May 2021
trend publishing metals group  Volume 18 Number 05
May 2021
trend publishing metals group  Volume 18 Number 05
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Pulse graphic
fabricator Q&A
Whether overcoming supply chain delays or maneuvering an influx of backlogged orders flowing in, fabricators of all sizes look ahead and reflect on lessons learned
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features
Man near a machine
laser technology
Custom fabricator reflects on 15 years of business and the value of social media
Man working on machine
press brake/tooling
Crownless, servo-electronic press brake technology helps job shop save time and energy while raising throughput
features
Man near a machine
laser technology
Custom fabricator reflects on 15 years of business and the value of social media
Man working on machine
press brake/tooling
Crownless, servo-electronic press brake technology helps job shop save time and energy while raising throughput
Man setting up the machine
Man working on pipe
Hand near a cloud icon
Cutting machine manufacturer equips fabricators
bending/folding
Robotic bending cell supports domestic assembly line, helps OEM maintain growth trajectory
waterjet
Collaboration gives customers the right cutting solution along with service and support for the life of the equipment
software solutions
No longer tethered to a physical server, one metal solutions provider is the first to shift its entire operation to this cloud-based software
plasma technology
Cutting machine manufacturer equips fabricators with the right tools to reduce scrap and gain higher throughput
Man setting up the machine
bending/folding
Robotic bending cell supports domestic assembly line, helps OEM maintain growth trajectory
Man working on pipe
waterjet
Collaboration gives customers the right cutting solution along with service and support for the life of the equipment
Hand near a cloud icon
software solutions
No longer tethered to a physical server, one metal solutions provider is the first to shift its entire operation to this cloud-based software
Cutting machine manufacturer equips fabricators
plasma technology
Cutting machine manufacturer equips fabricators with the right tools to reduce scrap and gain higher throughput
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find even more metal fabricating & forming content online
custom fabricated aluminum fence
/customfabricator
two welders at work
/welding
pack of saw blades
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Online
Features
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customfabricator
Not Whole Fence is a custom fabricated aluminum homage to the simpler days of baseball
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welding
Students maneuver difficult joints with easy repositioning
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sawing
An unresponsive vendor forced one fabricator to find a new saw blade supplier
white at sign
woman welding
Facebook
Operation Next seeks to train 100 people for manufacturers in need of skilled workers
Photo: Gina Joseph – The Macomb Daily
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Instagram
@el.mago.de.oz_ working on his 5G TIG roots with @mawiiio
woman welding
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These women are changing who gets to ride
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@BicyclingMag
Photo: Natalie R. Starr
Portrait photo of Gretchen Salois

From the Editor

Gretchen Salois, Senior Editor

Onward and Upward

I

n this month’s cover story, we speak to fabricators large and small about what the last year has been like working through a pandemic and all that that entails. They discuss shifts in demand, supply chain interruptions, reluctant customers, unexpected setbacks as well as surprising benefits and takeaways to use going forward.

FACE TIME
Coworkers using a computer
Protecting Products
Softening the blows for high-end component shipping
T

he team at UFP Industrial is experienced with the industrial packing and logistics needs of dozens of industries, including agricultural, manufacturing, energy, technology and transportation. Whether it’s wood, steel, mixed materials or hard cases, the company can support any custom packaging project—from one-time applications to sustainable programs—blending functionality, durability and cost control into each solution. Todd Droze, regional sales manager, and Dave Watson, director of national sales, discussed UFP’s problem-solving process with FFJournal.

The Hot Sheet
stacked sheets of metal
Tariffs
The USITC will issue antidumping duty orders on imports from 16 countries.
fair trade
U.S. International Trade Commission finds 16 countries traded common alloy sheet imports unfairly
On March 31, 2021, the U.S. International Trade Commission (USITC) announced it had unanimously determined unfairly traded imports of common alloy aluminum sheet from 16 countries: Bahrain, Brazil, Croatia, Egypt, Germany, India, Indonesia, Italy, Oman, Romania, Serbia, Slovenia, South Africa, Spain, Taiwan and Turkey. The commission determined that these countries materially injured U.S. producers. In 2019, the value of U.S. common alloy aluminum sheet from these countries totaled approximately $2 billion.

Momentum Manufacturing Group LLC

Pulse graphic

Petty’s Welding Co. LLC

Petty’s Welding Co. LLC

ACE Metal Crafts Co.

Weldlogic Services Inc.

Fabrication q&A
By Gretchen Salois, senior editor
Pulse of the
industry
Whether overcoming supply chain delays or maneuvering an influx of backlogged orders flowing in, fabricators of all sizes look ahead and reflect on lessons learned
T

he last year has tested fabricators in numerous ways. Market uncertainty, supply chain interruptions, personnel disruptions and spiking steel prices have helped to fuel a pandemic-wrought chaos throughout the world. After steep declines in manufacturing jobs over the last year, the industry gained 53,000 jobs in March, according to the Bureau of Labor Statistics. The rise is gradual but trending upward, and fabricators are already experiencing renewed investment and customer demand. FFJournal asks fabricators employing hundreds to a 3-employee operation to discuss how they’ve coped with unexpected changes, kept their doors open, and how they plan to move forward with the wisdom gained through a difficult period.

Fabrication q&A
By Gretchen Salois, senior editor

Momentum Manufacturing Group LLC

Pulse graphic

Petty’s Welding Co. LLC

Momentum Manufacturing Group LLC

ACE Metal Crafts Co.

Weldlogic Services Inc.

Pulse of the
industry
Pulse of the
industry
Whether overcoming supply chain delays or maneuvering an influx of backlogged orders flowing in, fabricators of all sizes look ahead and reflect on lessons learned
T

he last year has tested fabricators in numerous ways. Market uncertainty, supply chain interruptions, personnel disruptions and spiking steel prices have helped to fuel a pandemic-wrought chaos throughout the world. After steep declines in manufacturing jobs over the last year, the industry gained 53,000 jobs in March, according to the Bureau of Labor Statistics. The rise is gradual but trending upward, and fabricators are already experiencing renewed investment and customer demand. FFJournal asks fabricators employing hundreds to a 3-employee operation to discuss how they’ve coped with unexpected changes, kept their doors open, and how they plan to move forward with the wisdom gained through a difficult period.

laser technology
By Gretchen Salois, Senior Editor
Online orders kept Foster Weld’s SmartShop | FC fiber optic laser from Laguna Tools busy during a tumultuous 2020.
Online orders kept Foster Weld’s SmartShop | FC fiber optic laser from Laguna Tools busy during a tumultuous 2020.
Bright lights
Custom fabricator reflects on 15 years of business and the value of social media
C

hris Foster is used to a challenge. What started as a two-person fabrication shop in his garage has transformed into a 5,000-sq.-ft. facility in Garden City, Idaho. Foster Weld began fabricating custom-made metal belt buckles, custom furniture and signage nearly 15 years ago. “We were small and hustling the first few years. [The business] began with my wife and I selling belt buckles on Etsy just as the handmade movement started becoming popular,” says Foster. “Then we started offering custom marquee lighted signage for small businesses and restaurants.

PRESS BRAKE/TOOLING
BY LYNN STANLEY, SENIOR EDITOR
It takes quality equipment to do quality work.
John Martin,
Southwest Welding LLC
More for Less
Crownless, servo-electronic press brake technology helps job shop save time and energy while raising throughput
S

outhwest Welding LLC took root in Wakarusa, Indiana, in 1985 under the skillful hands of owner John Martin. The fabricator learned to weld as a teenager under his Uncle Ray’s careful instruction. “A little 1,500-sq.-ft. shop became available, and I took it,” he recalls. “I moonlighted the first six years before I was able to quit my day job and take the business full time in 1991.”

Bending/Folding
BY LYNN STANLEY, SENIOR EDITOR
Shouldering the load
The versatile Dyna-Cell can automate bending operations or allow the press brake to be used in manual mode.
Robotic bending cell supports domestic assembly line, helps OEM maintain growth trajectory
K

urt Schie started WoodMaxx Power Equipment Ltd. in 2008 after his search for a compact PTO chipper robust enough to clear multi-acre lots proved futile. The Army infantry veteran filled the market gap by designing and building the first Hydrostatic Auto-Feed PTO wood chipper in 2015. WoodMaxx outsourced parts for the product at first. Its success soon led the Akron, New York, company to add PTO backhoes, snow blowers, flail mowers and rotary tillers as well as skid steer mounted snow blowers, wood chippers and stump grinders.

The versatile Dyna-Cell can automate bending operations or allow the press brake to be used in manual mode
The versatile Dyna-Cell can automate bending operations or allow the press brake to be used in manual mode.
Robotic bending cell supports domestic assembly line, helps OEM maintain growth trajectory
K

urt Schie started WoodMaxx Power Equipment Ltd. in 2008 after his search for a compact PTO chipper robust enough to clear multi-acre lots proved futile. The Army infantry veteran filled the market gap by designing and building the first Hydrostatic Auto-Feed PTO wood chipper in 2015. WoodMaxx outsourced parts for the product at first. Its success soon led the Akron, New York, company to add PTO backhoes, snow blowers, flail mowers and rotary tillers as well as skid steer mounted snow blowers, wood chippers and stump grinders.

Production Manager Tucker Smart was tasked to bring production for the PTO chipper in house and set up a domestic assembly line. It was a “huge undertaking,” he says. “In the beginning, I handled everything from purchasing, programming, running cutting and bending operations, and overseeing the assembly line. I was running from one job to the next. If I had some help, we were processing 24,000 lbs. of steel a day. If I was running the line by myself, I was cutting and forming 8,000 lbs. of steel per day.”

Waterjet
By Lynn Stanley, Senior Editor
MultiCam installed its 14,000th CNC machine
MultiCam installed its 14,000th CNC machine—a 3000 series waterjet paired with KMT pump—at Scott and Holly Kimbrell’s company, Kimbrell’s Kustom Machine Shop Inc.
Symbiosis
Collaboration gives customers the right cutting solution along with service and support for the life of the equipment
H

umans breathe oxygen produced by plants and exhale carbon dioxide. Plants use the carbon dioxide to create oxygen. The link between humans and plants is an example of mutualistic symbiosis—where different species benefit from a relationship with one another.

SOFTWARE SOLUTIONS
BY GRETCHEN SALOIS, SENIOR EDITOR
In the Cloud
No longer tethered to a physical server, one metal solutions provider is the first to shift its entire operation to this cloud-based software
In the Cloud
No longer tethered to a physical server, one metal solutions provider is the first to shift its entire operation to this cloud-based software
W

hen COVID-19 hit, Kloeckner Metals UK became the first SigmaNEST customer to switch its entire operation to a completely cloud-based infrastructure, and the change has proven to be invaluable. In 2020, fabricators of all sizes were forced to adapt to a world in shutdown. Many businesses scrambled to establish remote options for employees while others were more prepared with remote desktop or similar applications to continue operations away from the job site. But a full-cloud solution, which includes both the company and clients in the cloud, can be accessed anywhere with little to no latency.

PLASMA TECHNOLOGY
By Lynn Stanley, Senior Editor
Plasma Systems engineers its machines to cut shapes out of plate with superior hole and beveling technology.
Stay the Course
Cutting machine manufacturer equips fabricators with the right tools to reduce scrap and gain higher throughput
B

udding music artists are often cautioned about the importance of knowing their niche—their selling point. It’s advice that America’s Got Talent judge Simon Cowell gave to a 15-year-old country singer from Utah during the show’s 2020 season when he said, “I love artists who know what kind of lane they want to go down.”

Richard Keeton, president of Houston-based Plasma Systems Inc., learned the value of staying in his lane when he identified a niche and nurtured it. This year, the company celebrates its 30th anniversary.

Toolbox
A welder using a MIG gun
welding
MIG gun for aluminum applications

To improve performance and productivity in MIG and pulsed MIG aluminum welding applications, or when feeding wire long distances and around obstacles, Tweco, an ESAB brand, has launched the PullMaster2 push-pull MIG gun. The updated version of this pistol-grip-style gun improves ergonomics through an angled cable-to-gun connection combined with a ball-and-socket strain relief that enhances balance and reduces perceived cable weight. The easy-to-grip handle features a short-stroke trigger for easier activation, while an aluminum unibody reduces parts for greater reliability, easier repair and weight reduction.

Tweco/ESAB, Florence, South Carolina, 843/669-4411, esabna.com.

Custom Fabricator
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
Atmospheric Wave Wall

Motion is the central principle behind this public artwork, planned especially for Chicago’s Willis Tower. The dynamic pattern on the wall is activated by the motion of people walking, driving or biking past; by the motion of the Earth in relation to the sun as light moves across it; and by changes in the season and weather. Viewing the work from various positions and at various times of day produces a dramatically different experience. The artwork, designed by artist Olafur Eliasson, covers the wall with a pattern of powder coated steel tiles based on Penrose tiling. Discovered by mathematician and physicist Sir Roger Penrose in the 1970s, this approach produces a system of non-periodic tiling that is based on five-fold symmetry. Each tile is curved, a fragment of the inner surface of a sphere, and the main tones used in the work—blue, deep green, and white—are redolent of the surfaces of nearby Lake Michigan and the Chicago River. The massive piece measures roughly 30 ft. by 60 ft. and covers the exterior wall with a pattern of 1,963 tiles.

Photo: Darris Lee Harris/EQ Office
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Michael D’Alexander

Editorial
Senior Editor

Lynn Stanley

Senior Editor

Gretchen Salois

Senior Contributing Editor

J. Neiland Pennington

Contributing Editor

Lauren Duensing

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FFJOURNAL® (ISSN 1551-1006) MAY 2021 (Vol. 18, No. 5) is a registered trademark of Trend Publishing Inc. FFJOURNAL® is published 11 times by Trend Publishing Inc., with its publishing office located at 123 W. Madison St., Suite 950, Chicago, Illinois 60602, 312/654-2300; fax 312/654-2323. Michael D’Alexander, President, Trend Publishing Inc. Copyright 2021 Trend Publishing Inc. All rights reserved under the United States, International and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means—mechanical, photocopying, electronic recording or otherwise—without the prior written permission of Trend Publishing Inc. Opinions expressed in articles are those of the authors and do not necessarily reflect those of Trend Publishing Inc. Published free of charge for those who qualify. It is mailed at no cost to these qualified readers in the U.S., Canada and U.S. possessions. Single copies $14. Paid subscriptions in the U.S., $120/year. Canada, $140/year. Foreign subscriptions, $175/year surface mail and $255/year air mail. For subscription information, go to www.ffjournal.net or call 312-654-2300. Periodicals postage paid at Chicago and additional mailing offices. Postmaster: Send address changes to FFJOURNAL® c/o Creative Data Services, Inc., 440 Quadrangle Drive Suite E, Bolingbrook, IL 60440. Printed in the USA.
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