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March 2021
March 2021
trend publishing metals group  Volume 18 Number 03
March 2021
trend publishing metals group  Volume 18 Number 03
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The magazine for today’s metal
fabricating & forming technologies
metrology
Model-based metrology has evolved, allowing fabricators unprecedented measurement capabilities
The Virtual Trade
A two-month-long product and video demonstration showcase designed to present virtual exhibitors to fabricators, OEM/end-users, metal service centers and metal producers
features
Warehouse
laser technology
Manufacturer fuels growth with greater cutting capacity, automation and open architecture software
Steel
Machine
Caliber
Belt
press brakes/tooling
Tooling technology helps company bend abrasion-resistant steel while avoiding pitfalls like cracking
punching/drilling
Thermal drilling technology allows fabricators to produce their own inserts out of a part’s material for a bevy of benefits
tube & pipe
Size matters when fabricator invests in its largest cutting installation yet
deburring/finishing
Extra width and one-pass edge finish enables one fabricator to avoid process holdups
Steel
press brakes/tooling
Tooling technology helps company bend abrasion-resistant steel while avoiding pitfalls like cracking
Machine
punching/drilling
Thermal drilling technology allows fabricators to produce their own inserts out of a part’s material for a bevy of benefits
Caliber
tube & pipe
Size matters when fabricator invests in its largest cutting installation yet
Belt
deburring/finishing
Extra width and one-pass edge finish enables one fabricator to avoid process holdups
salvagnini | technology solutions
Salvagnini panel benders are lean, flexible and configurable for part processing.
Using an effective DFM strategy can not only improve your current production output but also set you up for a successful growth path in the future.
Salvagnini panel benders are lean, flexible and configurable for part processing.
Using an effective DFM strategy can not only improve your current production output but also set you up for a successful growth path in the future.
Could progress be as simple as smart part redesign?
Fabricators are looking for solutions to help them thrive in a digital industry, but disrupters like IIoT and the pandemic have complicated the path to sustainable production. Customer expectations for speed to market, cost and quality have also escalated, along with demands for adding value downstream. Balancing these tasks against the need to earn revenue and position production lines for future profitability is another challenge facing companies.
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From the Editor

GRETCHEN SALOIS, SENIOR EDITOR
Clear connection
T

he global Industry 4.0 market was estimated at $70 billion in 2019 and is expected to reach $210 billion by 2026, according to a Facts and Factors research report.

The ability to point and click in order to inspect parts, reverse engineer out-of-production parts, and collect data for assembly guidance and best fit analysis is increasingly valuable to shops in search of ways to gain an edge within the industry. Software can make current processes run smoother while leaving the possibility to grow and evolve as customer demand changes.

Guest Editorial
By Paxton Shantz, Beckhoff Automation LLC
View of and open-architecture IIoT system
An open-architecture IIoT system can help fabricators correctly prioritize immediate production gains and waste reduction.
Don’t wait to implement IIoT
A

s we begin the process of recovering from the pandemic, a key component for domestic manufacturing is our ability to embrace and harness the power of the Industrial Internet of Things (IIoT) and integrated systems. Although the terms are familiar, I see too much misinformation that overcomplicates these ideas and their implementation.

The Hot Sheet
PAC-CLAD high polish steel tiles on house facade
stainless steel
PAC-CLAD’s high-polish finish gives the steel tiles the look of glass block.
Make It Metal
Corrosion-resistant alloy mimics glass in architectural application
A new home in rural Pennsylvania is attracting attention with cupped stainless steel tiles that were used on the structure’s oversized entrance and as an accent wall. A high-polish finish gives the material the look of glass block. The cupped tile catches light from multiple angles and creates a strong contrast with matte steel roofing panels—both products from Petersen, which manufactures PAC-CLAD metal cladding. In all, 1,500 sq. ft. of the 26-gauge tile from Petersen’s line of Precision Series Tiles were used in a bright annealed finish, along with 17,000 sq. ft. of Snap-Clad 24-gauge roof panels in weathered zinc. The metal tiles offer an alternative to roll-formed panel-style cladding.
metrology
By Nick Merrell, Verisurf Software Inc.
The powerful SpaceX Falcon 9 rocket relies on Verisurf model-based metrology software for final assembly guidance to align rocket components, ensuring a straight shot.
Close the
Digital Loop
Model-based metrology has evolved, allowing fabricators unprecedented measurement capabilities
The powerful SpaceX Falcon 9 rocket relies on Verisurf model-based metrology software for final assembly guidance to align rocket components, ensuring a straight shot.
Close the
Digital Loop
Close the
Digital Loop
Model-based metrology has evolved, allowing fabricators unprecedented measurement capabilities
Photo: SpaceX
I

n today’s integrated shop floor environment, the lines between dedicated fabrication shops versus machine shops have become blurred. Customer demand for higher value from supply chain partners has prompted companies to expand their scope of services. There is also a greater emphasis on shortening overall manufacturing processes for parts and time to market.

A digital thread connects the development and management of a product’s entire life cycle into a single database. More customers are demanding Industry 4.0 levels of digital documentation across finished assemblies and parts, whether fabricated or machined, because they can. Metrology software and measurement devices have evolved and adapted to the point where 100 percent inspection is now routine. Today’s fabricators can meet Industry 4.0 expectations by implementing a digital model-based metrology strategy.

VTS2 – The Virtual Trade Show Exhibitor Guide
Live February 1 – March 31 at www.vts-thevirtualtradeshow.com
Tradeshow globe illustration
VTS2 – The Virtual Trade Show Exhibitor Guide
Live February 1 – March 31 at www.vts-thevirtualtradeshow.com
Tradeshow globe illustration
Abrasives: Gemtex Abrasives QR Code
ABRASIVES
Gemtex Abrasives: Trim-Kut® abrasive discs
Gemtex Abrasives: Flaptec - Premium zirconia and ceramic flap discs QR Code
ABRASIVES
Gemtex Abrasives: Flaptec – Premium zirconia and ceramic flap discs
LVD North America: Dyna-Cell QR Code
BENDING
LVD North America: Dyna-Cell
Salvagnini America Inc.: P2 Lean panel bender
BENDING
Salvagnini America Inc.: P2 Lean panel bender
Braner USA Inc.: CTL/Multi-Blanking Lines
COIL PROCESSING
Braner USA Inc.: CTL/Multi-Blanking Lines
Braner USA Inc.: Automatic CNC Slitter Rubber Stripper Ring Grinder
COIL PROCESSING
Braner USA Inc.: Automatic CNC Slitter Rubber Stripper Ring Grinder
Butech Bliss: Push-Pull Pickling Line
COIL PROCESSING
Butech Bliss: Push-Pull Pickling Line
Butech Bliss: Stretch Leveling Lines
COIL PROCESSING
Butech Bliss: Stretch Leveling Lines
Red Bud Industries: Slitting Lines
COIL PROCESSING
Red Bud Industries: Slitting Lines
Red Bud Industries: Stretchers & Stretcher Retrofits
COIL PROCESSING
Red Bud Industries: Stretchers & Stretcher Retrofits
Delta Computer Systems: RMC Motion Controllers
CONTROLS & SOFTWARE
Delta Computer Systems: RMC Motion Controllers
Steel Storage Systems Inc.: Conveyor systems
CONVEYOR SYSTEMS
Steel Storage Systems Inc.: Conveyor systems
Lissmac Corp.: SBM L G1S2 1500
DEBURRING
Lissmac Corp.: SBM L G1S2 1500
Lissmac Corp.: SBM XL G2S2 1500
DEBURRING
Lissmac Corp.: SBM XL G2S2 1500
Mid Atlantic Global: FINISHLINE metal finishing machine
DEBURRING
Mid Atlantic Global: FINISHLINE metal finishing machine
Folding: MetalForming, Inc.: EVO CENTER QR Code
FOLDING

MetalForming, Inc.: EVO CENTER

Trend Publishing Metals Group: MetalsAndMetalworkingSearch.com
INDUSTRY SEARCH ENGINE

Trend Publishing Metals Group: MetalsAndMetalworkingSearch.com

Ironworker: Scotchman Industries: Models available from 45 to 150 tons in three styles
IRONWORKER
Scotchman Industries: Models available from 45 to 150 tons in three styles
SUNRISE Ironworkers: 50 to 185 ton Ironworkers
IRONWORKER
SUNRISE Ironworkers: 50 to 185 ton Ironworkers
Amada America Inc.: ENSIS 3kW, 6kW, 9kW, 12kW Fiber Laser Series
LASER TECHNOLOGY
Amada America Inc.: ENSIS 3kW, 6kW, 9kW, 12kW Fiber Laser Series
Bystronic Inc.: ByStar Fiber laser cutting system
LASER TECHNOLOGY
Bystronic Inc.: ByStar Fiber laser cutting system
Bystronic Inc.: High Performance ByTube 130
LASER TECHNOLOGY
Bystronic Inc.: High Performance ByTube 130
Cincinnati Inc.: CLX Fiber Laser Cutting System
LASER TECHNOLOGY
Cincinnati Inc.: CLX Fiber Laser Cutting System
Mazak Optonics Corp.: OPTIPLEX NEXUS 3015 FIBER S7
LASER TECHNOLOGY

Mazak Optonics Corp.: OPTIPLEX NEXUS 3015 FIBER S7

Mazak Optonics Corp.: FT-150 FIBER
LASER TECHNOLOGY
Mazak Optonics Corp.: FT-150 FIBER
MC Machinery Systems Inc.: ASTES4 LASORTING
LASER TECHNOLOGY
MC Machinery Systems Inc.: ASTES4 LASORTINGs
Salvagnini America Inc.: L3
LASER TECHNOLOGY
Salvagnini America Inc.: L3
Trumpf Inc.: TruLaser 2030 fiber
LASER TECHNOLOGY
Trumpf Inc.: TruLaser 2030 fiber
Amada America Inc.: FLW 3000 Series — Fiber Laser Welder
LASER WELDING
Amada America Inc.: FLW 3000 Series — Fiber Laser Welder
Trumpf Inc.: TruArc Weld 1000
LASER WELDING

Trumpf Inc.: TruArc Weld 1000

KASTO Inc.: KASTO UNITOWER
MATERIAL HANDLING
KASTO Inc.: KASTO UNITOWER
Camfil APC: Gold Series X-Flo industrial dust collector
METAL DUST COLLECTION
Camfil APC: Gold Series X-Flo industrial dust collector
Churchill Steel Plate: Heavy plate
PLATE
Churchill Steel Plate: Heavy plate
Plate: Carell Corporation/Eagle Bending Machines QR Code
PLATE & ANGLE ROLLS
Carell Corporation/Eagle Bending Machines: Parmigiani VBH Series
SweBend: Angle and Plate Bending Machines
PLATE & ANGLE ROLLS
SweBend: Angle and Plate Bending Machines
Rolleri USA: Rolleri VARIO
PRESS BRAKE TOOLING
Rolleri USA: Rolleri VARIO
Automec Inc.: CoastOne Servo-Electric Press Brakes
PRESS BRAKES
Automec Inc.: CoastOne Servo-Electric Press Brakes
Presses:  Greenerd Press & Machine Company: Custom press solutions
PRESSES
Greenerd Press & Machine Company: Custom press solutions
Behringer Saws Inc.: HBE-320/523GA miter band saw
SAWING
Behringer Saws Inc.: HBE-320/523GA miter band saw
Behringer Saws Inc.: Eisele PSU-450A circular cold saw
SAWING
Behringer Saws Inc.: Eisele PSU-450A circular cold saw
Brobo USA: Brobo S350D & S400B ferrous metal cutting saws
SAWING
Brobo USA: Brobo S350D & S400B ferrous metal cutting saws
Cosen Saws: V-2026NC is a vertical tilt-frame bandsaw
SAWING
Cosen Saws: V-2026NC is a vertical tilt-frame bandsaw
Savage Saws: Savage Guillotine Line
SAWING
Savage Saws: Savage Guillotine Line
Sawblade.com: Q501 IC band saw blade
SAWING

Sawblade.com: Q501 IC band saw blade

Sawblade.com: Trajan Q1400 Carbide Chop Saw
SAWING

Sawblade.com: Trajan Q1400 Carbide Chop Saw

Cincinnati Inc.: CIberDash
SOFTWARE
Cincinnati Inc.: CIberDash
Metamation Inc.: Flux bending software
SOFTWARE
Metamation Inc.: Flux bending software
SigmaTEK Systems LLC: SigmaTEK Suite
SOFTWARE
SigmaTEK Systems LLC: SigmaTEK Suite
Beckwood Press Co.: Custom Servo-Electric Presses
STAMPING PRESSES

Beckwood Press Co.: Custom Servo-Electric Presses

SEYI America Inc.: Direct drive servo presses
STAMPING PRESSES

SEYI America Inc.: Direct drive servo presses

Admiral Steel Products: Steel service center and distributor
STEEL
Admiral Steel Products: Steel service center and distributor
O’Neal Steel: Metal products and value-added services
STEEL, STAINLESS, ALUMINUM
O’Neal Steel: Metal products and value-added services
HGG Profiling Equipment: ProCutter900 RB pipe cutter
TUBE & PIPE
HGG Profiling Equipment: ProCutter900 RB pipe cutter
Parker Steel Company: Stainless steel capillary tubes
TUBE & PIPE
Parker Steel Company: Stainless steel capillary tubes
Parker Steel Company: Metric Flat Oval Tubes
TUBE & PIPE
Parker Steel Company: Metric Flat Oval Tubes
Prudential Stainless & Alloys: Aluminum pipe and tube in odd-ball sizes
TUBE & PIPE

Prudential Stainless & Alloys: Aluminum pipe and tube in odd-ball sizes

Watts-Mueller: Industrial computer-controlled pipe cutting machinery
TUBE & PIPE
Watts-Mueller: Industrial computer-controlled pipe cutting machinery
Flow International Corp.: Mach 500 waterjet system
WATERJET
Flow International Corp.: Mach 500 waterjet system
American Weldquip: Smoke Extraction Torches
WELDING
American Weldquip: Smoke Extraction Torches
John Tillman Co.: Tillman 1477 TrueFit glove
WELDING
John Tillman Co.: Tillman 1477 TrueFit glove
John Tillman Co.: Tillman 1457 Drivers glove
WELDING
John Tillman Co.: Tillman 1457 Drivers glove
T.J. Snow Company: Capacitor Discharge Resistance Welding
WELDING (RESISTANCE WELDING)

T.J. Snow Company: Capacitor Discharge Resistance Welding

T.J. Snow Company: Online resistance welding seminars
WELDING TRAINING

T.J. Snow Company: Online resistance welding seminars

To Enter VTS2:
The Virtual Trade Show, Go to
live February 1 – March 31
Planet connections illustration
laser technology
By Matt Garbarino, Cincinnati Inc.
Cincinnati Inc.’s high-volume CL-900 fiber laser and automation allow Gammons to cut thinner materials faster and more cost efficiently.
High volume
Manufacturer fuels growth with greater cutting capacity, automation and open architecture software
G

ammons Metal & Manufacturing Co. Inc. is no stranger to growth. The small metal parts and fabrication shop opened its doors in 1968 and has since maintained an upward trajectory. In 1998, the Indianapolis-based company changed hands. Today, Gammons, helmed by owner Dave Sutton, is one of the largest independent metal fabrication companies in the Midwest. The 70,000-sq.-ft. facility can saw, shear, punch, tap, bend, pierce and notch carbon steel, cold rolled, hot rolled pickled and oiled, galvanized, aluminum, stainless, brass and copper. Its skilled personnel can take parts from prototype to production runs, subassemblies, inspection and shipping. Seamless processing is a hallmark of Gammons. A bottleneck in its cutting operations prompted the manufacturer to look at fiber laser technology that could handle larger volumes.

press brakes/tooling
By Lynn Stanley, Senior Editor

Rolleri analyzed parts and press brake capacity to design/build tooling that could withstand tough materials.

Steel vs. machine
Tooling technology helps company bend abrasion-resistant steel while avoiding pitfalls like cracking
T

he W. L. French Excavating Corp. is used to pushing obstacles out of the way. The family-owned business based in North Billerica, Massachusetts, provides a wide range of construction services from mass excavation and soil management to site development, transportation, disposal and snow services. Its motto “We move Boston,” is fitting for a company that moves millions of cubic yards of earth annually, prizes its employees and is deeply embedded in its community. W. L. French needed an equally tough tooling solution to bend parts from Hardox 450 steel up to .50-in. thick using a 325-ton press brake.

Punching/Drilling
By lynn stanley, senior editor

Formdrilling solves the problem of joining thin-walled material.

Hole in One
Thermal drilling technology allows fabricators to produce their own inserts out of a part’s material for a bevy of benefits
P

art failure can be a public relations nightmare for manufacturers. It’s a complaint that Todd Bieri, operations manager for Formdrill-USA Inc. hears on a fairly regular basis. “Prior to coming to us, customers have talked about various product failures as a result of using inserts or weld nuts and how that has created a negative image issue for them that they are anxious to reverse,” he says.

Tube&Pipe
By gretchen salois, senior editor
Operator rides on the cutting carriage of the Watts-Mueller WM-60
Operator rides on the cutting carriage of the Watts-Mueller WM-60.
Cutting caliber
Size matters when fabricator invests in its largest cutting installation yet
C

utting large-diameter pipe can be cumbersome and time consuming when done manually. After Piping Systems Inc. completed the largest project in its history—a 375,000 linear ft. project with diameters up to 72 in. and wall thicknesses up to 1.5 in.—the fabricator realized its current equipment conveyor system wouldn’t keep up in the long-term. “The equipment’s conveyor we had at the time was only rated for a maximum 500 lbs. per ft. There was no way we could run heavy-wall, large-diameter pipe,” says Tony Kent, vice president, Piping Systems.

Deburring/ Finishing
BY GRETCHEN SALOIS, SENIOR EDITOR
Heat and Control uses the Lissmac SMD 526 RR (65 in. wide) to deburr and grain stainless for the food equipment industry.
Lissmac’s SBM L 2000 with motorized conveyor
Lissmac’s SBM L 2000 with motorized conveyor is used for parts 6 in. long and above. The SBM XS 300 Vacuum processes smaller parts under 7 in. long and down to 2-in. by 2-in. parts.
Heat and Control uses the Lissmac SMD 526 RR (65 in. wide) to deburr and grain stainless for the food equipment industry.
Heat and Control uses the Lissmac SMD 526 RR (65 in. wide) to deburr and grain stainless for the food equipment industry.
Lissmac’s SBM L 2000 with motorized conveyor
Lissmac’s SBM L 2000 with motorized conveyor is used for parts 6 in. long and above. The SBM XS 300 Vacuum processes smaller parts under 7 in. long and down to 2-in. by 2-in. parts.
Fast finish
Extra width and one-pass edge finish enables one fabricator to avoid process holdups
E

conomic activity in the manufacturing sector is growing. In January, manufacturing PMI registered at 58.7 percent. According to the Manufacturing ISM Report on Business, “this figure indicates expansion in the overall economy for the eighth month in a row after contraction in March, April and May 2020.”

Businesses like Heat and Control Inc. design specialized machinery for the food industry. “We needed a new laser to meet demand while ensuring high-quality finishing so our customers won’t hurt themselves,” says Jessie Castillo, director of manufacturing.

Custom Fabricator
fabled Norse god of snow sculpture at twilight
Let It Snow

While Breckenridge, Colorado’s December 2020 Ullr Fest was cancelled due to COVID-19, a collaboration between Breckenridge Grand Vacations and Scottish sculptor Andy Scott gave hope that the fabled Norse god of snow will nevertheless provide the area with a frozen bounty. A 25-ft.-tall, 1-ton sculpture of Ullr was assembled and erected at the base of Peak 8 at the Breckenridge Ski Resort November 11, 2020, a few days before the opening of ski season. Scott constructed a wire frame from his concept sketch and covered it with 1-in. pieces of steel welded together to contour the shape. Scott, who told the Summit Daily newspaper he “sees little segments of steel in his sleep,” said his approach of using thousands of tiny pieces of steel came about slowly while he evolved his style. He credits taking some of his inspiration from American painter Chuck Close, who creates portraits by combining hundreds of smaller painted squares. Locals are looking forward to the 2021 Ullr Fest celebration in hopes of another powder-filled ski season.

installing the sculpture with a lift
making the sculpture in the studio
Legend has it that Ullr was a master of the bow and could outrace anyone on skis. It was believed that each winter he covered the earth with snow to protect it from harm.
Photos, finished/installed sculpture: Carl Scolfield; works-in-progress: Andy Scott
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