’t accept the bottom 100, so
we’ll turn it over to our partners.
We share our leads, because we
want them to be strong. In fact,
we’ve had some of our fabricator
partners add equipment, like a fi-
ber laser, because we’ve helped
them build a new market. This

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 Fabricating better together
How technology enables a new business model
By Tim Heston As the number of employees grows, the busi- to very busy some of the time, other times just

S
ness needs a human resources manager. And very bored.
ix years ago, Kurt Wollenberg wasn’t hap- to ensure a safe environment and abide by The same challenges applied to human re-
py. He had founded a custom fabrication OSHA, the business needs someone to manage sources, information technology, and qual-
company and grew it to a $10 million-plus safety—perhaps not a full-time environmental, ity assurance. A medium-sized fabricator’s QA
business. He liked the actual fabrication work, health, and safety manager, but at least some- manager might be swamped preparing the pa-
of course. He wouldn’t have launched the busi- one to manage EH&S functions when needed. perwork for a PPAP one day, then have a very
ness if he didn’t. He thrived when faced with Wollenberg found that as his previous com- light work load the next, inspecting pieces as
a complicated project. But he didn’t like the pany reached about 70 employees and neared needed on a laser scanner and coordinate mea-
regulatory and personnel headaches of running $10 million in revenue, he and his team discov- suring machine.
a 75-person organization. ered they needed many functions of a larger As Wollenberg has found over the past three
Intending to leave those headaches behind, business, but not all the time. Engineering was years, an entrepreneur can take alternative
Wollenberg sold his fabrication business six a prime example. Demand for engineering work paths to launch a fabrication business—and
years ago. But he still wasn’t happy. He liked ebbed and flowed with the product mix. Engi- The Village Companies, or “the village,” as the
the projects and, especially, the people. He had neering jobs filled inboxes all at once, delay- member companies call it, happened to open
spent his entire adult life in the business and ing order release and ship dates. But then jobs one of those paths.
had so many friends who also happened to be came in that didn’t require much engineering
co-workers and customers. work, especially if the 3D CAD files were clean. It Takes a Village
So three years ago he got back into the fabri- This made it difficult to justify hiring more Although it didn’t have a name and was only
cation game by launching Kaukauna, Wis.-based than one engineer. Two would be moderately a way of doing things, the village was born 40
Metal Fab Solutions (MFS), but not as a typi-
cal startup, with one or a few people working
nonstop out of a garage. MFS is a member of a
unique organization called The Village Compa-
nies. Like any village, its population shares cer-
tain resources to be more competitive.
As Wollenberg put it, “We’re better together.”

Challenges of Being Medium-Sized

When a fabrication shop launches with a few
welding machines, brakes, and a cutting table,
operations are pretty straightforward. A few
people can carry projects through from be-
ginning to end. But as the shop grows, things
change, as they did for Wollenberg’s previous
fabrication company.
As the number of jobs grows, a shop needs an
engineer or CAD technician to work with cus-
tomer drawings. Quality assurance duties ramp
up as customers require production part ap- » Metal Fab Solutions’ Diamond BH press brake comes with the Videre operator assistant that projects a simulation
proval processes (PPAPs) and ISO certification. of the bend sequence onto the press brake ram.

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 lenberg said. “They were telling me how they paying their fair share.
always wanted to get into metal, but it was not “If I’m a five-person company, hiring a
their area of expertise.” The idea took root. $100,000 engineer just isn’t practical,” Wollen-
MFS was born and joined the village. berg said. “But if I use 10 percent of that per-
The Village Companies is a unique entity. son’s time, I pay 10 percent of the engineer’s
It’s not a parent or holding company, and MFS salary, or $10,000. That’s affordable, even for
and the other companies (which now total 14) a five-person shop.” MFS also gained access
aren’t subsidiaries. Because The Village Compa- to (and shares the cost of) MCL’s quality engi-
nies members aren’t under one corporate um- neers and EH&S and HR professionals.
brella, each company remains independent and Being independent, MFS isn’t a captive fabri-
has its own profit and loss statement. cator to MCL, Bay Tek, or other companies in
As Paul Knoll, president of MCL, explained, the village. Only half of MFS’s work comes from
“Each [member company] is expected to give supplying fabrications internally to other village
» MFS General Manager Kurt Wollenberg (left) and more than it takes from the village through the companies. The other half comes from compa-
Fabrication Shop Manager Tad Kallas (right) have known sharing of resources, relationships, ideas, and nies outside the village.
each other for more than 20 years. dreams. Often, as a village company is getting The sharing of certain resources gets around
started, it will benefit from the resources the the problem of variable demand. Indirect labor
years ago when the Treankler family began Bay
larger companies can provide, and then give becomes a variable cost. When a spate of work
Tek Games (now Bay Tek Entertainment) and
back in other ways.” arrives requiring some engineering, MFS can
MCL Industries in their home. MCL is an elec-
MFS launched with just five employees, but turn to an engineer in the village. Same goes for
trical enclosure and contract manufacturer in
being part of the village, it could act much PPAPs. If a job requires ISO certification, the
Pulaski, Wis., that sourced its fabrication work
bigger. If a job required a little engineering, customer can work with MCL Industries, which
to, among other fabrication shops, the one Wol-
MFS could send it to one of MCL’s engineers. is ISO-certified; MCL then can subcontract the
lenberg used to run. Bay Tek Entertainment, also
The work didn’t come free; engineers divide work to MFS, which follows MCL’s established
in Pulaski, is an inventor and maker of amuse-
their time among various companies, each ISO procedures.
ment games—products that require sheet metal
enclosures.
As member companies grew through the
addition of other businesses, Larry Treankler,
chairman of The Village Companies, along with
his partners Carl Treankler and Terry Hanstedt,
wanted to ensure that the way of doing busi-
ness that they had in the beginning was pre-
served—so they formalized the concept and
put in print (and online, at thevillage.bz) the vil-
lage’s reason for being:
• To work with people we love and care about.
• To create opportunities for those people.
• To make a difference in the lives of our cus-
tomers and suppliers.
• To run successful businesses so we can give
back to the communities we live and work in.
MFS entered the village about four years ago.
“The idea came about from a weekend snow-
mobiling with the partners in the village at that
time who were past customers of mine,” Wol- » A welding programmer at MFS reviews a program on the teach pendant.

» MFS’s Mitsubishi laser cutting system has automated material loading and unloading. As the shop grows, MFS will add a material handling tower to the existing system.
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 How Technology Enables a Business Model That sheet metal expert is often Tad Kallas. MFS’s be using to air-bend the part. So
The relationships among village companies are closer fabrication shop manager, Kallas has been in sheet the print would go back to engi-
than a typical farming-out scenario, and collabora- metal long enough to know that the village concept neering. “This would happen seven
tion abounds in various facets of the business. Village might not have worked 25 years ago, when he and Wol- times out of 10,” Kallas recalled.
If this happened today, the village
company members meet periodically at what they call lenberg first met. Back then Kallas worked at a sheet
concept really wouldn’t work as
“joint leadership meetings” to discuss business chal- metal firm close to Wollenberg’s previous fab shop,
well as it does. If Kallas continually
lenges and opportunities. Quite often someone knows and he was all too familiar with the engineering chal- sent jobs back to engineering, shar-
someone who knows someone who could solve a prob- lenges—particularly when it came to forming. He’d re- ing an engineer’s time with other
lem or lead to new opportunities. For instance, if MCL ceive a print and discover a hole too close to the bend companies wouldn’t be practical.
has an issue with a sheet metal enclosure, then a sheet line, or find that the bend allowance and bend deduc- But today MFS needs relatively
metal expert at MFS can help. tions didn’t account for the actual die widths he would little of an engineer’s time. Sure,
the occasional fabrication project
does require a little engineering.
But for the most part, MFS simply
requests a solid model alongside
PDFs of the drawings that serve as
the baseline for inspection.
The process occurs very dif-
ferently today, thanks largely to
offline bend programming and
simulation. Modern software—in
MFS’s case, DiamondBend from
MC Machinery Systems—ensures
bending happens correctly the
first time. When Kallas receives a
solid model, he uses the Diamond-
Bend software integrated into the
shop’s design software (MFS uses
SolidWorks, but DiamondBend
can be integrated into Inventor
and SpaceClaim as well).
“The software immediately tells
me if it can or cannot be bent,
writes the program based on the
tools we’ll use, and calculates the
flat,” Kallas said, adding that the
flat dimensions are sent to the la-
ser nesting software. “It’s like fab-
ricating in reverse.”
When the cut parts arrive at the
press brake, the operator retrieves
them, calls up the program, then
turns away from the control screen
“The Best is Now The Simplest”
and looks right at the press brake
ram, where a simulation of the
Dot Peen Marker bend sequence appears. Integrated
ER
00
IAL: 011 7
- with MFS’s Mitsubishi Diamond BH
TS

21

press brake, the Videre operator

-17
ARC TEX

18:27

assistant projects a 3D bend simu-

2D DATA MATRIX Impo rt Graphics lation directly onto the face of the
X T ram, guiding the operator through
MIRROR TEXT
R TE
LA the sequence step by step.
GU
REVERSE TEXT AN
REVERSE TEXT
ANGULAR TEXT For this to work smoothly, MFS
does require the solid model, and
Type or teach positioning customers don’t always supply one
r r r r r r

Compact flash card memory at first. Some hesitate for revision

Automatic serializing control reasons. “But then I tell cus-
Date/time shift coding tomers about our process and its
Mark virtually any material
benefits, and I emphasize that we
always inspect to the PDF drawings
The KM-64 True chipless engraving
they give us,” Kallas said. “Then, al-
most always, they’re happy to send
[email protected] (815) 363-8268 www.kwikmark.com MADE IN USA over the solid-model file.”

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 Let the Village Grow new business model—so few can be so productive. on its core competency. “The village allows us all to
Today MFS employs 30 people, 24 As the village member companies collaborate more, focus on what we do best, and for us that’s sheet
of whom work in the welding shop they can offer customers more services. And the metal and welding,” Wollenberg said. “That’s what
where the fabricator employs both more services they provide, the more turnkey pack- really makes it so fun. And an important part of our
manual and robotic welding. ages they can offer, which in turn helps with customer business model is fun. We all need jobs, and we need
MFS also supplies customers retention. A fabricator that cuts and forms blanks can to get the work done, but let’s have fun while we’re at
on a replenishment kanban pro- be easily replaced; a fabricator that works closely with it.”
gram, a concept Wollenberg pro- a larger organization—one that provides services
Senior Editor Tim Heston can be reached at [email protected].
motes with as many clients as he through a larger contract manufacturer and a variety
Metal Fab Solutions, www.mfswelds.com
can. “A customer might want, say, of other companies—can’t be replaced so easily.
50 of one product just to meet Most important, the business model allows MFS to MC Machinery Systems Inc., www.mcmachinery.com

minimum quantities for an out- provide a variety of services while remaining focused The Village Companies, thevillage.bz
side powder coater. But then I
ask them, ‘How many do you re-
ally need? If you only need 25, then
we can run 50 and hold 25 in our
building.’ They’ve just reduced
their required footprint for the
job and increased their inventory
turns.” The arrangement gives
MFS scheduling flexibility and bet-
ter material yields, allowing Kallas
to nest filler parts for these kan-
ban replenishment orders along-
side on-demand work.
Only three full-time work in the
sheet metal shop, where they use
one 6-kW Mitsubishi laser with
automated loading/unloading, one
press brake, a hardware insertion
press, and a few other pieces of
equipment. Those three employ-
ees churn out 15,000 to 20,000
pounds of work a day, enough to fill
a 24-pallet truck that heads to the
MFS welding facility in Green Bay.
“Those five workers feed
enough work to keep 24 weld-
ers very busy,” said Kallas, adding
that much of the forming work is
quite complicated, including a fair
number of construction equip-
ment buckets that require consis-
tent bump (incremental) bending.
But thanks to modern equipment,
the work flows quickly. Some low-
volume or prototype orders can be
programmed, cut, and formed in
less than an hour.
Within three years Wollenberg
and his partners plan to move the
entire business under one roof,
but the location won’t be just any-
where. He and most other mem-
bers of The Village Companies
plan to be on one campus. Wollen-
berg envisions one day driving cus-
tomers and prospects around the
campus, describing the concept
and showing how—with the help
of modern sheet metal fabrication
technology, complemented by a

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 What high-powered fiber lasers
mean for a fabricating shop » High-powered lasers are in demand for all kinds of
cutting needs, not just for thick materials.

It’s more than just cutting thick materials;

ductor diodes are excited in ytterbium-doped
fiber optics until the laser is produced; all of the
it’s cutting process time modules are spliced to an active fiber, which is
then used to deliver the laser beam.) That’s
By Brian Kent A Closer Look at How We Got Here why the recent rise in wattages has occurred so

F
It was only in the mid-2000s when high-pow- quickly: From a pure technology point of view,
abricators don’t have to be an expert in fi- ered CO2 laser cutting machines were deemed adding power is not complex. In fact, fiber laser
ber laser cutting technology to know that the tool necessary to process the plate quickly welding systems today can exceed 100 kW in
if they can cut 0.25-inch plate with a 4-kW and efficiently for the creation of armor kits for some instances.
laser, they can cut it faster with an 8-kW laser U.S. troop vehicles deployed in Afghanistan and The reason that fabricators don’t have 100-
power source. Now think what they can do Iraq. Improvised explosive devices were a huge kW systems on their shop floors is that the
with a 12-kW fiber laser cutting machine. What threat, and the kits protected military person- beam delivery systems just can’t handle that
about a 15 kW? nel in a way that the bare transport vehicles much power. That’s why so much research is
Those choices are available for metal fabrica- couldn’t. being done in cutting head design. Each laser
tors today, but to focus solely on thick metal Only a few years later fiber laser technology cutting system manufacturer is looking to pro-
cutting with these new high-powered fiber la- debuted, and its adoption rate exploded by duce a reliable cutting head that can deliver
sers would be wrong. These 10-, 12-, and even the middle of this decade. Without the need the fiber laser beam for an extended amount
15-kW machines can do much more than cut to worry about mirror or lens cleaning, bel- of time in the face of harsh cutting conditions,
thick materials, even if that may be the first low checks, and beam alignments, fabricators which is more than likely to occur when cutting
thing that comes to mind for a metal fabrica- found a new cutting tool that required little thick materials.
tor when talking about these powerful machine maintenance and that cost about half of what a In recent years those same machine tool
tools. The reality is that a large majority of CO2 system cost to run. manufacturers have developed cutting head
metal fabricating companies in North America The fiber laser also produces a beam wave- optics that can modulate the beam size during
process metal that is 0.25 in. or thinner. There’s length that is about 10 times shorter than the cutting. This technology development has pro-
simply not a lot of shops requiring laser cutting 10-micron beam wavelength associated with a pelled fiber laser cutting machines from being
of very thick specialty metals for something like CO2 resonator. This focused beam produces a strictly a tool for cutting thin sheet metal. As
nuclear reactors. Those types of applications higher power density that, when coupled with material gets thicker, a wider beam is needed
are not abundant. the technology’s higher absorption rate, trans- to create more kerf so that molten metal can
The story of high-powered fiber laser tech- lates into cutting speed that greatly outpaces be removed.
nology is about decreasing process time in laser that of a CO2 laser, particularly in material So how powerful of a fiber laser does a fabri-
cutting. That’s why we are seeing metal fabrica- thicknesses less than 0.25 in. cator need? A company should look at the typi-
tors buying one high-powered laser cutting ma- With fiber laser technology manufacturers cal thickness range that makes up 80 percent of
chine to replace two or even three older lasers. can increase the power of these machine tools its work. If it’s really thin gauge, a 15-kW laser is
They can get parts off the laser bed faster and with the addition of laser-producing modules. not likely needed. (Even if a shop had a 15-kW fi-
cheaper than they ever could before. (In the modules, light emitted from semicon- ber laser, it would turn down the power to 6 kW

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 and cut that thin material at a very fast speed Making the Most of Material Exchange Fiber laser cutting machines will continue to
and at low cost.) Of course, processing time on a fiber laser cut- grow in power if the cutting head and material
Here are some general rules for cutting com- ting machine is greatly tied to the system’s abil- handling technology can complement the in-
mon metal such as steel, stainless steel, or alu- ity to load sheets or plate and unload cut parts creased power. Fabricators will take advantage
minum with nitrogen: and skeletons. A fabricator is not going to gain of the power if they are able to feed these rav-
Up to 9 gauge—6 to 8 kW any cycle time advantage if it has to wait several enous cutting machines. Thick or thin material,
0.25 to 0.75 in.—8 to 10 kW minutes for material movement to take place. it doesn’t matter.
Over 0.75 in.—8 to 15 kW A lot of pallet changers offered today were Brian Kent is a co-founder of Fairmont Machinery,
Keep in mind that a fabricator with a high- designed to work with CO2 lasers, which cut 833-667-7889, [email protected], www.
powered machine can produce more parts per at much slower rates when compared to fiber fairmontmachinery.com, a distributor of Eagle fiber lasers.
hour and the part cost plummets as the power lasers. They most likely use hydraulics and can
goes up. But this occurs only if the laser cut- take 35 to 50 seconds to exchange a sheet.
ting machine is quick enough to maximize the
The most modern pallet changers rely on
power of the machine.
servo-driven technology and can swap a pallet
What Is Meant By Quick? in under 10 seconds. If a fabricating operation
Operating costs probably will go up as the pow- typically changes sheets six to 10 times an hour,
er level on a fiber laser cutting machine goes up. a modern pallet changer can add one to two
Generally, doubling the power increases laser hours of cut time per week that might other-
operating costs by 20 to 30 percent. That’s why wise be unavailable with slower material han-
it’s so important that the fiber laser is operat- dling technology.
ing at peak efficiencies, so that part cycle time This automation of loading and unloading is
can be decreased to offset the higher operating critical. A fabricator that can cut and get that
costs. By decreasing cycle time, a fabricator can sheet or plate off and replaced in seconds is
reduce the impact of variable and fixed costs getting maximum production out of its fiber
and increase profitability. laser cutting machine. A fabricator that is able
Luckily, fiber lasers cut fast. Just watch them to cut faster, but still experiences downtime re-
race up and down a piece of sheet metal at lated to slow material handling, is pushing the
a tradeshow. Unfortunately, most fabrica- laser for no reason.
tors aren’t cutting parts that feature long and When it comes to selecting pallet changer
straight lines. They are cutting small holes and technology, a fabricator should select one that
unique geometric shapes. In this reality a fabri- can handle the thickest, heaviest material it pro-
cator needs fast acceleration to take advantage cesses. A 1-in., 5- by 10-ft. plate weighs 2,100 lbs.
of the machine’s linear speeds. For most shops, a pallet changer with a 2,200-
For instance, a 1G machine that accelerates lb. capacity should be sufficient. Anything over
at 32.2 feet per second squared is easily outper- that thickness requires a heavy-duty system de-
formed by a 2G machine, which accelerates at signed to manage the much heavier loads.
twice the rate. When the Gs are doubled, the
machine needs half the time and half the dis- High-powered Lasers for All?
tance to reach the same programmed speed. Not all metal fabricators need a high-powered
The rate the machine can decelerate into and laser, particularly if it doesn’t have enough work
accelerate out of corners and tight arcs often has to load its current laser cutting machine. For
a greater impact on cycle time than laser power example, if the shop’s laser cutting work load is
or maximum machine speed. Acceleration is vital.
not expected to grow and consumes just half of
For further illustration, consider laser cut-
a work shift, then paying for a more powerful
ting 20-gauge aluminum with a 4-kW laser that
laser to reduce the work load to a quarter of a
can cut at a speed of around 2,250 inches per
shift likely won’t deliver a good return on invest-
minute. If the fabricator is cutting a 3-in. line
ment.
with a 1G machine, that 4-kW laser will never
But if metal fabricators are maximizing their
accelerate to the potential cut speed before it
current laser cutting capacity and looking
has to start decelerating. Meanwhile, a 6G ma-
chine will be at the cutting speed for 2.4 in. of to possibly add another shift, they definitely
the 3-in. line. should take a look at high-powered lasers. This
When discussing cutting efficiency, it also is particularly true if they are using older laser
helps to look at the rapid traverse speed and technology.
the acceleration. This involves movement of Today’s high-powered fiber laser cutting ma-
the cutting head when the laser is not in use, chines can replace two or three older lasers. In
which is about 15 to 25 percent of cutting head a time when fabricators struggle to find reliable
movement over each sheet or plate. Machines and experienced operators, they can actually
that deliver higher rapid traverse speeds, great- invest in a fast and efficient laser and reduce
er than 12,000 IPM, require high acceleration to the number of laser operators needed, deploy-
utilize the high rapid traverse speeds. ing them to other important jobs in the shop.

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 Clever racking design
boosts lifelong powder
coating coverage
Recreational products fabricator
meets high-volume, high-quality demand
The powder coat booth line is equipped with automated guns and two
manual sprayers. The manual sprayers reinforce the part areas that are
hard for the automated sprayers to reach. The conveyor moves the parts
through continuous curing ovens, and finally into the assembly area, where
personnel take the parts off and partially assemble and then package them. 
Order. “In designing the production order, we usually start with the
packaging design and work backwards,” said Brad McAllister, manufactur-
ing engineer. “We look at how those parts are going to be placed in the
package. We design unique racking so that when the parts come down
the line, our assemblers can take a whole unit off of one rack in an orderly
fashion, assemble them quickly, and box them ready to ship.”
One of the biggest engineering challenges has been designing the rack-
ing systems so that the automatic and manual powder coat sprayers can
coat the parts thoroughly but also quickly. The metal parts are tubular,
stamped, roll formed, and laser-cut. Each model, with different shapes,
bends, and curves, must be sprayed at the same time. 
» A Lifetime basketball hoop gets the color treatment in a powder coat line.
“It’s a challenge because parts that are  harder to spray are racked
By Kate Bachman with  parts that are easier to  spray. We have to position them so that

L
they go through our system with-
ifetime Products, Clearfield, Utah, manufactures sturdy, durable out defects,” McAllister said. One
metal and blow-molded plastic basketball sets, picnic and utility rack holds one entire product
tables, chairs, sheds, swing sets, coolers, and playsets.  “All of our unit. “So  essentially,  we’ve had to
backyard playsets are simple to set up and built to last,” the company creatively design racking, gun set-
promises. tings, and iron phosphate pretreat-
Demand for the products is tremendous. The company manufactures ments  so that we can penetrate
and powder-coats more than 100,000 metal parts a day. It makes up to difficult-to-reach areas.”
13,500 folding chairs alone per day. Trying to meet that volume demand What makes a part section dif-
while achieving the quality standards required to make recreational prod- ficult to spray? Bends with 90-de-
ucts that are simple to set up and last a lifetime is no picnic. gree or tighter angles. The interior
“The volume of parts we have going through—that would be our biggest of a long flange. The area of a part
challenge for sure,” said Ryan Miller, powder coating manager for Lifetime. where the hook blocks the spray. »Parts getting different colors travel on
“All of our lines run at 14 to 18 feet a minute.  Trying to keep up with the “Our technicians adjust the auto- one line, then are separated to proceed
output is difficult.”  mated spray guns to try to get the into their respective color booths, then
are rejoined for curing and packaging.
Meeting that challenge takes innovative engineering and a well-planned appropriate spray patterns and de-
and well-executed powder coating process. liver the correct air-to-powder ratio
so the part gets adequate coverage.
Challenge: Good Coverage, Fast Then manual sprayers reinforce the
Lifetime categorizes its products into three separate systems, manufac- remaining hard-to-reach areas,”
tured mainly in three buildings. Miller oversees operations of all three sys- Miller said.
tems. “Each building houses what we call a family of product. A basketball Mils. “It’s important to get pow-
set is made in one building, tables and chairs are made in another building, der down into those blind spots
and in our third building we run playground and shed parts.” so that there is adequate powder
The manufacturer organizes its production for kitting, performing sub- coverage. A too-light coating could
assembly and packaging each product unit at the end of an automated propagate or promote rust in those
conveyor line for consumer final assembly. areas. We have to make sure every-
Process. The parts are positioned on racks on the conveyors, which thing is covered, to have appropri-
go through the mostly automated powder coat line. The conveyor system ate mils on it, so that we present a
» Lines are flexible in that various
feeds the parts on the racks through a pretreatment system, a dryer oven, good product,” said Mike Seegmill- products being painted the same color
and then into powder booths. er, powder coating technician. can run on one line.

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 Seegmiller said the mil thickness goal is 2¹₂ to 4 mils. “That middle range spray guns on its lines. “On our
of 2¹₂ to 4 is very good. It’s where we can hit that requirement for the range shed line we have a Nordson  Col-
of the product and still not be wastefully throwing powder out the door.” orMax® quick-changeover system
that allows quick color changes. Be-
Racking Line Speed fore that we had a spray-to-waste
The engineers calculate the racking positions as methodically as FedEx cal- booth,” said Seegmiller. “All of one
culates its delivery routes. powder color had to be emptied be-
“How we present a part to the auto guns makes a big difference,” said fore another color could be added.
Keith Maw, manufacturing engineer. It  actually took six manual spray-
The density of the racking directly determines the throughput, so obvi- ers to coat our product on that
ously they are positioned as densely as possible without overwhelming the line. Since we were able to switch to
manual powder coaters and assemblers. “It’s all about being able to put as that, now we have only two.”
many parts as we can on a rack as efficiently as possible, yet not overwhelm It is a  flexible line, meaning dif-
the powder coating booth’s ability to coat them and the employee’s abil- ferent products’ parts, such as for
ity to keep up with that,” Maw said. “It’s a balancing act; when we spread »Parts of all sizes and contours in the
tables and chairs, are run togeth- same product model are powder coated
those racks further apart, we reduce the capacity of that line and it slows er simultaneously through the same together and must be presented to the
production down. powder guns for optimal coverage.
color booths.
“You’d have a hard time walking through the line, but we have gapped
The company actually can run
out the individual racks so that the employees can keep up,” Maw contin-
four colors at the same time on one main line, as for playgrounds, Miller
ued. “As engineers, when we get a new product, we design how we’re go-
said. The system works similar to a train spur. The parts split off from the
ing to hang it and what speed we’re going to deliver it to all the employees
main line and go through different booths for different color applications
who are adding value to the product.
and then come together back on the main line.
“We do a prototype of those racks and we put the parts on them. We do a
“The hooks are fashioned so that one line grabs a part and it goes through
mil check on them to make sure they’re getting the proper mil powder cov-
a separate line of a different color and then transfers the part back onto the
erage on them. We also see how the employees can handle the spacing. If
main line and through the cure oven. It’s pretty innovative. For visitors who
they can’t keep up with it, then we go back to the drawing board,” Maw said.
look at the system, it’s kind of a jaw-dropper,” Miller said.
Some of the adjustments the engineers have made are to optimize the
racking and parts so the automatic guns reach the maximum and for optimal PCI 4000 Certification
ergonomic positioning for the employees.  The manufacturer sought the Powder Coating Institute’s PCI 4000 certifi-
McAllister added, “We try to face the difficult-to-reach areas toward the cation as both a goal and a knowledge resource, according to Miller. “The
auto guns so that they can cover them. Instead of presenting them perpen- biggest reason we reached out for that was to make more resources avail-
dicular to the guns, we turn the parts on an angle to allow the powder to able for us … and to be part of the powder coating community.” Seegmiller
flow through the rack and wrap around the parts. said that having the PCI auditor come out to the plant to provide some of
“If parts are too high for shorter employees, we’ll bring them down low- his insights was especially helpful. The auditor individually audited each
er on the rack where they can reach them,” he continued. “Parts that are one of the lines, looking at the processes and how the company handles
long, we’ll put them up higher because the smaller or shorter employees quality control.
can reach the lower area of that part, and take it off the rack to dissem- “Some of the things he looked at were whether we had consistency in
ble it. Parts that are heavy, we’ll usually put on racks by themselves so that our process; mil consistency; how we store, use, and then track our powder.
an employee can handle them one at a time.”  We have that all climate-controlled. He looked at how we do our PMs [pre-
ventive maintenance] on our equipment,” Seegmiller said.
Innate Ingenuity
Now others seeking the PCI 4000 have reached out to them to ask ques-
Lifetime is no stranger to ingenuity. In fact, the company was born 33 years
tions, he added. “It just opened up doors for us in that aspect.”
ago from the founder’s reinvention, called Quick Adjust®, of how a basket-
The company qualifies all of its powders before they are put into produc-
ball set could be assembled and adjusted so that his kids could play with
tion. Test samples undergo 15 different tests, such as a 500-hour salt spray
it. Lifetime’s founder Barry Mower devised a basketball unit that could be
test. The salt spray test is performed in a lab to eliminate all other variables.
height-adjusted with a broomstick
because his kids couldn’t reach the Endgame: Longevity and Dependable Strength
hoop.  He also came up with the The finishing group relayed some funny stories from customers about al-
breakaway rim  and a three-piece ternative uses they’ve discovered for Lifetime’s products that demonstrate
pole so that the whole unit could be their strength and durability. One customer sent a photo of a swordfish
packaged in one box.  he displayed on a Lifetime table. Another customer sent a photo of herself
sledding on a folding table. Another customer used the basketball set as
Color Changes
an engine hoist. “Some people send videos of themselves using our tables
Most of the parts are powder-coat-
as surfboards and snow shovels. And we fed our cooler to a grizzly bear to
ed in  blocks of 500 to 1,000 units
see how it would fare,” Miller said.
on  a  line. After those are coated,
Which won? The bear or the cooler? “The cooler, actually. We show a vid-
there is a small gap as the line is
eo on YouTube of a bear trying to get into a can of sardines in that cooler.
readied for the next block of models.
He fought for quite awhile, but he couldn’t get it open. It’s certified bear-
Offering a broad range of prod- »All parts are kitted so that they can be
subassembled and packaged immediately proof,” McAllister said. “Your food is safe in our coolers,” Maw added.
ucts makes multiple color changes
at the end of the line, ready for the
a necessity. Lifetime is equipped consumer. Can you tell which product Contributing Editor Kate Bachman can be reached at [email protected].
with  Nordson  and  Gema powder these metal parts comprise? Photos courtesy of Lifetime Products, Clearfield, Utah, www.lifetime.com.

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 Pipe welding
» An operator monitors a pipe welding cobot in action.
and
A feed from a camera-based vision system is shown on
the monitor.

the Cobot Cobots designed for pipe welding look very

different from other cobots designed for ma-
chine tending and assembly. They usually con-
sist of a single arm with a welding gun on the
How the collaborative robot could change the pipe welding shop
end. The robot moves up and down (Y) and for-
By Soroush Karimzadeh What Makes the Cobot Unique ward and back (X) to track the workpiece. Dur-

F
Nothing stops a conventional robot from mov- ing the operation it performs a weaving motion,
inding an experienced pipe welder doesn’t similar to the weaving motions seen on other
ing from point A to point B, hence the need for
happen often these days. Industry needs robotic pipe welding setups.
safeguarding. Standing in its way can lead to se-
more of them but doesn’t know where to When you look at a pipe welding cobot in ac-
rious injury or even death.
find them, and so turns to automation where tion, you’ll see a robot welding and an operator
Not so with a cobot. Bump into a cobot and
possible. This includes pipe spool welding and nearby observing, perhaps using the pendant
the cobot won’t keep moving unabated. It will
similar setups in which the pipe is fixtured and control to make slight (albeit rare) adjustments
stop. This allows the operator and others to
rotated. when necessary. The cobot doesn’t stop through-
stand near the robot during the operation itself.
How well automation works, both from a out the entire operation. It performs continuous
An operator can in this sense “collaborate” on a
business and practical standpoint, has always welding, from the root to the cap pass.
project, adjusting the robot motion in real time. In a manual welding situation, most pipe is
depended on a range of variables, two of which This has all sorts of implications for basic as- presented to welders with three or four bridge
are how the pipe is presented to the automa- sembly and machine tending, areas where co- tacks. To prep weld joints for pipe welding
tion and how adaptable that automation is to bots have received plenty of media attention. with certain cobots, technicians need to pro-
unexpected changes. The better and more con- But it also has some significant implications for duce feathered tacks that the cobot can weld
sistent the pipe weld prep, the fewer surprises, more complex tasks in manufacturing, includ- over. So instead of welding conventional bridge
and the easier the operation is to automate. ing pipe welding. tacks, they place three or four 1-inch stitches
One challenge with pipe welding automa- (depending on the size of the pipe), then grind
tion—and with any kind of automation, for that Pipe Welding With a Cobot (or feather) them to make a smooth transition
matter—is that once a cycle starts, an opera- To be clear, cobots won’t be contorting them- between the stitch and the joint side wall.
tor usually can’t account for unexpected varia- selves to weld pipes out of position, at least not When welding over them, the cobot operator
tions in root opening, the bevel angle, or round- anytime soon. They instead will thrive in areas presses an option in the control that changes
ness. A new category of robots, however, has that require less extreme ranges of motion, in- several welding parameters on-the-fly, allowing
changed the equation: the collaborative robot, cluding in-the-shop pipe welding where the the cobot to weld over and achieve complete
or cobot. workpiece is fixtured on a rotating chuck. fusion over those tacks. After traveling over the

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 cobot shifted to fill pass parameters, and the
entire process became much more stable,
with the help of laser-based joint tracking. But
during the critical root pass, laser-based joint
tracking wasn’t as effective as required, and op-
erators had to remain vigilant.
Current installations still use laser-based
tracking that includes a three-line laser for
» This arc hood evacuates fumes and has welding- tracking new joints and another point laser for
grade filters, so the cobot operator need not wear a real-time height adjustments. And laser track-
welding helmet. ing still does very well at tracking distinct geo-
metric features of the joint, like the top edge of
a V groove.
That said, tracking deeper into the V can be
Once a robot welding cycle starts, a challenge, usually because of reflections of
an operator usually can’t account arc light and even changes in the light condi-
for unexpected variations in tions caused by bevel geometry variations. All
this causes significant interference problems
root opening, the bevel angle, requalifying pipe welding process requirements for traditional approaches to laser-based joint
or roundness. A new category are small prices to pay compared to efficiencies tracking inside the V-groove joint geometry.
that can be gained.
of robots, however, has changed
Vision for Welding Cobots
the equation: the collaborative Operating a Welding Cobot Certain pipe welding cobot installations on the
robot, or cobot. Even though they have a short history, cobot near horizon will support enhanced vision with
pipe welding applications continue to evolve— camera-based systems. These allow the cobot
and quickly. Much of it has to do with the nature to make automatic adjustments during the root
tacks, the operator presses the same button of the process, including how the operator inter- pass to weld over tacks. And using frameworks
to return the system to the normal root weld acts with the system. like artificial intelligence (AI) and machine learn-
process. In early installations, operators loaded ing, pipe welding vision systems will perform root
The transition from manual to robotic pipe prepped pipe and selected some basic parame- seam tracking, viewing the root and overcom-
welding usually doesn’t require much change ters, including the pipe diameter, schedule, and ing root-seam-tracking challenges. The track-
to the operation itself, particularly if welders al- joint geometry. After the weld program loaded, ing measures the distance between the toes of
ready work with consistent weld preparations. the operators hit “start” on the pendant. Dur- the bevel (top of the land) and can detect the
They might need to revise their tacking prac- ing the root pass, they observed the operation stitches applied in the tacking operations. It also
tices, but that’s about it. carefully, ensuring the gun and wire extension detects changes in bevel geometry, root open-
And because cobots do not require perimeter were in exactly the right place. When they ing, and similar inconsistencies. If those varia-
guarding, they do not need much more room saw the weld gun approach a stitch or a varia- tions are within a certain tolerance window, the
than a manual operation does. A pipe welding tion from inconsistent weld preparation, they vision system will make welding process changes
cobot workcell can be as small as 4 by 4 feet. So pushed certain buttons on the control. on-the-fly.
in most cases, integrating this kind of collabora- Operators didn’t need to adjust every weld In the past operators of cobots usually had to
tive automation requires no significant changes parameter manually on-the-fly, but they did be very vigilant during the root pass, observing
to the shop floor layout or overall part flow. need to initiate the cobot’s parameter-change the weld and adjusting on-the-fly. When they
process. Upon completion of the root, the observed changes in arc characteristics—due
Welding Process Factors
These days cobots can be integrated with a vari-
ety of processes, including gas metal arc welding
(GMAW) and gas tungsten arc welding (GTAW).
And while it’s technically possible to use cobots
for both welding processes for different pass-
es—say, have a GTAW root with a pulsed GMAW
cap and fill—it’s not a common application. If
a job demands GTAW for the root pass, often
a company will opt for manual GTAW and then
move the pipe to the cobot, which performs the
cap and fill with GMAW.
Of course, it’s ideal to stick with one
process—like pulsed GMAW or a metal-cored
wire process for high deposition rates—for all
pipe welding passes. In many cases, because
cobots offer so much efficiency, changing and » A real-time vision system monitors the weld, including the root opening.

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 to welding over stitches or changes in root changes in arc characteristics, and learning bevel angle for the weld joint should be 37.5 de-
opening or bevel geometry—they had to adjust to adjust for an ever-greater number of situa- grees. If the bevel prep is 35 degrees, the cobot
accordingly, just as a manual pipe welder would tions. But unlike the welder, a cobot will learn still can work within the set parameters. If the
need to do. not just from every welding application in front bevel angle is farther outside the tolerance win-
For instance, like a manual pipe welder per- of it, but also from information shared by other dow, the cobot still can work, but it will most
forming a root pass, the cobot operator ob- cobot welding applications. All this could lead likely require operator intervention.
served the weld and looked for signs of blow- to reduced labor requirements, with a cobot Traditionally, automation has required up-
through. If he saw one was imminent, he finishing a weld, from root to cap pass, without stream processes to have a certain level of re-
triggered a root-save function on the teach any supervision. One person could operate and peatability. If a fabricator couldn’t achieve such
pendant, and the cobot would change about a monitor more than one cobot welding system, repeatability, automation just wasn’t an option.
half-dozen welding parameters to prevent the perhaps even perform weld prep as a nearby Cobots still require some level of repeatabil-
blow-through from occurring. Once the danger cobot welds. ity and reasonable tolerances, of course, but
of blow-through had passed, the operator dis- because of the kinds of input an operator can
engaged the root-save function on the control A New Approach to Automation make, the tolerance window can be much larg-
and welding continued. A rookie operator could be trained to operate er. So even if a pipe welding operation needs
New vision systems for pipe welding cobots, the cobot and, at the same time, learn the fun- to deal with a few bad pipes here and there,
however, might not require such operator vigi- damentals of pipe welding. Technicians can look the cobot, with the operator’s help, can still get
lance. An operator will no longer need to moni- at a screen to view and monitor exactly how the those pipes through production.
tor the cobot so closely during the critical root cobot lays down weld pass after weld pass, from This is one reason that, under many industry
pass. For instance, the vision system will be able the root to the cap. They can see how the cobot standards, welding with a cobot isn’t classified
to adjust weld parameters as the root opening adjusts during the root, note common joint ge- as robotic welding, where the cell is set up and
is changing. ometry variations to look out for, observe weave the machine takes over with little if any in-pro-
Vision systems could have several effects on motions that work for different weld passes, and cess operator intervention. Depending on the
cobot pipe welding applications. First, they will more. exact cobot used and the nature of the appli-
provide data that, if collected and analyzed, Operators still can make in-process adjust- cation, a cobot can be classified as “machine
could make cobot pipe welding more intelli- ments should they be deemed necessary. For welding” or “mechanized welding.”
gent and adaptable. Each weld log will include instance, they might make an ever-so-slight This means that if an operation was welded
voltage, current, heat input, and other weld high-low adjustment during the fill passes. Or by hand using semiautomatic GMAW, adopting
parameters used. The more cobot pipe weld- they might choose to change the weave ampli- a cobot would be considered a nonessential
ing applications share their data, the better the tude or frequency. The vision system and laser change, so you might not have to requalify the
algorithms will be, and the more intelligent the tracking should make these adjustments on- welding procedures, though you would still need
cobot’s vision system could become. the-fly, but if an operator observes a problem, to qualify welders on the new process. (Note
This is where machine learning will play an he can correct it immediately. that welding requirements vary depending on
increasingly important role. In a sense, cobot The ability to intervene manually can be criti- the job, the code, the contract documents, and
systems will learn just as a human pipe welder cal if, say, the cobot receives a sloppy weld prep- the specific welding technology used—so as al-
learns—by looking at a lot of welds, analyzing aration. For many applications, for instance, the ways, refer to the source material.)

74 The FABRICATOR AUGUST 2019

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 A New Pipe Welding Career
JOIN US FOR THIS FREE WEBINAR
Today a pipe welding cobot operator need not even don a welding helmet. Brought to you by thefabricator.com
Instead, a local fume collection device covers the weld, and the operator
can view the weld through filters built into the end of the fume collec-
tor. The operator also views the welding action on an adjacent screen that
shows weld deposition as it’s taking place—a recording made by a camera
that filters out all but the most critical light wavelengths, so that the tech- TRENDS IN BONDED ABRASIVE
nician can see weld metal being deposited. That video recording also can
be saved to support subsequent weld inspections. TECHNOLOGY: REDUCING LABOR
This clear view of the process helps welders learn.
COSTS BY ADDING COMFORT
Date: Tuesday, October 22, 2019
This would be a midlevel or even entry-level welding position that
could replace the need for repetitive manual welding, where pipe weld- Time: 2:00 p.m. EST
ers spend hours trying to maintain a steady weave for horizontal, fixed-
Presented by:
position pipe weld after horizontal pipe weld.
Cobot operators could spend part of their days tacking and ultimately
learning how to perform a pipe welding manually—not just in the hori-
zontal fixed position but also in vertical and inclined positions. They also
could spend time observing the cobot, watching the screen and seeing
the effects of various changes to the process in great detail, like stick-out
on arc parameters, including the cone of the arc and the level of penetra-
tion that arc achieves.
This clear view of the process helps welders learn. When they progress For metal fabricators, the cost of grinding abrasives
as manual pipe welders, they think about the arc view on the screen in
normally represents only a small portion of the total cost
the cobot welding cell and use that visual reference as a guide. As they
become more skilled, they climb the career ladder until they reach guru of a project, yet cutting down on consumable costs often
status, when every day they’re presented with an out-of-position or simi- seems attractive in order to keep spending low.
lar pipe welding challenge.
The reality is much different: fabrication shops will only
More experience gives pipe welders greater skill, which makes them
more reliable and productive. And with vision systems feeding data to see real savings by reducing their labor costs. Most of
the cloud, sophisticated data analytics makes the cobot more adaptable, the improvements and trends in bonded abrasive
reliable, and productive over time. People learn, the automation learns, technology have been to reduce labor time by
and pipe welding reaches new levels of productivity.
improving productivity, safety and added comfort for
Soroush Karimzadeh is CEO of Novarc Technologies, Unit 6, 1225 Keith Road East, North Vancouver,
BC V7J 1J3, 604-428-0050, www.novarctech.com. operators. For a grinding disc to save fabricators real
dollars, it must strike a balance between these three
key trends.

Discover how Walter Surface Technologies has helped

strike this balance on the shop floor in order to save
fabricators time and money, and help operators work
more efficiently and safely.

Presenter:

MARC BRUNET-GAGNÉ,
Senior Product Manager,
Bonded Abrasives,
Walter Surface Technologies

Register today for this free webinar!

Visit www.thefabricator.com/webcast
AUGUST 2019 The FABRICATOR 75

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WalterSurfaceWebcastHTAug19FAB.indd 1 7/24/19 11:20 PM
 SERIOUS WELDING IN SECONDS
Ultrahigh-power process shows promise
concluded that rotating machinery was more
power-dense and could cover a wider range of
applications,” Zowarka said, “and so that’s what
we pursued, researching pulsed power and ro-
tating machinery.”
Some of UT-CEM’s early work included the
design of machines that could provide the im-
mense power that tokamaks (torus-shaped de-
vices that confine hot plasma) required for ex-
perimental nuclear-fusion generators. Over the
years UT-CEM’s teams pursued myriad homo-
polar research avenues, doing work funded by
grants and industry partnerships. For instance,
the center did work for DARPA to develop ho-
mopolar generators for railguns, weapons that
shoot projectiles at seven times the speed of
sound—and need a large pulse of power to do it.
The research also included what Zowarka
called “Friday afternoon experiments.” On
many Fridays the team pursued a range of ex-
By Tim Heston » A press fixture holds workpieces as a homopolar periments in a quest to answer a basic question:

I
generator sends a pulse of energy to complete a large
magine a technology that could weld a cir- weld in seconds. What else can we do with the HPG machine?
cumferential seam of the Trans-Alaska Pipe- On a Friday afternoon in the 1980s, one
Most modern generators, everything from of those experiments involved welding. As
line in less than three seconds. It turns out
power plant turbines to the alternator in your Zowarka recalled, “We took two pieces of
the technology, an ultrahigh-power forge-re-
car, are heteropolar, producing a current by round 1080 steel barstock. We literally black-
sistance process called homopolar-generator
passing a conductor by different magnetic smithed two copper busbars, hammering them
(HPG) welding, has been around for decades. fields in opposite directions and alternating around these two round bar samples. We
In the 1980s researchers at the Center for from one to the other—hence the term “alter- pressed them together with a fixture made out
Electromechanics at the University of Texas at nating current.” of heavy spring-loaded washers, discharged
Austin (UT-CEM) worked to perfect the pipe A homopolar generator has one source of an the homopolar [energy] through it, and lo and
welding process in a joint industrial program electromagnetic field, which spans from the behold, it welded those two pieces of steel to-
with major oil companies, looking for a way to center of a spinning disc to the rim. Producing gether. We were probably passing something
streamline welding for offshore J-lay pipeline direct current, the generator’s polarity hinges around 500,000 amps through the interface.”
construction. They came close, nearly perfect- on the disc’s direction: spin it in one direction The area of highest resistance, at the weld
ing the joint prep and welding parameters to and you get a positive polarity; spin it in the neg- interface, immediately turned orange and then
produce a clean weld within a few seconds. ative direction and you get a negative polarity. white-hot as the metal heated beyond forging
The pipe being tested wasn’t as big as the Being solid metal, that spinning disc has very temperature. Pressure in the fixture forced
Alaska pipeline, but the process would have low electrical resistance, or impedance, which the bars to forge. After welding, all that was
been straightforward enough to scale up. Alas, made it particularly valuable for researchers left was a little bit of upset metal that, once
HPG welding never caught on, in part because at UT-CEM, including Associate Director Ray- scraped off, revealed a clean weld line around
of equipment costs. mond Zowarka. “Because the metal disc has the circumference of a single, now longer piece
But technological advancements have incredibly low resistance, if you have a way of of barstock. The team had performed its first
changed that cost equation. Today a decades- getting power out of that spinning disc, then HPG weld, a resistance weld on steroids.
old technology is being dusted off, tested, and you can draw tremendous current.” That first machine’s rotating metal disc was 3
perfected again—this time for bridge welding. The spinning disc builds voltage, and thanks feet in diameter and about 1 ft. thick. “It had the
If UT-CEM researchers and industry partners to the low impedance, a relatively few volts can weight of a small Volkswagen,” Zowarka said,
prevail, HPG welding could transform the world produce an immense amount of current. Just a “and it spun at 4,000 RPMs. We had black tape
of industrial, structural, and pipe fabrication. few dozen or hundred volts can be converted on half of the rotor shaft and white tape on the
into a burst of more than a million amps. other half. And when it was spinning, all you’d
The Faraday Disc That burst, or pulse, of power is what made see is a gray blur.
HPG welding has roots in the early experiments it so useful for the researchers at UT-CEM, a “Within one second, the shaft came to a
in electromagnetism, going all the way back to center launched in the 1970s to tackle the op- dead stop. It was a classical electromechanical
Michael Faraday’s work in the 1830s on the ho- portunities of pulsed power. Early work ana- conversion. We had converted all that kinetic
mopolar generator, what would become known lyzed pulsed-power capabilities in capacitors, energy, that small Volkswagen spinning at 4,000
as the Faraday disc. batteries, and rotating machinery. “Our studies RPMs, and put it into the weld. The magnetic

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 Economic Reality
The incredible speed of HPG welding makes it
sound as if it would make business sense, even
if the equipment were expensive. But as Scott
Pish, research engineer at UT-CEM, explained,
those few seconds accounts for welding time
only. It still takes time to position and align the
workpieces, and flash still needs to be removed
after welding. “Most of the time is spent loading,
aligning, and prepping.”
Even so, that time still is quite minimal, espe-
cially when you consider how long it takes to
weld the pipes manually. Even removing the flash
after welding doesn’t take long; a simple scathing
tool will do—no grinder necessary. So why isn’t
HPG welding a common pipe welding technology
today? Why didn’t the process take off?
Much of it had to do with the cost of the
equipment, which required hydrostatic bear-
ings to ensure consistent rotational motion.
“That made the rotor run on a film of high-
pressure oil,” Pish said. “And we used those for
years,” adding that those bearings also made
the machine expensive.
But by the mid-1990s, bearing technology had
» HPG welding uses pulsed power generated by the conversion of kinetic energy from the rotor into electrical evolved substantially. “By then the Japanese
energy and, finally, thermal energy at the weld.
had developed ceramic bearings, which have
field passing through the rotor starts interacting Nevertheless, HPG tests for pipe welding now become very common,” Zowarka said.
with every atom in the rotor that’s carrying cur- revealed that the pipes still needed to be bev- “These ceramics break the magnetic path.”
rent. Every electron attached to every atom feels eled to a particular land thickness for optimal This means that the machine no longer needs
the stopping force at the same time. Each atom results. A thin land concentrated the current all the auxiliary components it once did, which
passing current is grabbed by the magnetic field, flow, aided welding efficiency, and directed the also means that the machine cost is a fraction
converting all that rotational kinetic energy into forging action to minimize the amount of re- of what it was.
electrical energy. That’s where that huge burst maining flash that needed to be removed. For “That reduced the cost by a factor of four,”
of current comes from, and all that electrical en- pipe welding, the less flash that had to be re- Pish said. “And that’s using inflation-adjusted
ergy goes into the weld.” The Lorentz force at moved from the ID, the better. dollars.”
its most brutal, such energy can fuse a massive
amount of metal nearly instantaneously.
After those initial experiments, the team be-
gan welding all kinds of metal, including a vari-
ety of mild steels, stainless steels, chrome-moly
steel, aluminum, even tungsten. “We tried just
about everything,” Zowarka said, “and it’s all in
a big NSF [National Science Foundation] report
published in the early 1980s.”
Eventually came the joint industry project
with oil companies looking to streamline pipe-
line welding. Much of that work focused on
fine-tuning parameters, including workpiece
alignment and load forging pressure, as well as
the weld preparation.
The weld prep was particularly important,
because engineers were aiming to eliminate
as much postprocessing as possible, especially
on the inside diameter of the pipe. A butt joint
configuration requiring little to no prep would
have been ideal—just like the butt joints in
those barstock tests during those Friday after- »An engineer sets up an HPG welding machine. The large round enclosure houses the rotating disc that produces a
noon experiments. massive pulse of current.

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 A New Kind of Bridge Welding does require weld preparation, this time a K-bevel for The latest experiments incor-
All this research has set the stage for the latest poten- a double-V joint geometry with a 0.5-in. land. porate a kind of homopolar-style
tial homopolar application: bridge welding. UT-CEM “Once it reaches forge temperature, [the bevel postweld heat treatment. After the
answered a call from the U.S. Department of Transpor- section] flattens, and material extrudes out as flash,” welding cycle, the HPG starts rotat-
tation for proposals to weld bridge flanges out of high- Zowarka said. “This gets rid of any impurities and ox- ing the disc again to heat the work-
performance steel, an application now dominated by ides that were on the surface. They’re naturally driven piece and slow the weld cooling.
submerged arc welding (SAW). out of the weld zone.” “We’ve seen immense im-
Working with engineering consulting firm Koo and Researchers have worked with a Houston metal- provement in factors like tensile
Associates, the team has tested workpieces with HPG lurgy firm to study micrographs of the resulting weld. strength,” Zowarka said, adding
welds 6.5 in. long and 1 in. thick. Like the pipe welding “The metallurgists tell us that the grain size looks very that these latest welds have un-
application before it, this bridge welding application good at the weld interface,” Pish said. dergone destructive and nonde-
structive testing, including various
bend and tensile tests. “The tensile
specimens are excellent.”

A decades-old
technology is being
dusted off, tested, and
perfected again—this
time for bridge welding.
If researchers prevail,
homopolar welding
could transform the
world of industrial,
structural, and pipe
fabrication.

The welds have passed all tests

as dictated by industry weld-
ing standards like the AWS D1.5
Bridge Welding Code, save one:
the Charpy V-notch test for tough-
ness. As of this writing, the center
is working on a potential solution:
a new fixture with actuators that
could disengage the copper con-
tacts after welding. Currently the
fixture incorporates bolted cop-
per contacts that aid welding, but
afterward they act as a heat sink,
drawing heat out of the weld zone
quickly.
“We feel that if we have those
actuators that can pull those cop-
per contacts back, the weld will
cool much slower,” Zowarka ex-
plained. “This might bring us over
that final hurdle during this phase
of our research.”

Welding in Seconds
Shortly after winning the project
from the DOT, the UT-CEM team
visited a local structural and indus-
trial fabricator to observe current
practices, including the weld prep,
the SAW process itself, and the
postweld grinding and finishing.

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 The team analyzed an application involving four large welds placed on a
JOIN US FOR THIS FREE WEBINAR
150-ft.-long workpiece. “Using SAW, it took the shop just over two days,” Brought to you by thefabricator.com
Zowarka said. “We did a time study for the welding, and we found that
to load the large workpieces into our fixture, power up the homopolar
machine, discharge it, and make the weld, it would take [the HPG welding JUMP START YOUR JOURNEY
process] less than a day. And they told us that cutting out an entire day TO DIGITAL FABRICATION
in the production process would be extraordinarily significant for them.”
HPG welding does require large machinery, so it’s obviously suited for Date: Wednesday, August 28, 2019
in-house welding. Hauling a welding system to the field wouldn’t make Time: 9:00 a.m. CST
sense—in most cases, that is.
“This is designed to be an in-house process,” Pish explained, “but at the Presented by:
same time, we are discussing the potential of railcar-mounted machines
powered by diesel engines. These systems could weld railroad rail in the
field.” He also said that the previous pipeline project involved a system that
could be transported to an offshore J-lay pipeline construction platform.
“The DOT is interested in us commercializing this technology,” Pish
added. “So we’re now in the process of trying to identify potential appli- Technology has made it easier to keep up with the components
cations and industries that might be interested in this. We have a ma- of our daily lives. Calendar notifications, news alerts, traffic
chine, the bus work, the press that preloads the joint. It’s a system that’s forecasting … our devices walk us through every step of the day.
essentially ready to go to try a variety of welds.” Advancements in tracking have even enabled us to follow the
movements of our purchases, from check out to receipt to delivery.
Senior Editor Tim Heston can be reached at [email protected].
So why can’t fabrication processes have the same visibility?
Center for Electromechanics, Cockrell School of Engineering, The University of Texas at Austin,
cem.utexas.edu Fabrication is vital, but it is often overlooked from high-level process
planning. With better use of available digital information, this step
can influence both engineering and construction. Companies that
enable their workforce to be Digital Fabricators can achieve major
efficiency gains and have complete transparency within the process.
Takeaways:
• How digitizing your fabrication process can transform
your shop into an ultra-efficient operation with improved
productivity, reduced waste, and full visibility
• Why better visibility means happier workers and better
bottom lines
• How to take the first steps towards enabling your workforce
to become Digital Fabricators

Presenters:
MARCEL VELDHUIZEN
Vice President,
Fabrication Solutions
Hexagon PPM
Marcel Veldhuizen, Vice President of Fabrication Solutions, has worked
with Hexagon PPM since 1997 in several marine-related positions. With the
acquisition of Nestix Oy by Hexagon PPM in 2016, Marcel transitioned into
a managing director position, overseeing daily operations at the Nestix Oy
office in Finland. Marcel, along with the Nestix Oy team, helps Hexagon PPM
provide Industry 4.0 Shop Floor Management Solutions to steel service
centers, construction businesses, as well as steel and piping solutions for
shipyards around the world.

DAVID WHITTLE
Senior Business
Development Manager
Hexagon PPM
David Whittle is a Senior Business Development Manager at Hexagon PPM.
He is based in Middlewich, Cheshire, United Kingdom. He is responsible for
the global development of the fabrication market and product line business
plans as well as marketing programs to support sales. He has a wealth
of knowledge within engineering, design and fabrication in general and
specializes in piping.

Register today for this free webinar!

AUGUST 2019 The FABRICATOR
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HexagonWebcastHTJuly19FAB.indd 1 6/25/19 8:37 AM
 » A folding machine can make short flanges as
demonstrated with this 0.15-in. sheet in the process of
receiving a second bend.

How large can the sheets be? Folding ma-

chines have been built with bending windows
as wide as 40 ft. That’s not the average, but
manufacturers typically are looking for some-
thing pretty wide to take on bending work that

Where folding can’t be done as efficiently on the press brake.

The table attached to the folding machine

fits in the job shop

helps to make that efficiency possible. Only
one operator is needed to run a bending job,
no matter how large the sheet size may be. The
operator only needs to square and position the

Instead of more press brakes, sheet on the table for each bending step. Roller
balls on the table help the operator move the
fabricators might want to consider folding sheet around.

machines to improve bending efficiency This is one of the most important benefits
of a folding machine. It can form these large
sheets of material without the operator having
By Chandler Barden and Dan Davis material (up to 130 degrees), the lower beam
to support the material in the air during form-

F
with tooling, the folding beam that forms the
olding machines have been widely adopt- ing. This eliminates the need for multiple op-
metal around the upper beam rail, and a table
ed in the architectural and sign-making erators to help in handling these large parts, a
on which the material rests. The table has gaug-
sectors of metal fabricating for quite a situation that normally takes place when fabri-
ing that helps to put the material in position for
while. It might be time for those in the job shop cators are trying to work with large workpieces
the bend. Control software coordinates the at a press brake.
and contract manufacturing community to
gauging. An operator, working from the front For smaller jobs in which the operator
learn how this bending technology could help
where the folding beam is or from the rear near doesn’t need the table to be entirely flat for
them as well.
the table, initiates each bending cycle, typically material movement, the table’s pop-up fingers
Did you know that spray booth manufactur-
with a foot pedal. Robotics also can be used to help to position the parts. The fingers can be
ers use this technology to precisely bend large
run a folding machine. controlled individually to ensure the part is
sections of galvanized steel efficiently and to
When the sheet is in place, the clamping secure before the clamp comes down. On ad-
create interlocking mechanisms for the pieces
to lock together easily during installation? Did beam comes down and holds the material in vanced folding machines, the fingers move on
you know that some metal fabricators rely on place. That’s when the folding beam engages linear guides and are driven by a servomotor via
folding machines to make boxes with sides that the sheet that extends from the bending win- a ball screw. This provides precise bending and
are almost 12 inches tall? Did you know that dow. The beam swings up and overbends, then very quick positioning of the material between
other shops are using the machines to do ra- releases the sheet and allows the material to each bending step.
dius bends without the indentations commonly spring back to the desired angle. Tables can come in different shapes, an L-
produced by press brakes? These are just some or U-shaped table, for example, depending on
of the applications where folding machines are Bending Large Sheets where the operator needs to be to run a job or
being used in general industrial fabricating. The backgauge table comes into play especially the part type being bent on the folding machine.
Folding machines are not meant to be a re- when a fabricator is working with large sheets. From an operator’s perspective, he needs
placement for press brakes. Large-tonnage It supports the sheet during the entire bending to select the bending job from the control and
machinery and small, electric press brakes are process. place the sheet against the fingers. This should
great examples of machine tools that are de-
signed for specific jobs. But look around a typi-
cal job shop and you might see a collection of
midtonnage press brakes with 10-foot beds.
Does it make sense to have the same type of
tool for the variety of bending jobs that come
through a job shop? A folding machine can of-
fer a shop flexibility in bending that it simply
can’t get from another stand-alone press brake.

How It Works
Before exploring where a folding machine might
fit in a job shop, you need to understand how the
technology works.
A folding machine primarily comprises a » A large table in the rear of a folding machine helps to support large workpieces and allows one operator to handle
clamping beam with a straight rail for bending the bending job.

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 position, which determines the radius, and the get up and running on a folding machine much
backgauge fingers automatically feed the mate- more quickly that he could if placed in front of
rial forward. The job determines the distance a press brake.
between the folding beam and the clamping Folding technology fits in the modern job
beam, which then influences the smoothness shop. It’s just a matter of finding the applica-
of the radius. The operator only needs to hold tions that make the most sense for it.
the sheet against the backgauge fingers. Chandler Barden is national sales manager, CIDAN Machinery,
For thicker material, wing bending can be 665 Hwy. 74 S., Peachtree City, GA 30269, 770-692-7230, www.
»A folding machine can deliver an open (left) and a done on a folding machine. Here the folding cidanmachinery-americas.com.
closed (right) hem.
machine is doing the actual radius bending. It’s Editor-in-Chief Dan Davis can be reached at dand@
thefabricator.com.
useful when the material being bent is between
0.125 and 0.25 in. The backgauge finger advanc-
es the material, and the folding beam moves up,
creating the bend angle. The backgauge finger
continues to advance the machine for further
bends until the radius bend is completed.

Bending Complex Shapes

The addition of upper, folding, and lower beam
tooling that is segmented within the bend-
»Radius bends also are possible on a folding machine. ing window allows for the bending of complex
Unlike a press brake that digs into the material with
each bump bend, a folding machine doesn’t leave an shapes. This tooling makes it possible to fold pro-
indentation in the material as the radius bend is being files with positive and negative flanges with one
made.
setup. Also, folding machines with this capability
ensure that the part will be aligned during the typically have a table that moves up and down
bending process. to gauge the different parts in the right position.
When working with these large sheets, some- Imagine three bends being made to one end
times fabricators are looking for some sort of of a metal blank, and the part is then spun
locking mechanisms to ease on-site installation around to do the same in the opposite direction
of workpieces. The folding machine can assist of the original bends. The table moves down
with this as well by making edges with short to accommodate the three previous negative
flanges that interconnect, keeping the large bends. This Z-shaped part is just one example
part stable as final assembly takes place. These of the complex shapes that can be done with
interconnections can be kept on file within the a folding machine and the right tooling setup.
control software and called upon when needed. Boxes and panels also can be fabricated with
Also, the fabrication of these interlock- repeated precision. Segmented tooling can
ing panels usually requires both up and down accommodate flange heights near 12 in. The
bends. Modern folding machines are available precise bending leads to corners that are very
that can bend both ways to limit the material accurate, which helps to improve downstream
manipulation as much as possible. Again, these welding and finishing efforts.
complicated bending jobs can be done with Although most bending on the folding ma-
only one operator. chine relies on the machine’s straight rail, fabri-
cators that incorporate tooling into their bend-
Radius Bending ing mix won’t be spending the better part of an
A cylinder shape bent on a press brake can be hour with tooling changeover. Quick-change
identified fairly easily because of the indentations tooling limits downtime when tooling needs to
made in each step of the bending process. The be added or replaced.
material is moved a bit, and the press brake ram
comes down, slightly bending the metal sheet The Right Tool for the Job
into the open V die underneath. With each down- Folding machines aren’t found in every job shop,
stroke comes an indentation in the material. but maybe they should be. They can produce
For certain applications, that material defor- many of the same bends that a press brake can,
mation is OK. For those applications where the freeing up the press brakes for jobs that can be
indentations might be a concern, a folding ma- done only on those devices.
chine can make a difference. (It should be not- Also, with the dearth of skilled press brake
ed, however, that a folding machine can’t match operators, a shop might be doing itself a fa-
the tonnage strength of a press brake. That’s vor by adding a machine that doesn’t require
why a typical folding machine is OK for bump an operator with advanced machine tool ex-
bending material in the 16- to 9-gauge range.) perience. There are simply fewer moving vari-
When it comes to bump bending on a fold- ables to consider when working with a folding
ing machine, the folding beam is affixed in one machine. An inexperienced operator is able to

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 » With a change in punch tooling, Red Dot Corp. now can
perform shearing and louver forming in a single setup on
the punching machine.

creating the part blank; unloading the parts

and the skeleton; and reloading the parts indi-
vidually onto the punching machine so that the
louvers could be made. (In February 2008 Pri-
ma Industrie Group acquired the Finn-Power
Group, ultimately launching the Prima Power
brand in March 2011.)
All fabricators know what happens when you
introduce too much manual material handling:
You increase the chance of poor-quality parts.

A NEW APPROACH This situation at Red Dot was no different in

that sometimes the individual parts were re-

TO FORMING LOUVERS loaded onto the punching machine backwards

or they weren’t placed securely into the clamps.
At the heart of this inefficiency was a form-
HVAC system manufacturer finds forming ing tool that wasn’t spring-loaded. The form-
ing tool could stick out about 0.35 inch and
efficiencies with a specially designed punching tool catch something as the sheet moved beneath
the turret. In some instances, once that tool
By Dan Davis Today the company has stayed true to that caught the sheet, it could be ripped from the

A
original mission, even as it has added products machine’s clamps.
ny manufacturer of products that re- for the military market and built a part-replace- “Basically it could get caught when you were
quire some sort of temperature man- ment program over the years. It also has a foot- running the job, unless you really picked the se-
agement is very familiar with louvers. print that extends beyond the Pacific North- quence very carefully,” Abad said.
It’s a critical feature in these types of products. west, with manufacturing facilities in Memphis; The older tooling also created the louver pro-
To form those louvers, many manufactur- Suffolk, U.K.; and Shanghai. gressively, according to Abad, which was slow
ers rely on turret punching machines. These At its Seattle home base, Red Dot operates and decreased the tool’s working life. A new
workhorses of the metal fabricating industry three punching machines. Jericho Abad, a 21- tool that was capable of making the louver in
can not only produce the louvered forms, but year veteran of the company and a former one hit would be a much needed improvement,
also punch out holes, produce features such punching press operator, came from the com- especially if it was designed to avoid collisions
as countersinks and taps, and shear parts free pany’s quality assurance department a couple on the punching machine.
from the skeleton. A punching machine can do of years ago to help out in his former stomping
quite a bit if the right tooling and processing grounds in the punching area. A New Line on Punching
steps are in sync. Early on, an outsider’s eye provided a new John Nugent, a sales engineer for Mate Pre-
Red Dot Corp., a manufacturer of mo- perspective. Abad asked a question heard in a cision Tooling, called on Red Dot about this
bile heating, ventilation, and air-conditioning lot of metal fabricating facilities: “Why are we time. He was new to the territory, but familiar
(HVAC) units and components for heavy-duty doing it this way?” with punching machines. He had run and pro-
commercial and military vehicles, still relies on He was asking about a specific louvered part grammed turret punch presses for 16 years.
its punching machines to process parts for its made from 20-gauge galvannealed steel. The Upon meeting Abad, Nugent asked him what
products. Some recent changes in its tooling part-making process involved an excessive was causing him problems. Abad quickly re-
usage have helped to streamline production of amount of material handling—shearing a 96- ferred to the painstaking process of forming
one particularly troublesome part. by 48-inch sheet into five 17- by 48-in. sheets; louvers.
placing those sheets onto the Finn-Power C5 Nugent understood the situation and took
The Puzzle of Punching HVAC Parts turret punching machine for holemaking and into consideration Abad’s suggestions. That led
Red Dot can trace its roots to the late 1950s, to a discussion with Mate tooling engineers,
when Harcourt G. “Harky” Runnings started who came up with customized hardware for
building customized heaters as a side business the job.
in his automotive radiator repair shop in West “We came in and offered a spring-loaded bot-
Seattle. The heaters were made for mail trucks tom, instead of having the punch side absorb it
running up and down the Alaska Highway. all,” Nugent said. “So that allowed the tooling
As word spread about the quality of his work, to have a smooth surface and move across the
Runnings soon turned to making cooling and material without catching on something.”
heating equipment full-time. In 1965 he formally Red Dot now can throw a full 4- by 8-foot
incorporated Red Dot. Even in those early days, sheet on the punching table and form all the
Runnings planned to produce HVAC equipment louvers at one time without fear of the forming
for heavy-duty vehicles and off-highway equip- » Red Dot’s air-conditioner/heater units are used in tool getting hung up or even knocking sheets or
ment. construction, military, mining, and agricultural vehicles. parts loose from the machine’s clamps.

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 “With so many shops doing more laser cutting, the punch press is un-
derutilized. There’s a lot of money wrapped up in that thing, so we want
to find ways to increase its value,” Nugent said.
Tooling audits provide an excellent means to do that. The new louver
tool at Red Dot is indicative of the benefits that can result from this type of
interaction between a punching tool supplier and the machine operators.
A tooling audit in 2010 led Red Dot to improve its slitting tool hit count.
The manufacturer was able to improve its slitting hit count of approx-
imately 20,000 hits with standard Mate tools to more than 1,800,000
hits with Mate’s UltraTEC® tooling. This tooling, designed for thick-turret
punching, is made of premium, high-speed tool steel, which helps to ex-
tend tooling life when compared to standard tools.
This type of tooling change can help to improve part quality as well,
according to Nugent. The tool strength ensures that a form is created
» Jericho Abad (left), Red Dot’s production programmer, and John Nugent, a Mate sales cleanly, eliminating the worry of markings, such as hairlines.
engineer, show the louvered part that is now produced in one setup on the punching In the meantime, Red Dot continues its efforts to find more efficiency
machine. in its punching department. Abad mentioned that having a laser/punch
combination machine would be a nice addition, but streamlining punch-
The production savings that resulted from the new tooling and louver-
ing jobs and creating new capacity might be sabotaging that dream.
making process are significant. Red Dot went from a two-step, eight-hour
production process to a one-step, 2.5-hour process. Under the old pro- Editor-in-Chief Dan Davis can be reached at [email protected].

cess, the punching department required 20 minutes to cut 10 96- by 48- Red Dot Corp., www.reddotcorp.com
in. sheets into 50 17- by 48-in. sheets; 420 minutes of run time on the Mate Precision Tooling, www.mate.com
punching machine; and 50 minutes of loading and unloading time for the
sheets, parts, and skeletons. The new process eliminated the shearing
process, as well as 10 11- by 38-in. remnants that were left over from the
shearing. (Nugent also noted that Red Dot was able to get better sheet
utilization as the punching department improved the sequencing of its
parting tools, allowing them to punch farther into the corners than previ- Boschert-Gizelis
ously.) Now only 150 minutes are needed to form the louvers, and seven
minutes are required for loading/unloading.
G-Cut CNC
“We fabricate these parts up to three times a week,” Abad said. “Our
productivity with the new Mate louver tool increased 68 percent without
the hassle of finding use for the new remnant metal material.”
It also has become a much more reliable process.
“We just basically set it up, go home, and come back in the morning,”
Abad said. At that point it’s just a matter of removing the 300-plus parts
from the punching bed.

A Helping Hand
Mate has worked with Red Dot off and on over the last 15 years, conduct-
ing tooling audits when possible. The stakes have definitely grown over the
years, as Red Dot has gone from punching 298,000 pounds of sheet metal
Three Features:
per month in the mid-2000s to almost double that today. A Cut Above
the Rest

Three reasons to choose the Boschert-Gizelis G-Cut CNC

swing beam hydraulic shear:
1. Return to Front—Finished and appearance-sensitive pieces return to the
operator instead of behind the machine. Reduce repetitive motion. Increase
efficiency, productivity and safety.
2. Narrow Strip Cutting—An unconventional approach to thin strip shearing
eliminates waste and delivers a quality finished component nearly twist-free.
3. Auto Thickness Measurement—A simple sensor measures material to
optimize blade gap. Protect your blades. Eliminate guess work. Reduce waste
and downtime from fold-over jams. Safer, easier, more efficient.

BENDING, CUTTING & PUNCHING MACHINERY

800-354-3737 | www.boschertusa.com
» This tool was custom-designed to have a spring-loaded bottom that was sure to
retract during forming, ensuring that the tooling would not make unintended contact [email protected] | youtube.com/boschertsales
with the sheet during further punching or forming.

AUGUST 2019 The FABRICATOR 83

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 » An older plasma cutting table is the workhorse for
many shops specializing in heavy fabrication. A more
modern plasma cutting system can help those same
shops achieve new efficiencies that aren’t possible with
older technology.

Oxyfuel Cutting
Oxyfuel cutting is still the old standby and the
most economical way to cut carbon steel that is
more than 2 inches thick. Yet even this mature
technology has undergone several changes over
the years.
A quarter of a century ago, if a fabricator or-
dered an optional height control and igniters,
after about six months the operator typically
removed them. Operators saw them as some-
thing that just got in the way; were subject to
moisture, slag, and dirt; and were restricted in
movement, as the simple motor could only go
up and down. Today fabricators can have an
integrated height control that keeps the torch

Plasma cutting:
out of harm’s way and internal torch igniters
that work consistently when needed. Servo
controls provide for smooth and reliable move-
ment of the torches, and no tools are required

Then and now for tip changes.

In fully automated systems, the CNC can set
oxyfuel ratios to include flow rates for differ-
ent thicknesses. The operator just provides the
That 25-year-old plasma table thickness of the material to be cut and pushes
the start button.
can’t match today’s technology
Beveling
Beveling has improved over the years with the
By John Zuehlke the technology remotely should operational er-
advancements in hardware and software. Work

I
rors occur. Furthermore, custom software and
n many shops the “cutting machine” is the still needs to be done, but fabricators are getting
updates can be loaded easily into the CNC if a
plasma cutting machine. Waterjets and lasers closer to the goal of using plasma cutting sys-
new capability, such as marking, is added to the
also cut metal, but when it comes to cost- tems that make the job of beveling as simple and
equipment mix.
effective and efficient cutting of steel plate, the repeatable as possible for the machine operator.
plasma cutting machine is typically the equip- Some bevel heads now have zero offset. This
Plasma Power Sources
ment of choice. greatly helps the programmer especially with
In the early days plasma cutting systems used a
Unfortunately, when many people think of internal bevels. The head itself can achieve an-
tungsten electrode, nitrogen as the cut gas, and
their shop’s cutting machine, it’s a plasma cut- gles of ±47.5 degrees while the machine remains
CO2 as the shield. Most systems were 600 amps.
ting machine from the late 20th century. The completely stationary. (The machine does not
Now a 300-amp plasma cutting power source
cutting table has none of the capabilities of to- have to move its X and Y axes to achieve an-
with a hafnium electrode and with oxygen as an
day’s modern equipment. In fact, fabricators will gles.) In fact, this means that the torch can tilt
assist cutting gas can cut faster and more ac- as it approaches a corner, preparing for a bevel
find many tables now are equipped with drilling,
curately (especially with holes) on carbon steel on the next side of the part. This effectively ne-
tapping, oxyfuel cutting, marking, and beveling
than the old 600-amp systems. gates the need for a looped corner, which mini-
capabilities in addition to plasma cutting.
Changes are coming so fast in performance mizes the amount of plate that is cut to achieve
Let’s look at some of the significant techno-
that it’s difficult to keep up. Whereas a metal the bevel.
logical advancements made over the past 25
years. fabricator had only three gases to choose from The mechanical systems on modern plasma
25 years ago for ideal cutting parameters, to- cutting machines are compact. Now fabricators
Computer Numerical Control day fabricators can choose from six: argon, can even purchase beveling capability on a 5- by
CNC equipment from 25 years ago relied on CO2, hydrogen, methane, nitrogen, and oxygen. 10-ft. machine.
cathode ray tubes and reel-to-reel tape drives Some plasma cutting systems even use water For those interested in oxyfuel beveling, ser-
for operation. Today CNC machines are PC- to constrict the plasma arc when cutting ma- vo controls simplify setup of the cutting job and
based and probably connected wirelessly to the terials other than carbon steel. The technologi- actual operation of the machine. Also, continu-
web. This not only enables remote loading of cal advancements have helped plasma cutting ous rotation with these oxyfuel cutting heads
cutting programs, but more importantly allows to emerge as an economical way to shape-cut is possible without having to unwind them be-
the manufacturer of the equipment to diagnose stainless steel and aluminum. cause of twisted hoses.

84 The FABRICATOR AUGUST 2019

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 Marking mill. Automatic tool changers are now common. sulting from human intervention—a company
Twenty-five years ago marking was done solely How effective are these systems? A 60-HP saves a lot of money.
with zinc or a punch. (Zinc marking involved the drilling tool on a plasma cutting system can Additionally, the introduction of through-
use of zinc powder that was then melted with make a 2-in. hole through 4-in. material in 27 tool lubricant delivery in minimal quantities has
the plasma flame. The semipermanent marking seconds and a 3-in. hole through 5-in. material helped to improve drilling and eliminates both
could be welded over without issues.) in 60 to 90 seconds. the mess and cost associated with relying on
Now a machine can use a punch, pin, plasma, The cost associated with material handling flooding coolant.
inkjet, zinc, or laser for layout, part identifica- in a fabricating shop is really driving interest in
tion, and even bar coding in any axis. these additional capabilities. If the cutting sys- Other Factors
tem can produce a finished product in one step A modern plasma cutting system also may be
Secondary Operations without additional material handling to deliver equipped with additional cutting capabilities,
Today’s plasma cutting systems can be equipped the workpiece to downstream operations—all such as an oxyfuel torch, laser, or water; ma-
with tools to drill, tap, countersink, and even while avoiding possible processing errors re- terial load and unload automation for sheet or
plate; automated scrap removal devices; ma-
terial handling devices for 3D shapes, such as
tube and beams; and grate cutting capability. A
plasma system could have all of these, but that’s
not really probable. For example, a fabricator
may find it more practical to have a separate
machine for pipe if the plasma cutting machine
is dominated with plate work. As always, man-
agement must do its research to determine
what options are worth investing in.
The same thinking applies to software. Basic
software can cover machine programming, and
more elaborate packages can handle such tasks
as production scheduling and even interfacing
with existing ERP systems. Again, company
management needs to decide just what aspects
of these modern tools they want to better posi-
tion the organization for the future.
John Zuehlke is president, Profile Cutting Systems USA, 190 Mesa
» A finished part can be produced with a plasma cutting system that not only can cut, but also drill, tap, mill, bevel Drive, Boulder Creek, CA 95006, 831-338-8251, www.pcs
cut, and mark. With the addition of an oxyfuel torch, very thick material can be processed as well. machines.com.

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AUGUST 2019 The FABRICATOR 85

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 How to drill
» The Boeing 747 was cut down to size for transport—
along public highways—to its transformation location in
Nevada’s Black Rock Desert.

232 holes in
By Sue Roberts

I
t takes a flight of fancy to come up with an
art project that begins with transporting a

2-inch titanium 1985 Boeing 747-300 from the Mojave Air and
Space Port boneyard to the Black Rock Desert
of Nevada along 500 miles of public highways.

wing spars
Ken Feldman, CEO of Big Imagination, imag-
ined repurposing the aircraft to create an in-
teractive space where people can dance, enjoy
music, and leave their day-to-day lives behind
without actually taking off. (The Big Imagina-
Reassembling a disassembled, decommissioned tion Foundation is a 501(c)3 nonprofit organi-
747 as a huge party venue required ingenuity, zation. In its own words: “We incubate bold,
visionary projects that inspire the world to
holes, and splice plates dream big.”) Feldman put his faith in a small
crew and a cadre of more than 500 volunteers
to achieve the dream over a three-year period
that culminated with the plane’s debut at Burn-
ing Man 2018, an arts and music festival held in
northwest Nevada every fall. Most of the work
in transforming the jet was accomplished dur-
ing long weekends.
With highway travel lanes typically between 9
and 12 feet wide, according to the Federal High-
way Administration, moving the plane to the site
for its reinvention meant breaking it down into
much smaller sections that could be put back
together once they arrived at their new home.
Removing the tail and large portions of the
wings brought the size of the plane down to 135
ft. long, 32 ft. tall, and 60 ft. wide. It was still
too large to move on highways. Further disas-
sembly included cutting the aerospace-grade
titanium alloy backbones of the wings and land-
ing gear in half with a plan to reassemble using
7000 series aluminum splice plates.

» Keru McKenzie was the volunteer tasked with drilling

232 holes in the titanium wing spars.

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 is a little gummier than steel but cuts good up a fabricator to develop a process to drill the
to about a 1-in. depth,” McKenzie said. holes once the cut points were determined but
“But titanium is especially tough stuff. It before the cuts were made.
probably takes double the force needed to drill “We put aluminum plates around the beams
steel, and the chips don’t like to come out in to make them strong enough to be put back
nice little strings. And it likes to work-harden so together with structural integrity. To get the
if the drill is scraping and not actively cutting, strength back up to nearly flight strength after
the titanium will heat up, get stronger, and burn reassembly, we put 2 in. of aluminum plating on
up the tips on the drill. Titanium dissipates heat top and 1 in. below on each of the beam’s two
fairly slowly, and since it heats up so fast you flanges, as well as two 1-in. plates on the side of
need a lot of coolant during cutting. the beam. That meant we had to drill through
“Then, once you get down more than ½ in., nearly 5 in. of material at once to be sure the
even if you have a sharp annular cutter, it won’t bolts would line up. We wanted to match drill
readily feed out chips.” those holes,” said McKenzie.
The drilling problem was identified during Equipment, Tooling, and Creativity
test cutting of titanium samples before at- Finding a drill and tooling that could handle the
tempting the holes in the beams themselves. job took some trial and error. A hand-held drill
This prompted a search for equipment and and a magnetic drill failed to make it through the
tooling that would make the chore of drilling multiple levels of varying materials.
» Holes for use with splice plates to return the wings to
structural integrity during reassembly were drilled in the the 232 holes in the titanium beams possible. While the team was searching the internet for
titanium beams before they were cut. Although titanium was the most difficult other possibilities, the large MAB 485 portable
material of the project, other metals were in- magnetic drill from CS Unitec caught their
Drilling volunteer Keru McKenzie, part of the volved. McKenzie drew on his experience as attention.
team dubbed the 747 Mechanic Group, said
that the engineering plan for further disman-
tling called for removing the top half of the
fuselage and the wings basically by cutting the
plane’s ribs, skin, and stringers. The wing spar
material was the problem.
“The titanium wing spar beams were the big
bugaboo of the project. They were so big and
hard to work with that we didn’t really know how
we were going to do it right up to the month we
were going to work on it. The root of the beams
goes back into several hundred bolts and assem-
blies, so we couldn’t unbolt them without taking
the entire plane apart,” McKenzie said.
“We knew we could go in there with tools like
grinders and abrasive saws to cut the beams,
» The bottom section of the 747 fuselage waits for further work in the Mojave Desert. The top two sections of the
but we needed to be able to put them back fuselage have been removed and transported to the reassembly location in Empire, Nev.
together and maintain their structural integ-
rity. We needed to put splice plates with holes
across the cuts so they could be bolted back
together. What we didn’t know was how to drill
the 5/8-in. holes in the 2-in.-thick aerospace-
grade titanium alloy.”

Titanium Troubles
Titanium, with its high strength-to-weight ratio,
drills differently than steel or aluminum in some
important ways. Angular hole cutters that work
well in steel and aluminum have problems clear-
ing titanium chips and providing enough cool-
ant flow. When cutting 1- to 2-in. holes, work
hardening is likely and restarts after the cutter is
lifted to remove chips are difficult to impossible.
“If you’re going to drill steel and you have a
mag drill, you can put a cutter on the material
and you’re set. The drill bites into the steel and » The forged titanium wing spar that provides the main strength of the wing can be seen as a cut section of the wing
turns out a lovely birdnest of chips. Aluminum is ready to be removed.

AUGUST 2019 The FABRICATOR 87

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 with the drill’s magnets. He said that drilling
pressure was between 90 and 99 percent of
magnet liftoff force, and between 20 and 30
pounds of pressure were required to keep the
tool cutting. The steel plates also acted as a
template for properly placing the holes.
“We used the predrilled holes in the steel
plates to direct where we drilled the holes in
the ribs. That sped up the work quite a bit. Still, »To drill upside down, the crew bolted the top and
bottom aluminum plates along with a ½-in. steel template
drilling the 232 holes in the titanium took about
to the 2-in. titanium beam and match drilled as sets. Eight
two solid weeks of drilling. We had some very of these sets plus two sets of side plates were required to
good jigs set up so it was mostly a matter of reassemble the wing spar beams.
moving the drill to the right spot and pulling
duce the huge, rolling art project. There, the
on the handle for about 10 minutes per hole,”
747’s interactive space will be opened to party-
McKenzie said.
goers as part of the event’s goal to make par-
Ready to Party ticipants of everyone. Like the imagination that
Today the reassembled and reimagined 747 is gave a grounded plane a new design and pur-
parked in a storage area in Nevada where the pose, the nine-day gathering draws thousands
work is basically completed but things are occa- of people together to celebrate new ideas,
fresh beginnings, artistic self-expression, and
sionally fine-tuned, McKenzie said.
life with a new twist.
“We can add more railings or make more
dance floors … there is a lot of space in a 747,” Freelance writer Sue Roberts can be reached at
[email protected].
he added.
Big Imagination, www.bigimagination.org
This fall’s Burning Man festival in Black Rock
City, Nev., may be the perfect place to reintro- CS Unitec, www.csunitec.com

» A variety of jigs and clamps were used to make drilling

horizontally on the web of the titanium spar beam
possible.

McKenzie said, “We saw the big magnetic

drill with a long enough vertical stroke to allow
us to match drill the 5-in. stack of material. It
has a 2-speed drive so we could drill using low
speeds and high torque. Its Morse taper fit drill
chucks, and we also had the option of using a
regular machine tool with it. We bought a 9-in.
tool body that had through-body cooling and
replaceable carbide tips. One toolholder was
used for the entire operation with 2x carbide
inserts changed every 10 holes.”
The drill’s automatic internal lubrication sys-
» Two-in.-thick aluminum splice plates were drilled with the 5/8-in. hole pattern then clamped to the titanium beam.
tem with an external lubrication system option A 1-in.-thick aluminum plate was added on the opposite side and a ½-in.-thick steel template on the top to match drill
was a welcome feature; however, McKenzie de- the 5-in. sandwich with the MAB 485.
signed an additional large-capacity, gravity-fed
system to ensure a constant feed of coolant to
the cutting site regardless of drill orientation.
Each of the two wing spars needed 40 upright,
40 inverted, and 36 horizonal holes.
A constant flush of ProLube™ nontoxic cut-
ting lubricant controlled the friction and heat
generated while drilling the titanium, protect-
ing against material hardening and helping to
extend the life of the tooling.
McKenzie came up with a workaround for
positioning the magnetic drill on nonferrous
material. Sections of ½-in. steel plate, about 6
in. by 20 in., were clamped on to the titanium
beam to create a ferrous base that would work » Big Imagination’s Boeing 747 is shown partially disassembled.
88 The FABRICATOR AUGUST 2019

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2019 FORMING & FABRICATING® VENTILATION SYSTEM» BUYERS’ GUIDE©
Ambient
Collection Source Capture Application Filter System Nominal CFM

Process Dust, Powders

Slotted Backdraft Hood

Metalworking Dust

Wet Dust Collector

Portable Exhaust

Downdraft Table

Welding Smoke
Fume Scrubber
Dust Collector

Dust Collector

Self-Cleaning

Carbon Filter

1,001-2,000

2,001-5,000
Exhaust Fan
Air Cleaner

Air Cleaner

Disposable
Fume Arm

0-1,000

5,001+
Fumes
Booth
Model or Series

AIR SYSTEMS INTL., Chesapeake, VA

Fume-Air™ 230
4 4 4 4
Fume Extractor

AIRFLOW SYSTEMS INC., Dallas, TX

DCH Series
Portable Central 4 4 4 4 4 4 4 4 4 4 4 4 4
Collection Systems
DCH Series
Portable Central 4 4 4 4 4 4 4 4 4 4 4 4 4
Collection Systems
PCH-1 Portable
Dust Collection & 4 4 4 4 4 4 4 4 4 4 4
Filtration
E-Z Arm©
High-Flow 4 4 4 4 4 4 4 4 4 4
Extractor Arm
DC Series Dust
Collection & 4 4 4 4 4 4 4 4 4 4 4 4
Filtration
MP Series Mist
Collection & 4 4 4 4 4 4 4 4 4 4
Filtration
F Series Air
4 4 4 4 4 4 4 4 4
Cleaning Systems
DT and AL Series
4 4 4 4 4 4 4 4 4
Downdraft Tables
Dust Control Booth
& Panel Filter 4 4 4 4 4 4 4 4 4 4
PowerBooth©
Paint & Fume Booth 4 4 4 4 4 4 4 4 4 4 4
V Series High-
Vacuum Collection 4 4 4 4 4 4 4 4 4 4
& Filtration
BAGHOUSE.COM LLC, Las Vegas, NV
BA Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
STA Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
CAMFIL AIR POLLUTION CONTROL, Jonesboro, AR
Farr Gold Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
CLEAN AIR AMERICA INC., Rome, GA
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
DIVERSITECH, Montreal, QC Canada
FRED SR Self-
Cleaning Fume 4 4 4 4 4 4 4 4
Extractor
Green Filter
4 4 4 4 4 4 4 4
Cleaning Machine
Airhawk Cartridge
4 4 4 4 4 4 4 4 4 4 4
Dust Collectors
WX and Typhoon
4 4 4 4 4 4 4 4
Wet Dust Collectors
Monsoon Wet
4 4 4 4 4 4 4 4
Downdraft Tables
Extractor Fume
4 4 4 4
Extraction Arms
FRED JR Portable
4 4 4 4 4 4 4 4
Fume Extractor
FRED ECO Wall
Mounted Fume 4 4 4 4 4 4 4 4
Capture System
Mini DD Portable
4 4 4 4 4 4 4 4
Downdraft Table
DD 2x4 Self-Clean-
4 4 4 4 4 4 4 4 4
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2019 FORMING & FABRICATING® VENTILATION SYSTEM» BUYERS’ GUIDE©
Ambient
Collection Source Capture Application Filter System Nominal CFM

Process Dust, Powders

Slotted Backdraft Hood

Metalworking Dust

Wet Dust Collector

Portable Exhaust

Downdraft Table

Welding Smoke
Fume Scrubber
Dust Collector

Dust Collector

Self-Cleaning

Carbon Filter

1,001-2,000

2,001-5,000
Exhaust Fan
Air Cleaner

Air Cleaner

Disposable
Fume Arm

0-1,000

5,001+
Fumes
Booth
Model or Series

DONALDSON TORIT/DONALDSON CO. INC., Minneapolis, MN

Downflo 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Evolution (DFE)
Downflo 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Workstation (DWS)
Downdraft 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Bench (DB)
Easy Trunk Portable 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
T-2000 2-Arm 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
(Ceiling Mount)
PowerCore TG 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
ECOLO TECH INC., Madison Heights, MI
4 4 4 4 4 4 4 4 4

HASTINGS AIR-ENERGY CONTROL INC., New Berlin, WI

Flowtron by Filter-1 4 4 4 4 4 4 4 4
PowerBooth by 4 4 4 4 4 4 4 4 4
Airflow Systems
PCH-2 by Airflow 4 4 4 4 4 4 4 4 4
Systems
M30 by Air-King 4 4 4 4 4 4
DT-3000v2 by 4 4 4 4 4
Airflow Systems
E-Z Arm by Airflow 4 4 4 4 4 4
Systems
Hydrotron HWF 4 4 4 4 4 4 4
by Filter-1
Hydrotron DHYD 4 4 4 4 4 4 4 4 4
by Filter-1
AT and AC Series 4 4 4 4 4 4 4 4
by Amtech
F-240 by Airflow 4 4 4 4 4 4 4
Systems
IMPERIAL SYSTEMS INC., Mercer, PA
CMAXX Dust &
Fume Cartridge 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Collector
CMAXX Laser &
Plasma Table Dust 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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BRF Baghouse Dust 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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Design & Installation 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Services
INDUSTRIAL SAFETY PRODUCTS, Colchester, VT
70102 Spot Fume 4 4 4 4 4 4 4 4 4 4
Eliminator
70600 Spot Fume 4 4 4 4 4 4 4 4 4 4
Eliminator
KELLER USA INC., Fort Mill, SC
VARIO eco 4 4 4 4 4 4 4 4 4 4 4 4 4
L-Cut 4 4 4 4 4 4 4 4 4 4
TR-1 4 4 4 4 4
VDN 4 4 4 4 4 4 4 4 4 4 4
PT Filter 4 4 4 4 4
Jet Set 4 4 4 4 4
Mobile Welding 4 4 4 4 4 4
Fume Collector
eLine 4 4 4 4
Source Capturing:
Add-Ons for All 4 4 4 4 4 4 4 4 4
Listed Collectors

AUGUST 2019 The FABRICATOR 91

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2019 FORMING & FABRICATING® VENTILATION SYSTEM» BUYERS’ GUIDE©
Ambient
Source Capture Application Filter System Nominal CFM
Collection

Process Dust, Powders

Slotted Backdraft Hood

Metalworking Dust

Wet Dust Collector

Portable Exhaust

Downdraft Table

Welding Smoke
Fume Scrubber
Dust Collector

Dust Collector

Self-Cleaning

Carbon Filter

1,001-2,000

2,001-5,000
Exhaust Fan
Air Cleaner

Air Cleaner

Disposable
Fume Arm

0-1,000

5,001+
Fumes
Booth
Model or Series

KEMPER AMERICA INC., Alpharetta, GA

Kemper Clean Air 4 4 4 4 4 4 4 4
Tower-Freestanding
Kemper 8000
PTFE Self-Cleaning 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Central Unit
Kemper 9000
PTFE Self-Cleaning 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Central Unit
Kemper Filter 4 4 4 4 4
Master-Mobile
FilterMaster XL
Self-Cleaning PTFE 4 4 4 4 4 4 4
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Kemper Profi-
Master-Medium 4 4 4 4 4 4 4 4
Capacity
Kemper MaxiFil- 4 4 4 4 4 4 4
High Capacity
Cartridge Filter
Self-Cleaning Wall 4 4 4 4 4 4 4 4 4 4
Mount
Kemper Dusty-
Mobile 2 Port Torch 4 4 4 4 4 4 4
Extraction
High Vac 4 Port
Self-Cleaning 4 4 4 4 4 4 4
Extraction Unit
KICE INDUSTRIES INC., Wichita, KS
4 4 4 4 4 4 4 4 4 4 4 4
MARTECH SERVICES CO., Mazeppa, MN
4 4 4 4 4 4 4 4 4
MICRO AIR, Wichita, KS
Force-FRP Dust
Collector with 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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Cleaning System
Extreme Air Down- 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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HYDROMAX Wet 4 4 4 4 4 4 4 4 4 4 4
Dust Collector
HYDROMAX Wet
Downdraft Table 4 4 4 4 4 4 4 4 4
(WCDDT)
RP Self Cleaning
Dust Collector with 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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Cleaning System
Taskmaster Portable
Fume Extractor 4 4 4 4 4 4 4 4 4 4 4 4 4
(TM1000, TM500)
Clean Air 4 4 4 4 4 4 4 4 4 4 4 4 4
Booth (CAB)
SCA Source
Capture Arms and 4 4 4 4 4 4 4 4 4
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MISTMAX Mist 4 4 4 4 4 4 4 4
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Intelli-Touch Energy
Savings Controls 4 4 4 4 4 4 4 4 4 4 4 4 4 4
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MIDWEST AUTOMATION LLC, Minneapolis, MN
Niagara DC 500 4 4 4 4 4
Wet Dust Collector
Niagara DC 1200-
5500SS Wet Dust 4 4 4 4 4 4 4
Collectors

92 The FABRICATOR AUGUST 2019

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2019 FORMING & FABRICATING® VENTILATION SYSTEM» BUYERS’ GUIDE©
Ambient
Source Capture Application Filter System Nominal CFM
Collection

Process Dust, Powders

Slotted Backdraft Hood

Metalworking Dust

Wet Dust Collector

Portable Exhaust

Downdraft Table

Welding Smoke
Fume Scrubber
Dust Collector

Dust Collector

Self-Cleaning

Carbon Filter

1,001-2,000

2,001-5,000
Exhaust Fan
Air Cleaner

Air Cleaner

Disposable
Fume Arm

0-1,000

5,001+
Fumes
Booth
Model or Series

PARKER HANNIFIN, FORMERLY UNITED AIR SPECIALISTS (UAS), Lancaster, NY

SFC Downward
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Flow
MCB Cross
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Ventilation
V Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Smog-Hog
4 4 4 4 4 4 4 4 4 4 4
SHN/SG
C Series Cyclone 4 4 4 4 4 4 4 4 4 4 4
Smog-Hog
4 4 4 4 4 4
MSH
PNP Series:
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Plug-n-Play
MIB Modular
4 4 4 4 4 4 4 4 4 4 4 4 4
Industrial Baghouse
SHM Media Mist
4 4 4 4 4 4 4 4 4
Collector
XA 4 4 4 4 4 4 4 4 4 4 4 4
PLYMOTH USA, Cincinnati, OH
PLYMOTH USA 4 4 4 4 4 4 4 4 4 4 4 4 4
PLYMOVENT INC., Mississauga, ON Canada
DraftMax 4 4 4 4 4 4
ROBOVENT, Sterling Heights, MI
Clarion CFX Series 4 4 4 4 4 4 4
Clarion Ambient
4 4 4 4 4 4 4 4 4
Series
CrossFlow Table 4 4 4 4 4 4 4 4 4 4 4 4
HiVac Series 4 4 4 4 4 4 4 4 4 4 4
FloorSaver Series 4 4 4 4 4 4 4 4 4 4
Fusion Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
PFX Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Plaser Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Spire Series 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Ambient Spire
4 4 4 4 4 4 4 4 4 4
Series
Extractor Fume
4 4 4 4 4 4 4 4 4 4 4
Guns
VentBoss Portables 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Exhaust Fans &
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Make-up Air
Replacement Filters
4 4 4 4
(All Industries)
Engine Exhaust
4 4 4 4 4 4 4 4
Systems
SCHUST, Auburn, IN
4 4 4 4 4 4 4 4 4 4 4 4 4
VENT-A-KILN CORP., Buffalo, NY
Vent-A-Fume 4 4 4 4 4
FE-500 Fume
4 4 4 4 4
Extractor
FE-800 Fume
4 4 4 4 4
Extractor
FE-1200 Fume
4 4 4 4 4
Extractor
PFE-750 Portable
4 4 4 4 4
Fume Extractor

This information is provided by the manufacturers. For more information, use the links in the online buyers’ guide at www.thefabricator.com. ©Copyright 2019 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.

AUGUST 2019 The FABRICATOR 93

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2019 FORMING & FABRICATING® GMAW POWER SOURCE» BUYERS’ GUIDE©

Applicable Processes Output Rating (DC) Input Rating

Running Gear Std.

Carbon Arc

Duty Cycle
GMAW-P

Gouging
Wire Wire Feed

GTAW-P

Brazing

Voltage
GMAW

SMAW

Phase
CAC-A
GTAW

Other
FCAW

Amps
Type of Power Feed Speed

Volts
Spot

SAW

Hz
Model or Series Source Options Range

DAYOK ELECTRICAL CO. LTD., TACHUNG CITY, TAIWAN

Plasma:
100
Multi-50HFP Inverter External 4 4 4 200 35 220 1 60
GTAW: 18
SMAW: 27
60@250A
FR-250A Inverter External 60-780 4 40-250 15-30 220 1/3 50/60
100@195A
60@350A
FR-350A Inverter External 60-780 4 50-350 14-36 220 1/3 50/60
100@270A
60@500A
FR-500A Inverter External 60-780 4 50-500 15-45 220 3 50/60
100@387A

FR-500K Transformer External 60-780 4 60-500 65-75AC 220/440 3 60

FR-600K Transformer External 60-780 4 100-600 AC 65-75AC 220/440 3 60

OK-IV300D Inverter 4 10-300 32 60 220 1/3 50/60

OK-IV500D Inverter 4 10-500 32 60 220 1/3 50/60

OK-400AA Transformer 4 400 AC 220/440 1 60

OK-600AA Transformer 4 600 AC 220/440 1 60

ESAB WELDING & CUTTING PRODUCTS, Denton, TX

Rebel EMP 215ic Inverter Built-in 59-476 4 4 4 4 205 24.3 25 120-230 1 50/60

Rebel EMS 215ic Inverter Built-in 59-476 4 4 4 205 24.3 25 120-230 1 50/60

Rebel EM 215ic Inverter Built-in 59-476 4 4 205 24.3 25 120-230 1 50/60

230/460(400i)
Warrior 500i MV, Microbased Inverter, External
Various 4 4 4 4 4 4 400/500 36/40 60 or 3 50/60
Warrior 400i MV Multiprocess (CV/CC) Dedicated
380/460(500i)
208-
ArcMaster 401MST Inverter External Various 4 4 4 4 4 400 34 25 1/3 50/60
230/400/460

Mig 4002c, Mig 6502c Chopper CV/CC External 32-1,000 4 4 4 4 4 4 4 4 4 4 4 400, 650 34, 44 60 230/460 3 50/60

Fabricator 3-in-1
Inverter Built-in 90-400 4 4 4 4 4 140 19 15 115 1 50/60
141i MP
Fabricator 3-in-1
Inverter Built-in 100-650 4 4 4 4 4 210 23.5 20 115, 208/230 1 50/60
211i MP
Fabricator 3-in-1
Inverter Built-in 67-700 4 4 4 4 4 250 26.5 40 208/230 1 50/60
252i MP
Aristo Mig 4004i Microbased Inverter, External 380/400/415/
32-1,000 4 4 4 4 4 4 4 4 4 4 400/500 34/39 60 3 50/60
Pulse and 5000i Multiprocess (CV/CC) Dedicated 440/460

LIBURDI DIMETRICS CORP., Dundas, ON, Canada

Weld
208/230/400/
OrbiMIG II Orbital MIG Head-De- 0-800 4 4 450 20@450 100 3 50/60
460/475
pendent
LINCOLN ELECTRIC CO., THE, Cleveland, OH

20@90A,
POWER MIG® 140C Rectifier Built-in 50 - 500 4 4 30 - 140 19.5 120 1 60
19.5V

60 @
POWER MIG® 140 MP Inverter Built-in 40-500 4 4 4 4 30-140 18.75 120 1 60
95A/18.75V

[email protected],
90A on
120V:
POWER MIG® 180 Dual Rectifier Internal 50-500 4 4 30-180 34 120/208/230 1 60
30@20V,
130A on
230V
120V:
40@100A/
120V: 20-
Max. OCV: 19V,
POWER MIG® 210 MP Inverter Buit-in 50-500 4 4 4 4 140, 230V: 120/230 1 60
56 230V:
20-220
25%@200A/
24V

40@250A, 208/230/
POWER MIG® 256 Rectifier Built-in 50 - 700 4 4 4 30 - 300 40 1 60
26V 460/575

This information is provided by the manufacturers. For more information, use links in the online buyers’ guide at www.thefabricator.com.
©Copyright 2019 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.

94 The FABRICATOR AUGUST 2019

Aug19FAB_GMAW BuyersGuide.indd 94 7/25/19 5:07 PM

 2019 FORMING & FABRICATING® GMAW POWER SOURCE» BUYERS’ GUIDE©

Applicable Processes Output Rating (DC) Input Rating

Running Gear Std.

Carbon Arc

Duty Cycle
GMAW-P

Gouging
Wire Wire Feed

GTAW-P

Brazing

Voltage
GMAW

SMAW

Phase
CAC-A
GTAW

Other
FCAW

Amps
Type of Power Feed Speed

Volts
Spot

SAW

Hz
Model or Series Source Options Range

40@250A, 208/230/
POWER MIG® 260 Rectifier Built-in 50-700 4 4 4 30-300 26.5 1 60
26V 460/575

60@300A, 208/230/
POWER MIG® 350 MP Chopper Built-in 50 - 700 4 4 4 4 4 4 4 4 5 - 350 76 1 50/60
32V 460/575

208/230/
Power Wave® C300 Inverter Built-in 50-700 4 4 4 4 4 4 4 300 29 40 1/3 50/60
400/460/575

208/230/380/
Power Wave® S350 Inverter External 4 4 4 4 4 4 350 31.5 40 1/3 50/60
415/460/575

208/230/380/
Power Wave® S500 Inverter External 4 4 4 4 4 4 450 36.5 100 3 50/60
415/460/575

MAGNATECH LLC, East Granby, CT

On head,
MPS 4000 Inverter 20 - 866 4 4 4 400 70 50 200/230/460 3 50/60
Push-pull
MILLER ELECTRIC MFG. CO., Appleton, WI
60@350A,
34VDC;
XMT 350 FieldPro Multiprocess External 50-780 4 4 4 4 4 4 4 15-425 10-38 208-575 1/3 50/60
60@300A,
32VDC
60@350A,
XMT 350 FieldPro Po- 34VDC;
Multiprocess External 50-780 4 4 4 4 4 4 4 15-425 10-38 208-575 1/3 50/60
larity Reversing 60@300A,
32VDC
External -
100@400A 230/380/400/
PipeWorx 400 Multiprocess Single or 50 - 780 4 4 4 4 4 4 4 4 40 - 400 10-44 3 50/60
36 VDC 460/575
Dual
60@235A,
Dynasty 280 DX Multi- 19.4VDC;
Multiprocess External 4 4 4 4 4 4 1-280 14-28 208-575 1/3 50/60
process 60@200A,
28VDC

60@300A,
Millermatic 350P All-in-One GMAW All-in-one 50-700 4 4 4 4 25-400 32 200/230/460 3 60
32VDC

100@500A,
Continuum 500 Advanced GMAW External 50-1,000 4 4 4 4 4 20-600 10-44 230-575 3 50/60
39VDC

100@650A,
Dimension 650 Multiprocess External 50-780 4 4 4 4 4 4 15-815 10-65 380/460 3 50/60
44VDC

60@300A,
32VDC;
Invision 352 MPa Inverter External 50-780 4 4 4 4 4 5-425 10-38 208-575 1/3 50/60
60@350A,
34VDC

60@350 A,
AlumaPower 350 MPa Inverter External 4 4 5-425 10-38 208-575 1/3 50/60
34 VDC

NU-TEC SYSTEMS LLC, Mooresville, NC

Dual
Inverter (Full Bridge Wheel
M130 100-600 4 4 130 25 20 120 1 50/60
IGBT) Wire
Feeder
OTC DAIHEN INC., Tipp City, OH
MIG 135 DC CV Spool Gun Spool Gun 4 20 230/460/575 1

WB-M350 Inverter – DC External 20 - 705 4 4 4 4 4 4 30-350 31 60 208/230/460 1/3 50/60

WB-M350L Inverter – DC External 20-705 4 4 4 4 4 30-350 31 60 208/230/460 1/3 50/60

WB-P400 Inverter – DC External 20-705 4 4 4 4 4 4 4 30-400 34 50 208/230/460 3 50/60

WB-M500 Inverter – DC External 20-705 4 4 4 4 4 4 4 4 30 - 500 39 100 460 3 50/60

WB-P500L Inverter – DC External 20-705 4 4 4 4 4 4 4 30 - 500 39 60 460 3 50/60

HD-500 SCR External 20 - 780 4 4 500 45 50 230/460 3 50/60

WB-M350 Inverter External 20-780 4 4 4 4 250/350 26.5/31.5 60 208/230/460 1/3 50/60

DA-300P AC + DC External 20 - 780 4 4 4 - 300 22 - 30 40 460 3 50/60

DL-350 Inverter External 20 - 780 4 350 36 60 200 3 50/60

AUGUST 2019 The FABRICATOR 95

Aug19FAB_GMAW BuyersGuide.indd 95 7/25/19 4:30 PM

 ADVERTISERS
CLASSIFIED ADVERTISING
INDEX

USED MACHINERY FOR SALE PRODUCTS FOR SALE

Classified Advertising
Integrate your efforts to maximize your effectiveness by combining
print ads with online classifieds for added visibility and reduced
costs. Reach thousands of fabricating professionals with the
strongest print and online publications in the market.
Use classified ads in the industry’s leading magazines to build
Used Machine Source
. .
exposure for your:
• Used equipment or rebuilt machinery

.
CO2 & Fiber Lasers Turret Punch Presses • Financing services and business opportunities
TOOLS & SUPPLIES • Auctions, open positions, machine time, and more
Press Brakes Standard Classified Rate:
$120 per column inch (8 lines of copy at approximately 30 characters
(844)4ALTMACHINE
www.AMADAONLINE.com per line, including spacing). One inch minimum. No border,
(844-425-8622)
background and limited bold faced type.
Premium Classified Rate:
PARTS & SERVICES $140 per column inch. May include border, background, shading,
reverse type and/or company logo. No photographs, drawings, or
clip-art will be allowed.
Color Logo:
Having Press Brake Control Problems? For an additional $25 you can add your color logo to your premium
Regain productivity of your press brake ad. (color will be converted to cmyk).
with a new control for your backgauge. Column Width:
We upgrade most competitors’ backgauges. The FABRICATOR: 1.73", The WELDER: 2.16", The Tube & Pipe Journal:
2.30", STAMPING Journal: 2.14".
Box Numbers:
“c/o FMA Communications Inc.” may be used in place of your
82 Calvary Street, Waltham, MA 02453 company name and address. Add $15 to cover the cost of handling
www.automec.com 781-893-3403
and postage.
Frequency Discount:
The same copy used in 3 or more consecutive issues in a calendar
year earns a 10% discount per ad. All such ads payable in advance.
Place your ad in The FABRICATOR. Classified advertising is not subject to commission. Payment must
accompany order. Major credit cards accepted.
John Mathews
815-227-8219 [email protected]

SERVICES

BUSINESS FOR SALE The Power of Print

Light gage sheet metal fabrication shop in WNC for sale

CNC Turret Press, Press Brakes, TIG,
MIG & spot welding, among other capabilities.
Established manufacturing facility for 30 years. Last 3 years average
sales of 645K. If you would like to be a hands-on owner, ready to run
your own company, this is for you. Owner ready to retire and pass the
THE

business to someone who has the energy to expand the customer base
and take it to the next level.
Box 4700-F
The FABRICATOR, 2135 Point Blvd., Elgin, IL 60123

96 The FABRICATOR AUGUST 2019

96-97 AUG19FAB.indd 96 7/25/19 10:00 AM

 ADVERTISERS INDEX

Admiral Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fabrication Solutions & Technologies . . . . . . . . . . . . 23 Powder Coating Institute . . . . . . . . . . . . . . . . . . . . . . 40

[email protected] www.fststeelfab.com www.powdercoating.org/certification

Alliance Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fabricators & Manufacturers Practical Machinist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

www.alliancesteel.net Association, Intl. . . . . . . . . . . . . . . . . 11,28,55,57,75,78,79 www.practicalmachinist.com
www.fmanet.org

Alternative Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Prima Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

www.altparts.com FABTECH® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
www.fabtechexpo.com www.primapower.com

Amada America . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,12,13

www.amada.com Flexovit USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Profile Cutting Systems USA . . . . . . . . . . . . . . . . . . . . 74
www.flexovitabrasives.com www.profilecuttingsystems.com

American Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

www.aafintl.com Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Punch-Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
www.greinerindustries.com www.punchtools.com

ARKU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
www.us.arku.com Hans Weber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Radan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
www.weberamerica.com [email protected]

ATI Industrial Automation . . . . . . . . . . . . . . . . . . . . . 24

www.ati-ia.com Heck Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Rosler Metal Finishing USA . . . . . . . . . . . . . . . . . . . . . 18
www.heckind.net
www.rosler.us
Automec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
www.automec.com Hougen Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
www.hougen.com Saar Hartmetall USA . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
www.saarusa.com
Bluco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
www.bluco.com Kalamazoo Industries . . . . . . . . . . . . . . . . . . . . . . . . . . 36
www.kalamazooind.com/fab/ Sellick Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
www.sellickequipment.com
Boschert Precision Machinery . . . . . . . . . . . . . . . . . . 83
www.boschertusa.com Kern Laser Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
www.kernlasers.com SigmaTEK Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
www.sigmanest.com
Central Wire Industries . . . . . . . . . . . . . . . . . . . . . . . . 41
www.centralwire.com Kwik Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
www.kwikmark.com SlatPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
www.slatpro.com
CIBC US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
www.us.cibc.com Laser Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
www.lasermech.com
Steel Storage Systems . . . . . . . . . . . . . . . . . . . . . . . . . 81
www.steelstorage.com
Cidan Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
770-692-7230 LISSMAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
www.lissmac-usa.com; 518-326-9094
Strong Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
www.StrongHandTools.com
Cincinnati Incorporated . . . . . . . . . . . . . . . . . . . . . . . . 36 LVD Strippit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
www.e-ci.com 716-542-4511 / 1-800-828-1527
Therma - Tron - X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Bystro
www.ttxinc.com 800-24
Clemco / Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Mate Precision Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . 3
www.clemcoindustries.com www.mate.com
T J Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CS Unitec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 www.tjsnow.com
Mazak Optonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
www.csunitec.com www.mazakoptonics.com
Trilogy Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DAVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 MG Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 www.trilogymachinery.com
www.davi.com/us www.mgsrl.com
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Dener Makina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Mitsubishi Laser / MC Machinery Systems . . . . . . . 25 [email protected]
www.denermakina.com www.mcmachinery.com

United Lens Company . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Diamond Ground Products . . . . . . . . . . . . . . . . . . 37,39 Murata Machinery USA . . . . . . . . . . . . . . . . . . . . . . . . . 63 www.unitedlens.com
www.diamondground.com 1-800-428-8469

Dimeco Coil Technologies . . . . . . . . . . . . . . . . . . . . . 40 Vytek Laser Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

OTC Daihen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 www.vy-tek.com
www.dimeco.com www.daihen-usa.com

Durma North America . . . . . . . . . . . . . . . . . . . . . . . 20,21 Peddinghaus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Waldemar Design & Machine . . . . . . . . . . . . . . . . . . . 31

www.durmanorthamerica.com www.peddinghaus.com 931-946-8474

ERMAK USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Plasma Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wila USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

www.ermakusa.com www.plasmasystemsinc.com www.wilausa.com

AUGUST 2019 The FABRICATOR 97

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 BACK PAGE
Healing the invisible wounds of war
through metal art
Warrior StoryField gives veterans
an outlet to express themselves

Read more from Amanda Carlson at “I thought they’d be here for like a day, but
www.thefabricator.com/author/ they stayed for nine months. In the process of
amanda-carlson them coming back every day we got to talking
about war issues, the ghosts, and the demons.
By Ann Thompson and
Amanda Carlson It wasn’t like I was asking questions—I never

M
asked direct questions about their war experi-
ilitary veterans who have experienced ences. But I did ask how they wanted to express
combat are profoundly changed, re- themselves through art. They just offered these
gardless of the conflict or generation. bits of information. And slowly it just woke me
Some even say the real war began when they up and made me realize that as a civilian I could
returned home to their civilian life. That’s why do something. » Warrior StoryField provides military veterans a way to
a grassroots organization called Warrior Story- express themselves through metal sculpture.
“I know what art has done for me. So, I started
Field (WSF) uses metal art as a vehicle for vet- handing them the decisions on where the scales “The purpose of this isn’t to build sculptures.
erans to express and process complex thoughts go or where the feathers go on the rooster and It’s to have a conversation about the emotional
and emotions.   how to shape them. I stood in the back and I expression of the sculptures. Working on the
Spearheaded by co-founder Robert Bellows, welded while they pounded and shaped. It got sculptures is the common purpose that draws
WSF is a labor of love that was born through his to be really fun.” us together, and we keep coming back to go
own need for expression. He is not a veteran, After the sculpture was complete, the three deeper into that conversation.”
but that doesn’t mean he can’t identify with their men decided to keep going, except on a larger
demons. He can, because he’s got them too. As scale. In 2013 they invited other veterans, their Interested in Helping?
a younger man he suffered bouts of severe de- families, and civilians to the shop to embark on WSF operates on a shoestring budget, meaning
pression, which he dealt with in an unhealthy a massive metal sculpture dedicated to veterans, Bellows has a little bit of equipment, like a few
way. That is, until he discovered metal sculpture. designed by veterans, and fabricated by veterans. power sources from Miller Electric, a Power-
Bellows found that the process of expression max65® from Hypertherm, and a CNC plasma
Over the last six years more than 50 veterans
through metal sculpture was therapeutic and it table from ArcLight Dynamics. He prefers it that
from six wars, their families, and local civilians
helped fill the void. It was a chance encounter way as it allows the group to problem-solve with
have been fabricating a 16-foot-tall dragon rep-
with friends that made him realize that perhaps wit and the tools that they have.
resenting the fierce warrior, and an 18-ft.-tall
this form of expression could help others too. “I like that way of making art because it forces
phoenix—a bird of rebirth—symbolizing the
innovation and collaboration,” Bellows explained.
men and women who return home from war,
The Dragon and the Phoenix Bellows estimates another four years’ worth
fundamentally changed on the battlefield and
Six years ago two of Bellows’ friends, Brad Gallup of work before the sculptures are complete.
seeking restoration. Locked in an eternal stare
(U.S. Air Force) and Danny Moore (U.S. Army)— That means fours years of procuring materials,
down, the space between the two mythological
both Iraq War veterans—showed up at his shop. PPE, consumables, and machine use that must
At the time, Bellows was working on a rooster creatures is the “story field” that represents the
be taken into consideration.
sculpture, and both Gallup and Moore asked if soul. When the sculptures are complete, Bellows
“We go through consumables like crazy. We
they could help him out. said he hopes they will be on permanent display
destroy gloves. In fact, I’ve never met a hot place
in a local Colorado park.
you couldn’t put a glove. We destroy face shields
The Process of Art as well. It happens.”
One of the challenges of opening his fab shop to Bellows said simple $10 donations are huge in
people who have no experience with metalwork- allowing this project to continue.
ing is teaching them how to do it safely. But af- If you’d like to learn more about Warrior
StoryField, find out how you can help, or donate
ter that the focus isn’t on perfection, it’s on the
process. He uses sensation and sound to teach to the project, visit www.warriorstoryfield.org.
the welding component and claims that tactic
Ann Thompson is marketing specialist at Hypertherm Inc.,
allows him to “get someone welding a pretty
800-643-0030, [email protected].
damn good bead in about 10 minutes.”
Contributing Editor Amanda Carlson can be reached at
“That doesn’t mean they don’t get air into the [email protected].
weld or burn the tip shut. We go through a lot of
tips!” Bellows laughed. 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
» Over the last six years more than 50 veterans from While Bellows hasn’t officially set a limit on those who qualify and who are involved in metal fabricating; sub­scription to all others
six wars, their families, and local civilians have been how many people he can accommodate at one
is $75.00 per year. Inter­national subscription is $140.00 per year. Periodical postage
paid at Elgin, Illinois, and additional mailing offices. POSTMASTER: Send address
fabricating a 16-foot-tall dragon and an 18-ft.-tall change to 2135 Point Blvd, Elgin, Illinois 60123. Printed in the U.S.A. ©Copy­right 2019 by
phoenix. When finished, they hope to put it on display in time, he finds that the fewer people there are, FMA Communications Inc. Repro­duction in whole or in part without written permission
of the publisher is pro­hibited.
a Colorado park. the better.
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