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March 2020
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March2020
a trend publication  Volume 17 Number 3
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16
Special report
Stamper supports smart mobility solutions by staying grounded with a stringent, quality controlled supply chain
Flight plan
laser technology
Two very different companies find the best way to combat secondary processing
Smooth Ride
Feasibility
Remove Rework
Point & Click
Good Form
Full Access
Constant Cut
features
Press Brake/Tooling
Fast, accurate bending software saves fabricator time and money on the production floor
Stamping/Presses
Pure physics provides manufacturers with a faster, cheaper, smarter way to shape metal
Waterjet Cutting
Wheelchair base manufacturer relies on garnet abrasive that cuts reliably and fast
Sawing/Cutting
A Midwestern steel fabricator relies on tried-and-true results
features
Feasibility
Press Brake/Tooling
Fast, accurate bending software saves fabricator time and money on the production floor
Good Form
Stamping/Presses
Pure physics provides manufacturers with a faster, cheaper, smarter way to shape metal
Full Access
Waterjet Cutting
Wheelchair base manufacturer relies on garnet abrasive that cuts reliably and fast
Constant Cut
Sawing/Cutting
A Midwestern steel fabricator relies on tried-and-true results
find even more metal fabricating & forming content online
Minimal Complexity sculpture by VLAD TENU
/aluminum
car bodies after welding
/welding
Manufacturer using DELMIAWORKS’ (IQMS) ERP software
/software
Online
Features
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/aluminum
The Minimal Complexity sculpture was developed out of the desire to create a minimal surface structure using modular construction
ffjournal.net
/welding
Advances in fiber laser technology improve aluminum welding
ffjournal.net
/software
Software helps fabricators adapt to the ebb and flow of industrial trends
Man welding
welder
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Grand Rapids CC gets second grant from Metallica to train students
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Researchers find copper to be the perfect match to significantly improve 3D printing of titanium
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Lynn Stanley headshot

From the
Senior Editor

Lynn Stanley

Sky Bound

I

saw my first flying car in 1962 when The Jetsons hit broadcast television. I was four years old and there were just three networks and 51 shows. Our “tube,” as my Dad called it, was black and white but it didn’t diminish my fascination with the Jetson family’s daily life—which included videophones, conveyor belt sidewalks, robot servants and the FX-Atmos. The flying car sported a glass bubble canopy, dashboard radar screen and tail fins and folded up into a briefcase light enough for George Jetson to carry into his office.

In 1966, I went to outer space with the crew of the starship Enterprise. Star Trek, with its ability to cross galaxies at warp drive and beam personnel to different locations via transporters, is still considered one of the most influential science fiction series in TV history. In 1977, a year after I graduated high school, Star Wars hit the big screen. Cloud cars, air speeders, light sabers and the Force, the source of a Jedi’s power, took my imagination in a different direction.

Guest Editorial
By Mario Davila, product manager, Norton | Saint-Gobain Abrasives
abrasives and resin technologies
Remove rework
Engineered abrasives and resin technologies improve productivity and parts finish
I

n today’s metalworking and steel fabrication markets, companies must use efficient manufacturing technologies in order to drive down costs and improve productivity. Achieving a competitive advantage amid domestic and international challenges is critical. Manufacturers continue to demand higher quality and craftsmanship from discretionary technical/consumable products and, at the same time, seek lower pricing.

However, when faced with the challenge of correctly identifying improvement initiatives, and/or bottlenecks in an operation, companies must often examine the effectiveness of their skilled workers. This poses the question of how to improve current manufacturing methods and measure processes when productivity is still largely influenced by operators.

Face Time
BY LAUREN DUENSING, CONTRIBUTING EDITOR
KMT’s heavy-duty H7-SA, H8-SA and H12-SA are used to cut structural steel.
KMT’s heavy-duty H7-SA, H8-SA and H12-SA are used to cut structural steel.
Point & click
An open-at-all-hours website is a crucial sales partner
Kalamazoo Machine Tool has been producing circular saws and bandsaws since 1986. General Manager Lee Larson has been working with his father at the company since high school. Knowing that a majority of customers tend to research online before making a purchase, Larson is ensuring that KMT is poised to answer their questions.
Q:
Are people shopping for equipment differently today?
A: When people want information, they want it now. They don’t want to wait and call to talk to somebody or wait for an email back. Two years ago, I updated KMT’s website to more of an e-commerce-type website. Recently, I had a customer who purchased a saw using his iPad on the beach in Hawaii over the Christmas holiday because our website was able to answer all his questions.
Toolbox
X Series markers Design
Dot peen markers streamline operations
The design of X Series markers helps boost performance for the most demanding applications. The cantilevered marking head provides a clear open line of sight while the retracting to clear other tooling and equipment. Up to 6 axes are motion control ready and no PC or control box is required. For custom integration with logic, additional I/O is available.

Kwik Mark Inc., McHenry, Illinois, 815/363-8268, www.kwikmark.com.

Abrasive wheels
Abrasive wheels for pipe welding
Velocity Pipeliner is a wheel designed to withstand the pressures of pipe beveling, smoothing flame-cut edges and root pass grinding. The premium grain and hard bond blend give Velocity long life and excellent wheel performance on stainless steel and high tensile alloys. A ¼-in.-thick version, Velocity Grinding Wheel, is available for general fabrication applications such as heavy weld grinding, beveling hard steels, grinding casting parting lines or removing weld deposits. The Velocity Grinding Wheel has maximum stock removal rate balanced with extended wheel life on stainless steel and ferrous metals.

Rex-Cut Abrasives, Fall River, Massachusetts, 800/225-8182, www.rexcut.com.

What’s Happening
Reshoring Initiative wins award
Reshoring Initiative wins national award
Harry Moser and the Reshoring Initiative team received the Made in America 2019 Reshoring Award during a four-day event, whose mission was to raise awareness for the economic, environmental and community impact of American-made manufacturers and brands. The Reshoring Initiative tracks and drives the reshoring and foreign direct investment trends.
Eye on People
Frank Klingemann Headshot
Frank Klingemann
Schuler adds die/press manager
Frank Klingemann was appointed to manage the Industry division at Schuler, overseeing the automated mechanical ProgDie and transfer presses. An engineer, Klingemann has 30 years of experience, including with Kuka and HLS Engineering Group GmbH.
Special Report
By Lynn Stanley, Senior Editor
Through the partnership with Uber, we will harness Hyundai’s businesses and technologies to deliver true freedom of mobility.
Euisun Chung, Hyundai Motor Group
Euisun Chung, left, executive vice chairman of Hyundai Motor Group and Dara Khosrowshahi, CEO of Uber, announced a partnership to launch a fleet of flying taxis during the 2020 Consumer Electronics Show.
stamper supports smart mobility solutions by staying grounded with a stringent, quality controlled supply chain

A

long time ago in a galaxy far, far away,” there were airspeeders. The repulsorlift vehicles—featured in the iconic Star Wars franchise created by George Lucas—used skylanes to move in and out of dense traffic and maneuver between towering buildings on urban planets like Coruscant.

The idea of people traveling highways in the sky is no longer fodder for science fiction and fantasy. On Jan. 6, 2020 Uber and Hyundai Motor Co. announced a new partnership to develop Uber air taxis for a future aerial ride share network at the Consumer Electronics Show (CES) 2020 in Las Vegas. As part of the media event, Hyundai unveiled its S-A1 prototype. The automaker will produce and deploy the all-electric personal air vehicles (PAV), and Uber will provide airspace support services, connections to ground transportation and a ridesharing app called uberAIR.

A

long time ago in a galaxy far, far away,” there were airspeeders. The repulsorlift vehicles—featured in the iconic Star Wars franchise created by George Lucas—used skylanes to move in and out of dense traffic and maneuver between towering buildings on urban planets like Coruscant.

The idea of people traveling highways in the sky is no longer fodder for science fiction and fantasy. On Jan. 6, 2020 Uber and Hyundai Motor Co. announced a new partnership to develop Uber air taxis for a future aerial ride share network at the Consumer Electronics Show (CES) 2020 in Las Vegas. As part of the media event, Hyundai unveiled its S-A1 prototype. The automaker will produce and deploy the all-electric personal air vehicles (PAV), and Uber will provide airspace support services, connections to ground transportation and a ridesharing app called uberAIR.

Laser Technology
by gretchen salois, senior editor
Elevator Interiors warehouse
the letter "e" cut out in sheet metal
Elevator Interiors previously cut sheet metal using a punch and shear, which was time consuming.
Smooth ride
Two very different companies find the best way to combat secondary processing
E

ach time you step onto an elevator or board a bus, there’s a level of trust the rider imparts to those who designed and built each mode of movement.

In Syracuse, New York, Elevator Interiors Inc.’s owner, Joe Piepho, found his operations were hindered by other people’s schedules. Rather than farm out cutting jobs, Piepho began to hunt for equipment that would give the elevator parts manufacturer the ability to cut components efficiently and cleanly in house.

Press Brake/Tooling
BY Lynn Stanley, Senior Editor
Metamation’s MetaCAM FluxBEND offline software eliminates potential design flaws and prevents errors before parts are formed.
Feasibility
Fast, accurate bending software saves fabricator time and money on the production floor
T

he 2005 film “Dreamer” was inspired by the true story of a thoroughbred racehorse that broke her leg and came back to win the Turfway Breeders’ Cup. When asked about her bold decision to nominate the filly for the race, owner Cale Crane said, “It’s a long shot … but why not Sonador? Why not us?”

Brookings, South Dakota, residents Don Deibert and Jeff Jacobson asked themselves a similar question when they couldn’t find the right job shop to produce sheet metal assemblies for their employer, a local manufacturer. After drafting a business plan, the two men formed Counterpart Inc. in 1995, and began making parts for their former employer with little more than a drill press, cold saw and ironworker.

TPMG
trend publishing
metals group
Coming in August 2020
FFJ - The Metal Fabricators Directory
Reach a print and digital audience of metal service centers, OEM/End Users, and other fabricators.
Display advertising closing: 6/26/20
Advertising material due: 7/3/20
For display advertising, contact your sales representative.
Stamping/Presses
BY Lynn Stanley, Senior Editor
Single or dual sleds can move sheet metal in and out of FluidForming’s FormBalancer, allowing one part to be removed while another is forming, increasing production speed.
Single or dual sleds can move sheet metal in and out of FluidForming’s FormBalancer, allowing one part to be removed while another is forming, increasing production speed.
Good form
Pure physics provides manufacturers with a faster, cheaper, smarter way to shape metal
M

agic is the art of illusion, aided by sleight of hand, deceptive devices and misdirection.

When it comes to fluid-formed parts, industrial users might have trouble believing what they see, but Paul Benny, CEO of FluidForming Americas, says, “There are no magic powders or mirrors. It is pure and simple physics that results in a highly repeatable, very accurate, cost-effective part.”

Founded in Hartsville, Tennessee, in 2014 as a German company’s North American subsidiary, FluidForming’s customers include Mercedes-Benz, BMW and Whirlpool Corp. Other end users run the gamut from aerospace, agricultural machinery and alternative energy to automotive and medical equipment.

Waterjet Cutting
By FFJournal Staff
AbiliTrax floor with Step-N-Lock seats “nested” together for storage to create more interior space.
Full access
Wheelchair base manufacturer relies on garnet abrasive that cuts reliably and fast
I

n Fenton Mobility Products Inc.’s world, a latch is the most critical component in seat configurations for vans and other vehicles equipped to accommodate wheelchairs. High-precision waterjet cutting with the right abrasive makes it possible to achieve the necessary quality.

Fenton Mobility Products designs and manufactures seat bases that ensure wheelchair passengers’ safety in vehicles. The bases contain the latches that attach to Fenton’s specialized AbiliTrax rail system in vehicles like the Ford Transit van, the RAM Promaster and the Mercedes Benz Sprinter. Fenton specializes in commercial applications for state agencies, public transportation and group homes where longevity, durability and versatility are of the utmost importance along with safety and comfort for passengers.

Sawing/Cutting
By Gretchen Salois, Senior Editor
The 2150A-PC3S-60 has a cutting capacity of 20 in. by 25 in. and a blade width of 1.5 in.
Constant cut
A Midwestern steel fabricator relies on tried-and-true results
F

or 16 hours a day, five days a week, Sawing and Shearing Services Inc. keeps its Amada Marvel 2150A-PC3S vertical tilt-frame saw running. The relentless pace wears on the equipment and, after years of 80-hour weeks running, it eventually is replaced in order to start the process anew.

Through the years, the machine’s controls have changed but the model’s cast iron construction remains constant. “We’ve had the 2150 since forever,” says Anthony Sambo, owner of Sawing and Shearing Services. “We just buy new models every few years. Amada Marvel takes back the old one and we don’t miss a moment.”

Custom Fabricator
Know a great CUSTOM FABRICATOR? Tell us. Email Mark Koenig at mkoenig@ffjournal.net.
The Soldiers of Sacrifice sculpture by ALFIE BRADLEY
Soldiers of Sacrifice
The Soldiers of Sacrifice sculpture by Alfie Bradley, which marked the 75th anniversary of D-Day by Alfie Bradley, is on display at The D-Day Story, Portsmouth, England. Fabricated using steel rods, steel sheet, welding wire and resin, Soldiers of Sacrifice represents Den Brotheridge, widely believed to be the first Allied serviceman to die on D-Day. The figure kneels atop 4,413 bullets, symbolizing his comrades in arms who also fell in battle. The soldier’s shape is crouched as if to throw a grenade, but instead is releasing a dove, which signifies peace and acknowledges the soldiers’ sacrifices were not in vain. “This has been such a meaningful project for me,” Bradley said. “I can’t even begin to imagine how terrifying it would’ve been to land in Normandy that day.” The more he learned during the making of the sculpture, the more he realized how grateful “we all should be” for their heroism.
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator
Photo: Steve Crawshaw
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Editorial
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Lauren Duensing
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