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Cover Story
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Cover Story
Stories Titles
December 2020
December2020
a trend publication  Volume 17 Number 11
FF Journal logo
special projects
Massive stainless steel swimming pools are carefully planned and executed by a team of well-trained experts
man welding with New York City skyline in the background
Cover photo: Golden Dusk Photography
agriculture equipment
waterjet cutting machine
precision tooling
close up of saw blade
cnc bending technology
features
Laser Technology
Agriculture equipment manufacturer implements new fabrication equipment to cultivate growth
Waterjet Cutting
Minimal maintenance and easy learning curve prove invaluable during an uncertain economy
Press Brake Tooling
Precision tooling helps manufacturers bend abrasion-resistant steels with ease, reduce setup time to minutes
Sawing/ Cutting
Determining the right tooth count, pitch and grind make all the difference
Tube & Pipe
CNC bending technology helps fabricators bridge skills gap, opens vistas for new applications
features
agriculture equipment
Laser Technology
Agriculture equipment manufacturer implements new fabrication equipment to cultivate growth
waterjet cutting machine
Waterjet Cutting
Minimal maintenance and easy learning curve prove invaluable during an uncertain economy
precision tooling
Press Brake Tooling
Precision tooling helps manufacturers bend abrasion-resistant steels with ease, reduce setup time to minutes
close up of saw blade
Sawing/ Cutting
Determining the right tooth count, pitch and grind make all the difference
cnc bending technology
Tube & Pipe
CNC bending technology helps fabricators bridge skills gap, opens vistas for new applications
find even more metal fabricating & forming content online
metal sculpture
/customfabricator
ultra-high power fiber laser
/laser
stamped piece of metal
/stamping
Online
Features
ffjournal.net
/customfabricator
Inspiration is artist Zachary Oxman’s sculptural homage to another form of creative expression: the written word
ffjournal.net
/laser
Ultra-high power fiber laser produces a higher volume of quality parts
ffjournal.net
/stamping
Components are designed and built to withstand the toughest conditions using the latest heat treating technologies
at sign
Artist Clint George
Facebook
Artist Clint George welds oral stories into massive steel sculptures
Photo: Athena Bonneau
man torch cutting
Instagram
#torchcutting #cuttingtorch #metalworking #metalsmith #welding #weldingart #lightartist
man using a hammer for welding
Twitter
Welding classes hurt by pandemic, but are still essential
Learn more
@arcurrent
Photo: Emily Mello
Gretchen Salois Portrait

From the
Senior Editor

GRETCHEN SALOIS

Mastering logistics

F

rom its headquarters in Wilmington, North Carolina, Bradford Products fashions buildings all over the world with its meticulously designed and fabricated stainless steel swimming pools. The manufacturer has a very specific criteria for its welders. To ensure it has a sufficient talent pool, the company works with Cape Fear Community College to train welders in skills specific to Bradford.

“Wilmington is not a huge town, so word of mouth has drawn a lot of interest and brought students to the area,” says Michael Brodeur, CEO. Once hired, these welders find themselves working anywhere from deserts, the sides of mountains or rooftops on high-rise buildings.

Fabricator’s POV
BY FFJOURNAL STAFF
Technician cutting sheets of metal
With OEMs adjusting their approach during COVID-19, Metcam has filled a niche for low-volume, high-mix production.
With OEMs adjusting their approach during COVID-19, Metcam has filled a niche for low-volume, high-mix production.
Riding waves
In a sector rocked by global adversity, small is now big, and short could go a long way
T

he trade war and COVID-19 pandemic have sent huge shock waves into the U.S. economy and manufacturing, but original equipment manufacturers are playing small ball by looking to shorten supply chains, as well as reduce processing runs and inventory—the little things that could add up in the long run.

“Even prior to COVID-19, there was an emerging trend to bring manufacturing back to this country,” says John Mazurek, director of sales and marketing for Metcam, the 2018 Georgia Manufacturer of the Year. “Based on the impetus of what the current administration was doing, far more people were looking to repatriate business here. COVID has sped that up dramatically.”

Toolbox
Flap disc provides high cut-rate
Tiger Aluminum flap discs feature a paired flap design for grinding aluminum. The top flap has a coating that prevents loading, provides a high cut-rate and eliminates the need to apply wax or lubricant. Alternating flaps of self-sharpening zirconia aluminum grains offer aggressive material removal. The combination ensures high performance.

Weiler Abrasives, Cresco, Pennsylvania, 570/595-7495, weilerabrasives.com.

What’s Happening
Master Fluid Solutions cap closeup
Line resists corrosion, is eco-friendly
Master Fluid Solutions, Perrysburg, Ohio, launched the WEDOLiT brand in North America. WEDOLiT products offer short- and long-term corrosion protection, super-fast dewatering products, and VOC-free products that are environmentally responsible. The WEDOLiT range is suited for cold forming and tube and pipe manufacturing applications.
Master Fluid Solutions cap closeup
Eye on People
Kellye Walker headshot

Kellye L. Walker

Lincoln expands board

Lincoln Electric Holdings Inc., Cleveland, elected Kellye L. Walker, executive vice president and chief legal officer of Eastman Chemical Co., to its board of directors. Walker was appointed to serve on the Nominating and Corporate Governance and the Compensation and Executive Development Committees. Walker’s appointment expands Lincoln Electric’s Board to 12 directors, 11 of whom are non-employee directors.

Craning in the first of two 65-ft.-long pool sections at a luxury residential tower in New York City.
Header
Title of article
Massive stainless steel swimming pools are carefully planned and executed by a team of well-trained experts

ithin the concrete monoliths in New York City lie pockets of respite in the forms of spas and swimming pools. Behind each high-rise oasis lies a long timeline of planning by architects, designers, engineers, fabricators and construction crews that take an idea and figure out the logistics behind making it a reality. At Bradford Products, stainless steel is used to create lighter, stronger and sleeker swimming pool designs, where fabricators bring architects’ visions to reality.

Header
Title of article
Craning in the first of two 65-ft.-long pool sections at a luxury residential tower in New York City.
Massive stainless steel swimming pools are carefully planned and executed by a team of well-trained experts

ithin the concrete monoliths in New York City lie pockets of respite in the forms of spas and swimming pools. Behind each high-rise oasis lies a long timeline of planning by architects, designers, engineers, fabricators and construction crews that take an idea and figure out the logistics behind making it a reality. At Bradford Products, stainless steel is used to create lighter, stronger and sleeker swimming pool designs, where fabricators bring architects’ visions to reality.

Laser Technology 
By Kaylee Swearingen, Mazak Optonics Corp.
Tilling
new

ground

Mazak’s OptiPlex Fiber III 10 kW fiber laser allowed Orthman Manufacturing to cut parts for equipment like its patented 1tRIPr strip tillage system in house.
Mazak’s OptiPlex Fiber III 10 kW fiber laser allowed Orthman Manufacturing to cut parts for equipment like its patented 1tRIPr strip tillage system in house.
Tilling
new

ground

Mazak’s OptiPlex Fiber III 10 kW fiber laser allowed Orthman Manufacturing to cut parts for equipment like its patented 1tRIPr strip tillage system in house.
Tilling
new

ground

Agriculture equipment manufacturer implements new fabrication equipment to cultivate growth

N

ecessity is the mother of invention.” This proverb is an apt description of Orthman Manufacturing Inc. The Lexington, Nebraska, company has a string of inventions under its belt including its 1tRIPr strip-tillage system, which allows farmers to perform ideal seedbed preparation, precision nutrient placement and optimal root zone conditioning in one pass. Today, the company produces a range of agricultural equipment for OEMs like John Deere, as well as conveying systems for the food, chemical, power and manufacturing industries.

Waterjet Cutting
BY GRETCHEN SALOIS, SENIOR EDITOR
Nanticoke uses its Techni waterjet to cut everything from metal, thermo plastics and upholstery.
Techni waterjet systems
Nanticoke uses its Techni waterjet to cut everything from metal, thermo plastics and upholstery.
Adapt & Go
Minimal maintenance and easy learning curve prove invaluable during an uncertain economy
A

s a fourth grader, Brent Huey spent his days after school at his father’s job shop. Since then, he’s taken over operations at family-run Nanticoke Consulting Inc., Houston, Delaware, serving the manufacturing, aerospace, medical and equipment sectors.

To become more versatile and cut more materials, Nanticoke invested in a TJ4000-X3 waterjet from Techni Waterjet. “We needed a [machine] that could cut everything from metal to thermo plastics to upholstery,” says Huey. “The Techni can run up to 8-in.-thick materials so being a job shop, we knew this would help us meet customer demand.”

Press Brake Tooling
BY JULIO ALCACER, ROLLERI USA
Warding
off wear
Precision tooling helps manufacturers bend abrasion-resistant steels with ease, reduce setup time to minutes
Warding
off wear
Precision tooling helps manufacturers bend abrasion-resistant steels with ease, reduce setup time to minutes
Metal contraption interlocking
Rolleri’s patented Vario adjustable V-die has been designed to handle bending operations for tough materials like abrasive steels.
Rolleri’s patented Vario adjustable V-die has been designed to handle bending operations for tough materials like abrasive steels.
T

he sheet metal fabrication industry has used abrasion-resistant (AR) steels for almost two decades. The material is coveted primarily for its durability and resistance to wear. Understanding AR steels and what it takes to form them is critical for fabricators that want to use these alloys. Precision press brake tooling manufacturer Rolleri S.p.A., Vigolzone Italy, has designed and built precision press brake tooling since 1987. Offering a wide range of products and services for the sheet metal industry, Rolleri has 17 branches worldwide, including one in Avon, Ohio, opened in 2014.

Sawing/Cutting
By Gretchen Salois, Senior Editor
Maintain optimum cutting rates by working with all facets of production. This blade used an excessive feed rate, causing chips to build up in the gullets.
Race to the FINISH
Determining the right tooth count, pitch and grind make all the difference
I

n Indianapolis, A.E.D. Motorsport Products is hard at work in the racing offseason. Pandemic or not, the hot rod and street performance business has been strong. “We process hundreds of suspension members for UPR Products (racing accessories),” says Al Lowe, owner.

A.E.D.’s workload varies from short-run cutting for packaging purposes, to high-volume orders. The company distributes finished metal products globally to the automotive performance, aviation and aerospace industries, performing cutting, profiling and end finishing. Its sister business, Boyce Industries, produces frame rails for companies such as Checkered Racing and Competition Engineering.

Tube & Pipe
By Lynn Stanley, senior editor
CML’s CNC mandrel bending machines, like the Erco 65 CNC 3V1, can process ferrous and nonferrous material including high tensile strength Grade B carbon steel.
Affordable efficiency
CNC bending technology helps fabricators bridge skills gap, opens vistas for new applications
W

hen it comes to tube bending, the process is “still a bit of a mystery to a lot of fabricators,” CML USA Inc. General Manager Scott Tunis says. Bending tube is necessary for a broad range of applications from automotive, aerospace and shipbuilding to handrails, wheelchairs and amusement rides. Yet despite its expansive reach, Tunis says manufacturers tend to see the technology as a niche market.

“When people hear the phrase tube bender, they typically think in terms of round tubing,” Tunis adds. “But the uses for equipment like our Erco 65 CNC 3V1 Mandrel Bender are so diverse that we are still discovering new applications.”

Custom Fabricator
Know a great CUSTOM FABRICATOR? Tell us. Email Mark Koenig at mkoenig@ffjournal.net.
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
BMW R80 ESG 649
Polish custom shop Eastern Spirit Garage, under the leadership of Sylwester Mateusiak, took a 1993 BMW R80 ESG 649 that was missing a number of key components and turned it into something radical—three bikes in one. To make that happen, ESG retrofitted the motorcycle with a modular design that would allow the rider to easily reconfigure it in several different ways. The restomod was commissioned by a Warsaw-based collector named Marcin. The collector wanted a modular café racer with removable fairings and a swappable seat, but was had enough height for a 6-ft., 5-in.-tall rider, according to Bike Exif. “At the beginning, I created a fairly long tank, then other body parts, a front lamp, fenders, tail, upper fairing, side fairings, all made of [hand-wheeled] aluminum,” Mateusiak said in an interview with Motogen.pl. “I built the whole thing so that you can quickly and easily assemble these elements into various configurations, while maintaining full technical functionality and the ability to drive.” In the end, Eastern Spirit Garage created something more than just a perfect café racer. “This was by far the hardest project I have ever undertaken,” said Mateusiak.
Sylwester Mateusiak's Motorcycle Side View
Sylwester Mateusiak's Motorcycle re-modeled
Photos: Eastern Spirit Garage
Zachary Oxman and sculpture
BMW R80 ESG 649
Polish custom shop Eastern Spirit Garage, under the leadership of Sylwester Mateusiak, took a 1993 BMW R80 ESG 649 that was missing a number of key components and turned it into something radical—three bikes in one. To make that happen, ESG retrofitted the motorcycle with a modular design that would allow the rider to easily reconfigure it in several different ways. The restomod was commissioned by a Warsaw-based collector named Marcin. The collector wanted a modular café racer with removable fairings and a swappable seat, but was had enough height for a 6-ft., 5-in.-tall rider, according to Bike Exif. “At the beginning, I created a fairly long tank, then other body parts, a front lamp, fenders, tail, upper fairing, side fairings, all made of [hand-wheeled] aluminum,” Mateusiak said in an interview with Motogen.pl. “I built the whole thing so that you can quickly and easily assemble these elements into various configurations, while maintaining full technical functionality and the ability to drive.” In the end, Eastern Spirit Garage created something more than just a perfect café racer. “This was by far the hardest project I have ever undertaken,” said Mateusiak.
Sylwester Mateusiak's Motorcycle Side View
Sylwester Mateusiak's Motorcycle re-modeled
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
Photos: Eastern Spirit Garage
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FFJOURNAL® (ISSN 1551-1006) December 2020 (Vol. 17, No. 11) 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 2020 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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