ith a collection of presses ranging from a 15-ton mechanical press to a 600-ton hydraulic press, Synergy Prototype Stamping LLC can take on an order for a single part or 100,000 units. For customers in search of sources for low-volume production, it can be difficult to find companies that won’t charge high prototype piece prices or huge tooling expenses seen for high-volume jobs.

A manufacturer of aftermarket off-road vehicle parts turned to Synergy to manage parts from start to finish. “We can buy turnkey with finished weldments, fully coated and inspected and ready for our final packaging. That saves us time and additional management on our end,” says an engineering product manager at an off-road aftermarket vehicle part manufacturer.

“Since Synergy is vertically integrated, they’re able to provide more production-oriented tooling setups and designs in order to optimize their process and get us a better price per piece as well,” he says.

Collaborative process

Clinton Township, Michigan-based Synergy Prototype Stamping produces 48 in. by 48 in. stampings for HVAC with extruded center holes. Press size, internal CMM capabilities and in-house 3- and 5-axis laser capabilities allow Synergy to provide customers with these services and to deep draw aluminum components. The latter is particularly desired among customers that make battery trays for electric vehicles.

Fracturing of materials is a big concern when working with various types of high-strength metals. “Having experience and knowledge of how certain materials stretch is invaluable in guiding our customers toward which materials to use, the radii needed and which thicknesses would work best,” says Ryan Willette, sales/estimating manager at Synergy Prototype Stamping.

The company can produce small, intricate stampings requiring 1/2-ton hand benders up to 600-ton hydraulic presses for large stampings.

“We have found that we are most competitive on long-term production jobs up to 15,000 pieces per year,” Willette says. Turnaround times typically range from three to five weeks.

“We design our own tooling in-house and cut our own tooling using four CNC mills,” Willette says. Between Synergy Prototype Stamping and its sister company, Synergy Additive Manufacturing, Willette says the group offers in-house laser heat treating for hybrids between prototype and production tooling methods.

“This process is more cost competitive compared to conventional heat treating and allows good heat treat depths locally with no tool distortion,” Willette says. “Tool distortion, in many cases, creates the need for secondary machining after heat treating, which adds unnecessary costs.”

A core group of customers deemed essential businesses kept Synergy busy during the initial shutdowns due to COVID-19. Serving industries spanning automotive, aerospace, heating and cooling, oil and gas, and the military, Synergy has adjusted its offerings, including producing hand sanitizer stations for its customers.

“Our established relationships with customers have allowed us to withstand the initial shortages experienced [early on during the pandemic],” Willette adds.

Moving forward

The last 10 years have proven challenging for tool and die makers in the U.S., says Willette. “One issue is finding a way to be competitive with die shops overseas,” he says. This is due in large part to continued use of outdated treating technologies such as flame and induction methods.

Consistent temperature ensures the tool and die components no longer require additional processes. Turnaround times are faster, and die makers have the freedom to make design changes. Synergy’s laser heat treating technology has helped local die makers improve profit margins, provide improved quality, and reduce the time to market to compete with overseas die shops, according to Willette. “This is one goal Synergy will always strive for—bringing more tool and die jobs back to the United States.”