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FF Journal logo
May 2020
May2020
a trend publication  Volume 17 Number 5
DEFENSE
Printing metal parts is changing the way the U.S. military responds to shortages, supply chain hold-ups
DEFENSE
Printing metal parts is changing the way the U.S. military responds to shortages, supply chain hold-ups
CutOutcovid
fabricators pov
Fabricators work together to provide PPE to essential workers
CutOutcovid
fabricators pov
Fabricators work together to provide PPE to essential workers
Measure of Force
Quick Study
Vertical Limit
Escape the Heat
Quandary
Secure Foundation
Big & Bold
features
laser technology
Fiber equipment helps manufacturer to push more parts quickly to meet growing customer demand
press brake
Finding it difficult to track down experienced operators, manufacturer uses technology to push efficiency forward
Software solutions
Integrated tools help users predict costs, navigate balance in pricing and grow bottom line
waterjet cutting
Cold cutting technology helps manufacturers prevent stress fractures and avoid secondary processing
end user report: heavy equipment
Markets growing amidst shrinking labor pool and other hurdles with the help of technology
stamping/presses
Press pit experts ensure equipment stays put
sawing/cutting
How inventive custom jobs become standards
features
Measure of Force
laser technology
Fiber equipment helps manufacturer to push more parts quickly to meet growing customer demand
Quick Study
press brake
Finding it difficult to track down experienced operators, manufacturer uses technology to push efficiency forward
Vertical Limit
Software solutions
Integrated tools help users predict costs, navigate balance in pricing and grow bottom line
Escape the Heat
waterjet cutting
Cold cutting technology helps manufacturers prevent stress fractures and avoid secondary processing
Quandary
end user report: heavy equipment
Markets growing amidst shrinking labor pool and other hurdles with the help of technology
Secure Foundation
stamping/presses
Press pit experts ensure equipment stays put
Big & Bold
sawing/cutting
How inventive custom jobs become standards
find even more metal fabricating & forming content online
30 foot stainless steel bunny
/stainless
deburring
/abrasives
welder
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Online
Features
ffjournal.net
/stainless
A 30-ft. stainless steel bunny leaps from the vineyard at a St. Helena, California, winery
ffjournal.net
/abrasives
Discs improve deburring results without deteriorating during the process
ffjournal.net
/training
Rulers of the Flame contest showcases the benefits of a technical education
Man welding
welded scrap metal dragon
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A metal monster made with love. Scrap metal dragon has a new home in Alaska
Photo: Hometown Focus
Aluminum welding
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#gtaw #tig #6061 #aluminum #weldlicious #weldeverydamnday #weldtime #primeweld #tigunit
MetalFAB machine
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Additive Industries and ArcelorMittal print large-scale spare parts
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@3dprintindustry
Photo: ArcelorMittal
ROLLA-V
The Solution for perfect bends
for all your tooling needs
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Fax: 630-691-8667 • www.fabsupplyinc.com
Gretchen Salois headshot

From the
Senior Editor

Gretchen Salois

‘Fight tonight’

ready
W

hile writing this, news reports bring word that new cases of COVID-19 in New York City—one of the hardest hit areas in the U.S.—are beginning to level out. Sheltering in place is working. Daily life around the world is inherently changed and each new week looks dramatically different from the last.

In the fabrication world, I’ve heard from shops managing with fewer people reporting to work while, in other cases, shops are ramping up production as their supply chains look locally instead of relying on vendors overseas. Still other shops are uncertain what their production schedules will look like in the coming months and are working to manage this new landscape.

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Fabricator’s POV
BY LAUREN DUENSING, CONTRIBUTING EDITOR
More than 500 members joined in the first week, and tons of ideas are shared every day.
Luke Hansen-MacDonald,
AXYZ Automation Group
#CutOutCOVID
Fabricators work together to provide PPE to essential workers
A

s the COVID-19 respiratory virus continues to spread, people around the world are adjusting to a new at-home lifestyle—working, learning and spending time with friends virtually instead of face to face. Despite the required physical distance, many communities are stronger than ever. Neighbors check in with each other, support local restaurants and businesses, and sing and shine lights every night to praise healthcare workers, first responders and other essential employees.

As COVID-19 was becoming an international pandemic, AXYZ Automation Group (AAG)—comprising AXYZ Routers, WARDJet waterjets and CNCShop—created an online LinkedIn group called Fabricators Fighting COVID-19. The company had noticed that many of its customers were eager to help in the fight against the virus by fabricating solutions for personal protective equipment (PPE) and other safety supplies.

Guest Editorial
By Rob Bisbee, Greenerd Press & Machine Co.
Seek experience
Navigating the ins and outs of press automation
S

ome manufacturers have automation requirements that are well-defined and documented. Others are uncertain about what automation solution to pursue or even how to get started.

The reasons for automating a press vary, and include working with cumbersome parts, hazardous materials, reducing repetitive movements, or freeing up operators for higher skilled work. Their goals can be realized by properly engineering automated solutions that can maximize productivity and improve parts quality and consistency, as well as reduce scrap.

Automation machinery
Automation can increase throughput, reduce cycle time and waste and increase part quality, among other benefits.
Toolbox
Generator allows for multiple welds at once
Generator allows for multiple welds at once
The Dual Maverick 200/200X arc welder/generator features two welders powered by a diesel engine with dual welding outputs, allowing two or more welders to work at the same time in structural, pipeline and maintenance and repair applications. With optimized operations for the most efficient weld, the Dual Maverick 200/200X dampens engine noise. Welders can also achieve fuel savings with variable engine RPM, based on welding output level and auto stop/start functionality. The output remains steady even during arc stops and starts in dual mode.

Lincoln Electric, Cleveland, 216/481-8100, lincolnelectric.com.

TIG gloves designed to protect
TIG gloves designed to protect
Model 1338 TIG welding gloves offer comfort while providing protection for welders’ hands. Made of soft, supple top-grain goatskin, the TIG glove provides the welder with outstanding dexterity and an incredible sense of touch and straight thumb for greater flexibility, which allows for laying down perfect welds.

John Tillman Co., Compton, California, 800/255-5480, jtillman.com.

What’s Happening
Victor names contest winners
Victor names contest winners
Victor, an ESAB brand, announced winners in its Rulers of the Flame oxy-fuel student contest. Students from six schools participated in two categories—either a team fabrication project or an essay competition. Individual winners are Joshua Doyle from Springfield Clark Career Technology Center, Springfield, Ohio (instructor Brian Sheward); Kyle Hiener from Oxarc Welding School, Spokane, Washington, (instructor Andrew Delateur) and Elizabeth Chaney from Carroll County Career & Technology Center, Westminster, Maryland (instructor Michael Schweinsberg). The team winners hail from Iron Workers 40 & 361 Training Center, Astoria, New York (students Sandy Matos, Anthony Larkin, Anastasiya Grishkevich and Mark Thomas); Rockland BOCES, West Nyack, New York (students Thomas McKenna, Tyler Moore, Kevin Onderdonk, Robert Shields and Robert Himelfarb) and Ogden-Weber Technical College, Ogden, Utah (students Darby McClelland, Michael Oakes, Colby Marker and Christopher Oakes).
Eye on People
John Hobbs Headshot
John Hobbs
Weiler appoints director
Weiler Abrasives, Cresco, Pennsylvania, promoted John Hobbs to director of national accounts. He manages a team of national account managers who sell to business partners across the U.S. and Canada.
Jill Post Headshot
Jill Post
AIDA adds project manager
AIDA-America, Dayton, Ohio, hired Jill Post as project manager. She has over 20 years of engineering and project management experience and joins the degreed engineer project management team.
Luke Brunsmann Headshot
Luke Brunsmann
Delta Steel adds regional sales managers
Delta Steel Technologies, Irving, Texas, has hired two new regional sales managers. Luke Brunsmann will be handling the Upper Midwest territory, while Braxton Buckley will oversee the Southeast territory.
Andrea Moseley Headshot
Andrea Moseley
Kloeckner selects new CFO
Kloeckner Metals Corp, Roswell, Georgia, promoted Andrea Moseley to chief financial officer. Moseley succeeds Kirk Johnson, who has retired. Moseley also joins Kloeckner Metal’s executive management team.
Salay Quaranta Headshot
Salay Quaranta
Trumpf names product manager
Salay Quaranta has been named 2D TruLaser product manager for Trumpf Inc., Farmington, Connecticut. Salay will provide technical expertise, and oversee the sales engineer and applications teams.
Gary Konarska II Headshot
Gary Konarska II
Society names executive director/CEO
The American Welding Society’s board of directors named Gary Konarska II as its new executive director and chief executive officer. Konarska succeeds Ray Shook, who held the position for 15 years and has agreed to remain as executive director emeritus for an interim period to ensure a seamless transition.
Defense
By Gretchen Salois, senior editor
Printing metal parts is changing the way the U.S. military responds to shortages, supply chain hold-up
T

he technology that moves us forward, affording people flexibility amid urgent situations, often makes its first inroads within the laboratory setting. Research continues to advance alloys to lighten the weight of vehicles as well as qualify more intricately printed parts. In metal fabrication, the military has installed its first metal printing solution to aid soldiers located far from the supply chain.

Where you really get the benefit of using additive manufacturing is you’re able to print crazy, organic designs that are both lightweight and structurally robust. You simply couldn’t create the part any other way.
Dr. Brandon McWilliams, U.S. Army CCDC
3D printing technology developed at U.S. Army CCDC will enable soldiers to print replacement parts for vehicles such as the M1 Abrams tank. Photo: Cpl. Israel Chincio / U.S. Marine Corps
Defense
By Gretchen Salois, senior editor
Where you really get the benefit of using additive manufacturing is you’re able to print crazy, organic designs that are both lightweight and structurally robust. You simply couldn’t create the part any other way.
Dr. Brandon McWilliams, U.S. Army CCDC
3D printing technology developed at U.S. Army CCDC will enable soldiers to print replacement parts for vehicles such as the M1 Abrams tank. Photo: Cpl. Israel Chincio / U.S. Marine Corps
Printing metal parts is changing the way the U.S. military responds to shortages, supply chain hold-up
T

he technology that moves us forward, affording people flexibility amid urgent situations, often makes its first inroads within the laboratory setting. Research continues to advance alloys to lighten the weight of vehicles as well as qualify more intricately printed parts. In metal fabrication, the military has installed its first metal printing solution to aid soldiers located far from the supply chain.

Laser Technology 
By Lynn Stanley, Senior Editor
The Salvagnini L5 fiber laser offers three cutting functions—Standard, PowerCut and DynamicCut—allowing JIT Manufacturing to choose the mode best suited to the application.
The Salvagnini L5 fiber laser offers three cutting functions—Standard, PowerCut and DynamicCut—allowing JIT Manufacturing to choose the mode best suited to the application.
Measure of force
Fiber equipment helps manufacturer to push more parts quickly to meet growing customer demand
T

he human heart is roughly the size of a large fist, weighing 10 to 12 ounces, yet it pumps blood throughout the body to feed organs and tissues with life-sustaining oxygen and nutrients.

For JIT Manufacturing Inc., Salvagnini L5 fiber laser technology is the heart that pushes parts to multiple operations 24/7 to support customer demand and nourish growth.

“We’ve had our eye on growth and looked at different ways we could capture new business,” says Nick Ricard, JIT Manufacturing’s vice president and general manager. “The fiber lasers have really helped to move us closer to those goals. These machines are the heartbeat of this company.”

Press Brake
by gretchen salois, senior editor
Bending parameters are automatically stored, which are cross-referenced against bending data experience on specific tools.
Bending parameters are automatically stored, which are cross-referenced against bending data experience on specific tools.
Quick study
Finding it difficult to track down experienced operators, manufacturer uses technology to push efficiency forward
W

hen prospective hires are brought in to tour G.A. Braun’s plant, many are struck by the general idea of how things are made. After touring the floor, they often view the machinery being used “as cool and exciting and they want to learn the technology behind it,” says Chad Perfetti, fabrication manager of the Syracuse, New York-based industrial laundry machine manufacturer.

After years of laying out sheet metal by hand and using various small tools to cut out part profiles, G.A. Braun’s leadership realized it should consider investing in laser and CNC press brake technologies. Perfetti’s crew found LVD Strippit’s team to be knowledgeable as well as close by in Akron, New York. “The layout of the laser with load/unload automation had a footprint that didn’t take up too much floor space,” he adds.

Software Solutions
BY LYNN STANLEY, SENIOR EDITOR
Color Offload digital program screenshot
Production schedules digital program screenshot
Vertical
LIMIT
Integrated tools help users predict costs, navigate balance in pricing and grow bottom line
M

anufacturers must frequently generate up to five times more quotes to land jobs, making the need to understand machine time, material and labor costs more important than ever.

Creating accurate quotes is a serious challenge for manufacturers, says Valter Bonelli, director of product management business systems for SigmaTEK Systems LLC. “Only a few factors have a bigger impact on a company than the ability to predict costs. It can be difficult to sell products and services if they are priced too high, but we find that manufacturers tend to set prices too low. So the question becomes, how do they find balance?”

Waterjet Cutting
BY LYNN STANLEY, SENIOR EDITOR
Cold cutting technology helps manufacturers prevent stress fractures and avoid secondary processing
Escape the heat
F

or the last decade, so much buzz about cutting metal has tended to revolve around fiber lasers. But according to MultiCam Inc.’s fabrication product manager, Rashad Galloway, some manufacturers have begun to sing a different tune that sounds oddly reminiscent of Elvis Presley’s hit, “Can’t Help Falling In Love.”

close up of the MultiCam V-Series waterjet
The MultiCam V-Series waterjet can cut materials with pure water or abrasives using a KMT Tri-Line pump that creates up to 55,000 psi cutting pressure.
“A lot of companies kind of forgot about the waterjet,” he says of the cold cutting technology. “But we’re asking parts and the machines that make them to push past limits we wouldn’t have dreamed about even five years ago. Whether you are talking about the Burj Khalifa in Dubai, the tallest manmade structure in the world, the latest commercial aircraft or steel vehicles that have evolved to aluminum-based frames, you can’t afford to have parts that could experience a stress fracture from heat during the cutting process.”

MultiCam demonstrated its V-Series CNC waterjet technology during a 2019 trade show, cutting carbon and stainless steels, titanium and Inconel. “When people saw the value adds they could realize with the final product, they fell in love with the waterjet all over again,” says Galloway.

end user report
Heavy Equipment
By Lynn Stanley, Senior Editor
Markets growing amidst shrinking labor pool
Quandary
Markets growing amidst shrinking labor pool and other hurdles with the help of technology

A

utomation, data collection, artificial intelligence and robotics aren’t just for smart factories and job shops anymore. These technologies are migrating to construction sites, crop fields and the design/build of new heavy equipment. Industry 4.0 and the Industrial Internet of Things (IIoT) notwithstanding, the construction, heavy equipment and agriculture industries are turning high-tech for reasons that sound familiar. The skills gap, a shrinking labor pool, demand for higher productivity and the need for machine-to-machine and machine-to-human communication are some of the drivers behind these changes.

The Associated General Contractors of America (AGC) conducted a survey that revealed respondents are optimistic about growth—particularly in the bridge/highway, transit, rail, power, water and sewer construction sectors—but scrambling to address the work shortage. Fifty-four percent of participants indicated increases in base pay rates for 2019. Sixty-two percent of respondents revealed plans to increase investments in training. Nearly 32 percent of participants reported that their companies will look to purchase labor-saving equipment such as drones, 3D printers and GPS-guided equipment.

Stamping / Presses
Secure foundation
Press pit experts ensure equipment stays put
Delta Industrial consults the drawings of the newly acquired machine or press to generate a foundation plan
Delta Industrial consults the drawings of the newly acquired machine or press to generate a foundation plan.

W

hole lotta shakin’ goin’ on” may be a popular Jerry Lee Lewis song, but it is not a popular tune when it comes to press pits and machine foundations.

Having a proper foundation that can hold a press that, when running, exerts extreme force and weighs many tons is absolutely essential, especially considering the complexity and power of today’s stamping presses.

This is why large-scale manufacturers and fabricators turn to Delta Industrial. The company offers a variety of professional contracting services, including machine foundations, press pit foundations, slitting line foundations, general building maintenance and construction, concrete flatwork, and steel fabrication and construction.

Sawing / Cutting
By Paul Beha, products manager, HE&M Saw
Big & Bold
How inventive custom jobs become standards
The latest version of the PS-31 saw is massive, weighing in at 65,000 lbs.
The latest version of the PS-31 saw is massive, weighing in at 65,000 lbs.
A

lthough HE&M Saw builds more than 70 standard saw models, the company also enjoys the challenges that accompany the uniqueness of custom projects. Fulfilling customers’ sawing needs is rewarding, regardless of which model fits their application, but offering the ability to engineer equipment tailored specifically to an individual company has been one of HE&M Saw’s strong points throughout its 56 years in business.

After completing a custom saw, the company is sometimes contacted by other companies that have the same or similar applications—often years later. In those instances, what was created as a custom saw, specifically designed and built for a single customer’s requirement, can become a “standard” saw after it is requested several times.

Controlling the PS-31 is an Omron PLC and touchscreen combination.
Controlling the PS-31 is an Omron PLC and touchscreen combination.
Custom Fabricator
Know a great CUSTOM FABRICATOR? Tell us. Email Mark Koenig at mkoenig@ffjournal.net.
Nerve Center
Artist Chris Williams said he made the “Nerve Center” neuron sculpture because he wanted people to start thinking about the type of research being performed at MIT’s Kendall Square, in Cambridge, Massachusetts. The 25-ft.-tall neuron with its 12-ft.-long dendrites is the centerpiece of the square, reaching outward in every direction. It symbolizes the connection that MIT has with its partners in research. Williams, a self-taught, third-generation metalworker, fashioned the sculpture out of a twisted metal frame and pieces of glass. The work is made up entirely out of formed bronze with 1/2-in.-thick slumped glass at its core nucleus. Lights built into the glass illuminate the sculpture from the inside. “I am very passionate about putting life into my work and creating installations that are both recognizable and yet provoke further thought,” Williams said. The piece was commissioned by BioMed Realty, a Kendall Square company that specializes in providing real-estate solutions for the life science community.
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator
Photo: Chris Williams
the “Nerve Center” neuron sculpture
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