Case Study: Reducing Costs with a Progressive Stamping Die
Customer
Motorcycle Manufacturer
Part
Fuel Filler Cup
Manufacturing Issue
Production costs increased after a splash guard and six drainage slots were added to meet updated safety requirements, rendering the customer’s existing tooling unusable.
Customer’s Goals
Reduce production costs by transitioning to a more efficient, repeatable manufacturing process.
Ensure the new features maintain the overall functionality of the fuel filler cup.
Redesign Process
A progressive stamping die was determined to be significantly more cost‑effective than the customer’s existing hand‑fed process. Ultra designed and built a new multi‑station die to create the part’s overall shape, form internal threads, and pierce the six drainage slots. Two stations formed the internal threads from the inside to eliminate burrs and meet cosmetic requirements. - With Ultra’s 800‑ton press and 168” bed, most operations were consolidated into one tool, reducing time, labor, and secondary operations.
The final operation used a smaller hydraulic press to accurately position and secure the splash guard, further reducing manual labor and improving consistency.
Customer Outcome
Ultra’s customized manufacturing process reduced costs and increased production rates.
The updated fuel filler cup met all required safety and performance standards.
The customer trusts our expertise and services to metal stamp two different sizes of this design for their assembly needs.
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