Parts, Pronto
Fit Tight, Weld Easy
infrastructure
Steel Story
March 2022
March 2022
trend publishing metals group  Volume 19 Number 03
March 2022
trend publishing metals group  Volume 19 Number 03
FFJournal
infrastructure
Poised for an infusion of cash, America’s infrastructure looks to new steel materials, products and technologies for low maintenance, lightweight solutions that are quick to install
FFJournal
Steel Story
features
Parts, Pronto
laser technology
Fabricator automates business so customers can price parts, order online and have their prototype or small-batch order in hand quickly
Parts, Pronto
Fit Tight, Weld Easy
Tooling Tips
Smooth Operator
tube & pipe
As the demand for 5G communication technology grows, fabricator automates 4G and 5G pole production
press brake/tooling
Despite labor shortages and long lead times for equipment, one manufacturer helps customers stay on track
deburring/finishing
Machine for deburring and edge rounding processes sheet metal parts in a single pass
Fit Tight, Weld Easy
tube & pipe
As the demand for 5G communication technology grows, fabricator automates 4G and 5G pole production
Tooling Tips
press brake/tooling
Despite labor shortages and long lead times for equipment, one manufacturer helps customers stay on track
Smooth Operator
deburring/finishing
Machine for deburring and edge rounding processes sheet metal parts in a single pass
FFJournal.net
find even more metal fabricating & forming content online
Moonlight Deities, a series of suspended perforated disks
/customfabricator
plasma laser in use
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metal that has been stamped
/stamping
Online
Features
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customfabricator
Artist Lindy Lee created Moonlight Deities, a series of suspended perforated disks that are emblematic of elemental energy, permeability and interconnection
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plasma
Unique tooling technology and software make plasma cutting 3D objects fast and accurate
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stamping
Metalworking fluid manufacturer talks 2022 trends for forming and stamping operations
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student welder
Facebook
Student welds her way to nontraditional career ithrough an apprenticeship
Photo: Wisconsin State Journal
Instructor Grant Ragland helps student Cody Brown run some MIG
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Instructor Grant Ragland helps student Cody Brown run some MIG #welding #fabrication #metalwork #handmade
Iowa welder
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Iowa welder turns metal into lifelike creations
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@wcfcourier
Photo: Tim Hynds, Sioux City Journal
advertorial
salvagnini | technology solutions
Robot and human hand nearly touching fingers
Automation is a journey
At the simplest level, automation on the production floor can help a job shop avoid potential bottlenecks and downtime. And, it has the ability to collect data that measures the progress of a job, helps to control costs and reduce scrap. Yet, over the last decade, job shops have struggled to adopt automation on a larger scale and balance the integration of smart systems with legacy equipment. Why?

For many job shops it is understanding that automation is a journey, not a destination. You don’t have to immediately jump into expensive full automation. Do take stock of what is out there. Decide where your entry point is and go from there.

Lynn Stanley headshot

From the Editor

lynn stanley

SUSTAINABLE STEEL

P

residents George Washington and Thomas Jefferson believed that a trans-Appalachian road was critical to the unification of a fledgling country. Bradford Road, which cut an 820-mile path through Illinois, Indiana, Maryland, Ohio, Pennsylvania and West Virginia, became the first federally funded road in U.S. history. Construction began in 1811 and was completed in 1834. Forty years later, the first major bridge built entirely of steel made its debut. Sporting three arch spans, the Eads Bridge was 6,444 ft. long and spanned the Mississippi River, connecting St. Louis, Missouri, and East St. Louis, Illinois.

The Interstate Highway System was authorized by the Federal-Aid Highway Act of 1956, with most of the system completed by 1990. The American Society of Civil Engineers, the country’s oldest national civil engineering organization, began issuing its quadrennial Infrastructure Report Card in 1998. Since then, marks for America’s framework have hovered at a D until 2021 when the country earned a C-. The bridge category scored a C.

Face Time
BY LAUREN DUENSING, CONTRIBUTING EDITOR
Steel manufacturing
Clean & green
Kim Olson, manager of technical initiatives, Construction Solutions, Nucor Corp., talks with FFJournal about Nucor’s current and future commitments to sustainability
Q:

What is driving the movement for carbon-friendly steel products?

A:

The movement has certainly gained traction in recent years. Government commitment to sustainability at both the federal and state level has been a primary driver historically, and this still has an impact today. Investors also are increasingly considering sustainability a requirement, and sustainability drives more customer decisions than ever before. It is worth noting that we do not limit our scope of competition to other steel and tube producers. We consider alternative materials to steel as a significant threat to our business, and many of these are also striving for sustainable solutions. We are paying a lot of attention to this.

Guest Editorial
BY MICHAEL HEPP, NLIGHT
Predictive Maintenance
How will machine learning impact industrial manufacturing?
T

he technological advancements of the past couple of decades make it easy to overlook just how reliable weather forecasting has become. I can remember my father laughing at the local weatherman’s predictions on the 5 o’clock news because he was often just flat wrong. Over time, however, weather forecasting has become so precise that a severe storm’s arrival can be predicted almost down to the minute, allowing whole communities to better prepare. If my father were alive, I think he’d say it is pretty spiffy just how accurate weather forecasting is nowadays. What is driving this incredible progress? Machine learning.

Fabricator’s POV
BY LAUREN DUENSING, CONTRIBUTING EDITOR
From left, Tim McMahan, Steve Rupp, Dennis Hobbs, Traci Warner and Garrett Warner lead the family owned fabrication operation.
From left, Tim McMahan, Steve Rupp, Dennis Hobbs, Traci Warner and Garrett Warner lead the family owned fabrication operation.
Sticking together
FFJournal talks with the Steffani Metals team about why relationships are critical and family comes first
H

ouston-based Steffani Metals has been in business for 40 years. At the start, the company received hand renderings for quotes and orders by phone and fax—items that are all electronic today. One thing that hasn’t changed, though, is the personal attention every customer receives.

Hot Sheet
a company president and two technicians examine a customer's part
Materials
CEP President Ken Kaufmann Jr. and engineer/technicians evaluate a customer’s part.
Options

As metal alloys become scarce, raw materials expert helps fabricators evaluate alternatives

Stampers, job shops and fabricators continue to feel the sting of the bullwhip effect in raw materials. With the list of scarce alloys growing, and lead times upwards of 52 weeks, “customers need to understand part requirements and consider alternative materials that might satisfy their specifications,” says Ken Kaufmann Jr., president of CEP Technologies Corp.

The Yonkers, New York, company produces standard and custom precision miniature to small stampings for markets that include automotive OEMs and aftermarket applications, EMI/RFI shielding, telecommunications, power protection, lighting and oil and gas exploration. CEP is using its rapid prototyping and engineering skill sets along with its experience in a broad range of alloys to help customers consider other options.

infrastructure
By Lynn Stanley, Senior Editor
Steel Story
Poised for an infusion of cash, America’s infrastructure looks to new steel materials, products and technologies for low maintenance, lightweight solutions that are quick to install
I

t took 7.6 million lbs. of steel, 2,000 men and 2,200 days of on-site labor to complete the Golden Gate Bridge in 1937. A $25 million grant from President Franklin Roosevelt’s New Deal program made construction possible for what is still considered an engineering marvel. Annual tolls and fees averaging $145 million help offset the Golden Gate’s yearly $85 million maintenance bill.

Laser Technology
By Lauren Duensing, contributing editor
CoolLine being used during the cutting process
Using CoolLine during the cutting process significantly increases reliability when processing heavy-gauge carbon steel.
Parts, pronto
Fabricator automates business so customers can price parts, order online and have their prototype or small-batch order in hand quickly
T

he on-demand service economy has grown exponentially over the past 10 years. Today, consumers can quickly and easily order rides, groceries, meals and book vacations through platforms like Uber, Airbnb, Doordash and Instacart. Analysts predict these services will continue to expand in the coming years; the healthcare market jumped on board during the COVID-19 pandemic, and other industries aren’t far behind.

Tube & Pipe
BY LAUREN DUENSING, CONTRIBUTING EDITOR

GRG Design fabricates poles on its Model SPC 500 R from HGG Profiling Equipment, integrated with a Hypertherm PowerMax 125-amp plasma system.

man working on a machine for GRG Design
GRG Design fabricates poles on its Model SPC 500 R from HGG Profiling Equipment, integrated with a Hypertherm PowerMax 125-amp plasma system.
Fit Tight, Weld Easy
As the demand for 5G communication technology grows, fabricator automates 4G and 5G pole production
U

ltra-fast fifth-generation cellular networks bring bigger channels, lower latency and the ability to connect more devices at once to accommodate every business and household’s thirst for smart technology. According to JP Morgan Research, 5G adoption reached one-third of global smartphone volumes in the fourth quarter of 2020, helped along by the launch of the 5G iPhone and is expected to reach 1 billion subscribers faster than the approximately two years it took for 4G.

And 5G’s potential growth doesn’t stop at the consumer level. JP Morgan analysts assert that the biggest opportunity for the technology is in enterprise-use cases, such as factory-floor automation and fixed wireless.

Press Brake/Tooling
Wila’s Smart Tool Locator shows an operator where tools must be placed in the tool holder and which bending process will take place.
Tooling tips
Despite labor shortages and long lead times for equipment, one manufacturer helps customers stay on track
S

killed labor shortages, material quality issues and equipment availability are just some of the problems Dave Bishop sees fabricators wrestling with these days. Wila USA’s business development manager covers the 11 contiguous Western States.

Wila’s customers pose this one question more than any other: How do I find qualified press brake operators? According to the U.S. Labor Department’s labor turnover report, the number of people quitting their jobs hit a record high of 4.5 million in November 2021. Economists have dubbed the mass exodus The Great Resignation. Bishop points to a couple contributing factors.

Deburring/Finishing

By Alan richter, contributing editor
Lissmac SBM-L G1S2 closeup of cuts
The Lissmac SBM-L G1S2 machine is suitable for edge rounding stainless steel parts such as these.
Smooth operator

Machine for deburring and edge rounding processes sheet metal parts in a single pass

N

o manufacturer wants to ship laser-cut, punched or waterjet machined parts with sharp edges, vertical burrs or both. The primary reason for rounding edges or removing burrs is for safety and handling, according to Tim Corley. He is director of sales—metal processing for Mechanicville, New York-headquartered Lissmac Corp.

Toolbox
Hypertherm DynaMAX waterjet pumps
WATERJET
New names for waterjet pumps
Hypertherm rebranded its HyPrecision and Echion intensifier-based waterjet pumps as DynaMAX. The DynaMAX systems will now begin with a 3 or 5, depending upon the performance, feature or technology of a particular model. This prefix will be followed by the horsepower number and, for pumps engineered with Hypertherm’s patented predictive technology, a “P” suffix. HyPrecision pumps will now have a black exterior to match the exterior of the Echion pumps. The products’ features and benefits will remain the same.
Hypertherm Inc., Hanover, New Hampshire, 800/737-2978, hypertherm.com.
Custom Fabricator
Convergence

Convergence, a project by the JANNY SABIN STUDIO, celebrates the thriving, vibrant and rich heritage of excellence at the University of Nebraska Medical Center, Omaha, through materialized concepts that embed change, transformation and contemplation. The project integrates advanced methods and innovations in digital and robotic fabrication with timeless and contextually sensitive materials. The project features stainless steel wire arc additive manufacturing through robotic 3D printing, CNC polycarbonate panels laminated with wavelength dependent dichroic film, and stainless steel rings. The design for Convergence incorporates part-to-whole 3D printed and machined component strategies to realize a work that celebrates lightness, dynamic structure and equilibrium through equal and opposite forces. Taking inspiration from the medical center’s role in global health through its response and leadership in both the Ebola epidemic and now the coronavirus pandemic, Convergence celebrates people coming together from around the world.

Learn more about this and other Custom Fabricators at ffjournal.net/customfabricator.
Photo: Jenny Sabin Studio and The Lincoln Electric Co.
Convergence

Convergence, a project by the JANNY SABIN STUDIO, celebrates the thriving, vibrant and rich heritage of excellence at the University of Nebraska Medical Center, Omaha, through materialized concepts that embed change, transformation and contemplation. The project integrates advanced methods and innovations in digital and robotic fabrication with timeless and contextually sensitive materials. The project features stainless steel wire arc additive manufacturing through robotic 3D printing, CNC polycarbonate panels laminated with wavelength dependent dichroic film, and stainless steel rings. The design for Convergence incorporates part-to-whole 3D printed and machined component strategies to realize a work that celebrates lightness, dynamic structure and equilibrium through equal and opposite forces. Taking inspiration from the medical center’s role in global health through its response and leadership in both the Ebola epidemic and now the coronavirus pandemic, Convergence celebrates people coming together from around the world.

Learn more about this and other Custom Fabricators at ffjournal.net/customfabricator.
Photo: Jenny Sabin Studio and The Lincoln Electric Co.
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Lynn Stanley

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Alan Richter

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FFJournal® (ISSN 1551-1006) March 2022 (Vol. 19, No. 03) 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: Omeda – FFJournal – 4 Overlook Pt., Ste. A25E, Lincolnshire, IL 60069. Printed in the USA.
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