Establishing Production Consistency and Minimizing Downtimes

Damaged dowel holes and pins were causing alignment issues and slowing tooling changeovers. A redesigned insert system improved durability and reduced production downtime.

High Volume Metal Stamping

A crimping operation was added to the metal stamping process to lower costs for this product line. Using only two progressive dies to produce five stamped components created significant manufacturing efficiencies.

Delivering Quality with Innovation

Piercing multiple small features on a formed breather cover created quality risks and tool wear. A dedicated sub-tooling design improved accuracy and protected the progressive stamping die.

Producing a Robust and Precision Metal Part

An aging water tray design required frequent repairs and created durability concerns. Ultra used FEA‑driven redesign and prototyping to add strengthening troughs, resulting in a robust tray and a consistent, cost‑effective manufacturing process.

Streamlining Production and Improving Quality

This metal part was experiencing quality issues and rising production costs. Adding a new locking feature resolved the quality problems, and implementing a more efficient progressive stamping die reduced costs.

Meeting Design Challenges

The tabs on this lock washer were not forming correctly leading to production delays. Prototyping established a feasible manufacturing process that could metal stamp this part and its tabs to the design print.

Prototyping to Production

A successful transition from a two-piece welded assembly to one-piece aluminum frame with 21 hardware insertions required the manufacturing expertise of our Die Designers and Toolmakers.

Reducing Costs with a Progressive Stamping Die

Safety‑driven design changes—including a splash guard and six drainage slots—made the customer’s existing tooling unusable and increased production costs. Ultra engineered a new progressive stamping die that reduced cost per part while ensuring all added features maintained the full functionality of the fuel filler cup.

Improving the Production Process

This customized bracket required six bends and eight holes, demanding a precise fabrication process. Ultra optimized forming, hardware insertion, and inspection to increase production rates and meet design requirements.

Achieving Manufacturing Cosmetic Standards

This stainless steel part is metal stamped in our 800-ton press using a 144-inch progressive stamping die that successfully removes sharp edges and cleans the surface areas.

Quality Controlled Manufacturing Process

This manufacturing process uses a blend of Ultra’s in-house capabilities and select outside suppliers. Continuous AQL inspections ensure each metal part is delivered defect-free.

Delivering Cost-Savings for a Metal Stamped Part

By redesigning the manufacturing approach and shifting assembly into a progressive stamping die, Ultra delivered significant cost and efficiency improvements.

Robotic Welding a Stamped Metal Part

Improvements were needed to the welding process to maintain a high-quality and functional metal part. And a more efficient method needed to be implemented to reach acceptable cost levels.

Metal Part with Weight Requirements

The total weight of this part and the positioning of its legs are critical to its performance. An automated inspection system was created to verify both of these features are met after metal stamping has been completed.

Precision Metal Fabrication Components

Established a metal bending and metal cutting process to produce components for a fan assembly requiring a precision fit to operate as designed.

Customizing Parts with Metal Fabrication

Providing high-quality and durable metal components for the manufacturer to support flexible assembly options at the customer’s facility.

Providing Innovative Tooling Dies

This project focused on improving the performance and quality of the cutting operation located in this production tooling. This also included an effort to increase accessibility of this cutting component.

Comprehensive Die Maintenance Services

Delivering comprehensive die maintenance services to extend tool life and keep the customer’s production running smoothly.

Forming a Metal Part With the 800-Ton Press

This ramp is manufactured on a progressive die that includes only one forming station to complete that stage of production. A detailed finishing process includes deburring and polishing.

Outdoor Power Equipment Metal Stamping Case Study

Manufacturer of Rotary Lawn Mower Blade Sharpeners and Balancers for the Outdoor Power Equipment Industry

A recommendation from their previous supplier brought Outdoor Power Equipment Manufacturer’s leaders, Gerd & Erik Bauer, to Ultra’s front doors to continue production of their lawn mower blade sharpener.