Vol. 2/12
Magazine for Sheet Metal Processing in North America
Transmitting quality Amplifying success
Making it happen Realizing ideas, defining a future
A fabricating family Early adopters of technology
Built on loyalty Champs of fabrication
Special Section FABTECH Buyers Guide
CONTENTS
EXPRESS VOL. 2/12
FEATURE
8 Unbroken waves portrait
Transmitting clear signals of success
10 14
TOPICS TECHNOLOGY
12 Seven aces in the hole Sharpen up your punch tooling portrait
14 Hard work and a little luck This Michigan-based job shop defines its own future. portrait
26 Diversification & relationships Symbiotic relationships help drive this Canadian fabricator. PROFILE
28 A family tree rooted in fabrication 26
A commitment to the latest technology keeps the Roach family profitable.
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Standards Special Page 17 FABTECH Buyers Guide 2
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03 04 30
TO THE POINT Panorama CHARACTERS
32 32 33
stories in sheet metal CREDITS CLOSING POINT
to the point
Rolf Biekert, President and CEO
Manufacturing Matters Manufacturing has long been a keystone of our country. During the 1970’s, significant value was placed on goods produced in America and considerably contributed to the overall GDP. As time passed, the population’s mindset shifted. Financial and service-driven employment appeared more desirable than the seemingly low pay and tough working environments associated with manufacturing. At the same time, low cost countries further developed their manufacturing capabilities and offered very low priced products which drove public opinion against manufacturing in the United States. As a result, GDP contributions experienced a steady decline. The latest financial crisis demonstrated a limited threshold for servicedriven employment while the weakened economy yielded high unemployment rates and a growing national debt. However, the latest developments in low cost countries like China indicate a shift in the mindset and expectations of their workers combined with an overall increase in the cost of doing business and production overseas. At the same time, the discrepancy between the value of the US dollar and foreign currencies has decreased, affording the U.S. an opportunity to regain position and competitiveness. Suddenly, there is renewed value in manufacturing on American soil. To support this opportunity, we need a functional manufacturing industry comprised of innovative products, state-of-the-art manufacturing tools and procedures, and a workforce trained for this type of manufacturing environment. Careers, opportunities and potential pay available under the “manufacturing” umbrella are marred by years of negative perception. At a young age, societal pressures dissuade students from trade schools in favor of traditional high schools. Subsequently, they gravitate toward four-year degrees with the allure of higher pay and greater prestige. To change perceptions, we must transform the mindset of our society. Leaders such as parents, teachers,
politicians and management of private or public businesses who believe in and understand the importance of manufacturing must combine efforts to reestablish a positive perception in the U.S. Students in all stages of their education need science, technology, engineering, and math (STEM) skills, but with manufacturing education integrated into their program of study. The Society of Manufacturing Engineers expects vacancies in skilled factory jobs to reach three million by 2015. Instead of allowing students to gravitate toward service sector jobs for part-time or summer work, manufacturing-reliant businesses must devote resources to student development as an investment in their future. For example, by partnering with youth programs, technical schools, community colleges and organizations to create opportunities for learning, TRUMPF serves as a platform for high-tech manufacturing. In-house programs extend from middle to graduate level schooling and range from simple open houses to apprenticeship programs. TRUMPF realizes the value of short and long-term internships for local and foreign students and training programs for service technicians. These programs open eyes to facilitate individual growth while helping to establish a competitive edge. Companies must recognize their social responsibility to support students across the entire course of their education and development. Local and national leaders who acknowledge the importance of manufacturing need to help execute industry efforts. This is fundamental to the success and wealth of our society and supports a return to manufacturing in the U.S. The time is right to transform the structure of manufacturing in our country but all resources must work together to change societal perceptions and provide the educational foundation necessary to establish a workforce capable of development, design and high-tech manufacturing. Working together we can re-establish a positive perception that Manufacturing Matters! ExpressVol. Vol.2/12 2/12 Express
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PANORAMA
TRUMPF Inc. recognizes Sales Reps Top award goes to FabMore Machinery TRUMPF Inc. recently presented the 2012 Sales Achievement Awards to FabMore Machinery, Sterling Fabrication Technology and Icon Machine Tool at the annual distributor meeting held at TRUMPF Inc. headquarters in Farmington, Conn. FabMore Machinery received the Outstanding Representative Performance Award in recognition of the company’s exceptional achievements in selling TRUMPF products during the past fiscal year. The Sustained Excellence Award was presented to Icon Machine Tool in recognition of their consistent performance in selling TRUMPF products. In recognition of their dedicated and successful efforts to increase the sales and support of TRUMPF products during the past fiscal year, Sterling Fabrication Technology was presented with the Most Improved Performance Award. The awards were presented to the distributors by Burke Doar, Vice President of Sales & Marketing, TRUMPF Inc. > Additional information: www.us.trumpf.com
Rob Anderson (C) of FabMore Machinery accepts the Outstanding Representative Performance Award from Craig Summers (L) and Burke Doar (R)
Aiding Patients and Doctors “SIGN has helped patients, no question about that, but they have also helped doctors.”
> Additional information: http://signfracturecare.org/
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Surgical Implant Generation Network (SIGN) Fracture Care International is a non-profit organization focused on helping trauma patients and surgeons in developing countries. SIGN began as the personal mission of Army orthopedic surgeon, Dr. Lewis G. Zirkle who sought to provide the equipment and training necessary to treat people who could not afford medical treatment. Headquartered in Richland, WA., SIGN’s state-of-the-art manufacturing facility produces innovative medical equipment such as IM nails which are laser marked by TRUMPF TruMark lasers and used for fractures of the femur and tibia. SIGN donations help patients; but they also change the lives of doctors. For example, after a discouraging start as an orthopedic surgeon in the Philippines, Dr. Luigi Sabal was hired by Southern Philippines Medical Center, an institution fortunate enough to have a SIGN program. Through the program, young doctors such as Sabal are trained to help patients who would not be able to obtain suitable orthopedic implants or procedures without SIGN. In Dr. Sabal’s case, SIGN renewed his ambition to continue his surgical career in his home country. Since its inception in 1999, SIGN has grown from four pilot projects in Southeast Asia to more than 200 programs across 41 countries. Donations have influenced the lives of more than 50,000 patients and 2,000 surgeons in SIGN programs around the world.
Tooling Gentle Bending Tip
RollaV die enables bending without deformation
RVT100-1
RVT100-2
RVT100-3
.059 in
.118 in
.236 in
30°
65°
75°
.315 in
.591 in
1.38 in
Max. loading
33.5 tons/ft
50.3 tons/ft
83.8 tons/ft
Minimum side length, outside dimension
.185-.220 in
.342-.402 in
.957-1.04 in
Max. recommended thickness Min. bending angle Die width
Bending that’s gentle on the surface and free of deformation is no longer just an engineer’s dream thanks to the RollaV die. This versatile tool is able to bend without damaging the visible surfaces or film finish of sheet metal panels. Thanks to its innovative design, the RollaV die enables the bending of sheet metal near holes, notches and cut outs, without deformation. To achieve this, the contact surfaces on the sides of the die press the sheet metal evenly into the
lower die as it rolls in unison with the metal. This action prevents movement between the tool and the part being formed – eliminating frictional losses. Depending on the design of the die, available in 3 sizes, sheet metal from approximately .02 to .24 inches thick can be processed. The RollaV has the ability to bend very short lengths and a wide variety of material gauges. It is also particularly well suited for use on tapered parts
and for diagonal bends. Overall the RollaV die allows for greater latitude in bending –with less risk to the material. RollaV dies can be used with TruTops Bend in the following TRUMPF bending technologies: TruBend Series 3000, 5000, and 7000, the TrumaBend V-Series and C-Series, and BendMaster. > Additional information: www.us.trumpf.com
Bending parameters on the go BendGuide app keeps bending parameters handy With the BendGuide app from TRUMPF, calculating major bending parameters is quick and simple. The new mobile application supplies major bending parameters for immediate access to simple calculations such as the press power, die width, minimum leg length, installation height monitoring, inside bending radius and the weight of the sheet metal and its tooling. The application was developed for those who design parts, operate press brakes or schedule bending jobs. It is easily accessed on a Smartphone or tablet PC so the resource is available whenever it is needed. Users also have direct access to bending news, updates and technical brochures. The operating interface for this mobile app is available in German, English, Spanish, Italian, French or Czech. BendGuide is available for the iOS and Android operating systems and as a web app for every standard PC. > Additional information: scan the QR code or visit www.trumpf-machines.com/bendguide
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PANORAMA
A cause for celebration The 10th anniversary of TRUMPF Photonics, Inc.
From left: Dr. Peter Leibinger, Vice Chairman of TRUMPF GmbH + Co. KG and President Laser Technology and Electronics Divisions, Congressman Rush Holt, Dr. Georg Treusch, Managing Director of TRUMPF Photonics.
On September 28, 2012, customers, sales representatives, trade and local media, local dignitaries, and TRUMPF executives attended the TRUMPF Photonics, Inc. 10th anniversary event in Cranbury, NJ. The event included speakers, technical presentations and a comprehensive tour of the production facility. In celebration of this momentous occasion, Dr. Peter Leibinger, Vice Chairman of TRUMPF GmbH + Co. KG and President Laser Technology and Electronics Divisions, spoke on the importance of TRUMPF Photonics to the TRUMPF Group. “It seemed a long and winding road, but we needed to achieve vertical integration of our laser systems.” He identified the facility as a “true competence center” and stressed, “The success of TRUMPF depends on the success of TRUMPF Photonics.” Guest speaker Congressman Rush Holt, representative for Central New Jersey, also emphasized the importance of research in America and praised TRUMPF Photonics for its contribution to “Einstein’s Alley”, a term coined for this section of New Jersey dedicated to research and technology. The event highlighted the various steps involved in manufacturing laser diodes and diode based components, optical components, and solid-state RF generators which are developed at the facility in New Jersey for use in TRUMPF lasers worldwide. > Additional information: www.us.trumpf.com
Industry: The multiplier effect Manufacturing’s rank in the economy Manufacturing Information Agriculture Construction
In economics, it is commonly understood that an increase in spending generates an increase in national income and consumption greater than the initial amount spent. This is called the multiplier effect. According to the U.S. Department of Commerce, Bureau of Economic Analysis, manufacturing has a higher multiplier effect on the economy than any other sector. For every $1 in manufacturing value added, $1.4 in additional value is created in other sectors.
Other Services Transportation Arts and Entertainment Mining Government Education and Health Care Utilities Business Services Financial Services Retail Trade Wholesale Trade
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Figure 1. Multipliers for Sectors of the Economy
DOLLARS
Source: U.S. Department of Commerce, Bureau of Economic Analysis
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PANORAMA
50 years and growing Geater Machining & Manufacturing celebrates milestone This year marks the 50th anniversary for Geater Machining and Manufacturing, Co. (GMM), a custom precision sheet metal fabrication company based in Independence, IA. Started in 1962 by Duane Geater, it took approximately two years for GMM to establish a manufacturing division for the production of electronic controls, small assembly and sheet metal work. At that point, the company operated with approximately 10 employees. Although Duane retired, President Scott Geater and GMM’s 150 employees now ensure the Geater commitment will continue. “The vision established by Duane Geater is a driving force for us today. Our commitment to our customers, our employees and our community
defines us and our culture. Because of these commitments and our continued growth we are expanding again in 2012, our 50th year,” states CEO Jerry Bitterman. The company supplies precision machining, assembly, finishing, and sheet metal fabrication. It’s TruPunch 2020 and other fabricating equipment is put to work for the aerospace, electronics and other hightech industries. This year, Geater continues to solidify its place in history as they expand their facilities with 27,000 square feet of floor space. > Additional information: www.geater.com
Never Forget
Photograph by Jeff Keller
Service Metal Fabrication contributes to the 9/11 Memorial
The view from one of the reflecting pools at the 9/11 Memorial in New York City.
September 11, 2001 is a day that is forever embedded in the minds and hearts of Americans. Most remember where they were and how they felt as news of the terror attacks spread. People united as they joined cleanup crews, contributed to the search and rescue, donated money and provided so many other selfless acts to those in need. These men and women humbly hold the memory of the role they played in honoring the victims. There is one role in particular that a fabricating company from in Rockaway, New Jersey will never forget. TRUMPF customer, Service Metal Fabrication was selected to cut the names of those who died into bronze plates for the 9/11 Memorial. The plates frame two reflecting pools, each with a manmade waterfall, representing the north and south towers that once stood in lower Manhattan in New York City. Each panel is approximately 5 feet by 10 feet and when the 152 bronze parapets are combined, they display nearly 3000 names and are backlit so they are visible at night. These pools serve as the main focal point of the powerful Memorial which opened to the public on September 12th, 2011. > Additional information: www.911memorial.org Express Vol. 2/12
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feature
Continuous waves Transmitting clear signals of success
A
s the sea finds its way across the Atlantic Ocean and the waves approach the shores of Nova Scotia, they are greeted by waves of a slightly different variety. Here, at one of the most eastern points of North America, employees at Nautel Limited are hard at work developing the latest radio broadcast transmitters for implementation around the globe. Tucked into Hackett’s Cove, Nautel Ltd. serves as the primary manufacturing center and is home to all engineering, R&D and company management functions. At the Nautel headquarters, a large number of FM transmitters from 300W to 40 kW and high powered AM transmitters are produced. Radio stations purchasing RF transmitters used to send signals for broadcast are Nautel’s most frequent customers, but the company also manufactures navigational radio beacons and a wide range of transmitters, such as Differential Global Positioning System (DGPS) transmitters, and even amplifiers for plasma rocket engines.
Welcome to Maine A few years after Nautel Ltd. was established in Canada, the company secured contracts with the U.S. government and the United States Coast Guard, justifying a need for production capabilities in the United States. Nautel Maine was established in Bangor, Maine to fabricate navigational beacon products and low power AM transmitters. While its primary focus has not changed, Nautel Maine is capable of manufacturing most products as market demands change. “We have a clear niche, but we also have the flexibility to build additional products,” explains Charles Drillen, Plant Manager of Nautel Maine. Whether the customer needs an RF transmitter for radio broadcast, prototypes for global positioning, or several transmitters linked together to increase output power, Nautel’s work is always varied. “Customers often request a custom piece of equipment which requires us to take one of our established products and adapt 8
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On the shores of Hackett’s Cove: Dennis Dickinson, Fabrication Shop Supervisor of Operations (L) and Jim Evans, Head of Operations at Nautel Ltd.
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feature
Charles Drillen keeps production running smoothly at Nautel Maine.
it accordingly to meet the customer’s highly specific requirements,” explains Dennis Dickinson, fabrication shop supervisor of operations in Nova Scotia. Nautel radio broadcasters and transmitters are often installed in remote areas with harsh environments. Charles asserts, “There are often additional design elements that must be considered to ensure the product will be weather tight or corrosion resistant. Weather standards are often a factor, especially for the beacon products. For a customer like the U.S. Coast Guard, for example, the effects of sea salt are detrimental if they are not appropriately considered.” The flexibility to design and adapt products was one reason Nautel Ltd. decided to invest in a new TRUMATIC TC 2000 punching machine in the year 2000. Dennis says, “The flexibility of that machine was an important factor, but the 360° rotational tooling also made a big difference. As we installed the machine 10 Express Vol. 2/12
we reconsidered current design elements. The punch tooling allowed our engineering team to develop new products.” Wind, sun, and sea Although access to salt water and air may be useful when developing products for the Coast Guard, Nautel’s picturesque location can be a challenge. Dennis explains, “We are about as far east as you can go on the mainland. Geographically, the facility is not easily accessed so we must have machines that are very dependable. The reliability of the TRUMPF product is important to our production and especially in Hackett’s Cove, we really appreciate that we do not have to call for service.” Adapting to the weather In 2008, Nautel purchased an additional TRUMPF punching machine in response to business demands. “We had a major contract
from Turkish radio for over 150 transmitters that we needed to build in a short time. Our business was growing quite rapidly and we ran out of capacity on the first machine. The addition of the TruPunch 2020 allowed us to keep up with the current demand in Hackett’s Cove,” remembers Dennis. But, machine dynamics were not the only driving force behind Nautel’s decision to purchase a second punching machine. “We have had times when TRUMPF has helped by developing the punch tooling we need for certain products and we appreciate this added support.” With an established environment of engineering innovation, Nautel not only supports special projects but also its own product development such as intelligent transmitters which provide complete convergence of technology at the transmitter site. This progress is crucial for customers such as the National Oceanic and Atmospheric Administration (NOAA), who mount Nautel
Dennis Dickinson punching parts in Hackett’s Cove.
transmitters in locations so remote, all terrain vehicles can be required. These groundbreaking developments have propelled Nautel to leadership status in innovation, product quality, and the best service and support in the industry. President and CEO, Peter Conlon explains, “Highly integrated manufacturing gives us extreme control over product quality and as a side benefit allows us to achieve fast prototyping, which helps us to be very innovative in the market.” As a result, Nautel has transformed from a point product supplier to the largest manufacturer of radio broadcast equipment worldwide in just five years. For a company that prides itself on engineering innovations, standardization of the technologies used in production is essential. The focus on flexibility and productivity led the Bangor facility to a recent investment in a TruPunch 3000. Charles describes the motives behind the purchase: “We decided to upgrade an aging piece of equipment to a new TRUMPF machine. This allowed us to address limitations in efficiency, capacity and production and with the enhanced productivity we are better prepared to respond to market demands.”
”The punch tooling allowed our engineering team to develop new products.” In the past, fabrication for larger parts began in Hackett’s Cove and parts were shipped to Bangor for final production. The new TruPunch 3000 eliminates this eight hour drive and the need to transport parts between Nautel facilities. “Other than the obvious technological and efficiency gains,” Charles explains, “it also gives us greater flexibility to share or move work between locations. We gain in machine knowledge, shared tooling, machine programming and it also allows our engineering team to design products that can be made at either facility without having to consider machine
limitations.” Decisions like this have allowed Nautel to nearly triple revenues and dramatically increase shipments in the past few years while maintaining the same factory footprints. With the flexibility and mindset to adapt to an ever changing market, the company is well prepared for the future and whatever the tide may bring. With more than forty three years of experience, Nautel has become a global leader in AM and FM radio broadcast transmitters and as sure as the tide will rise and fall, Nautel is positioned for future success. Nautel Limited Who:
Nautel Limited, Hackett’s Cove, NS., Canada, established in 1969. www.nautel.com
What: Largest manufacturer of radio broadcast transmitters worldwide and producer of navigational beacons and global positioning transmitters. How:
TRUMATIC 2000, TruPunch 2020, Bangor, ME: TruPunch 3000
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TECHNOLOGY
Seven aces in the hole Precise adjustment and regular regrinding of tooling are critical in achieving perfect punching operations. TRUMPF offers seven “aces” that will help keep your punching tools in good shape. They ensure greater tool availability and a longer service life.
1.
QuickSharp: Fine grinding at the flick of a wrist
The QuickSharp makes for fast and safe regrinding of punching tools. Its digital display and clearly laid out control elements make for easy handling. Integrated length measurement, chucking fixtures, and an automated machining process make offline regrinding simple and effective. The face grinding process minimizes the thermal and mechanical loading of the cutting edges and ensures high quality at the tool surfaces – even for whisper punches.
2.
QuickSet: Simple, correct setting
QuickSet allows you to affix the punch and the adjustment ring offline and away from operations at the punching and combination machines. Tool length and the amount to be grinded away are read from a digital display. Determining the punch’s insertion depth makes an active contribution to avoiding collisions in the stripper. A special mount in the base plate simplifies removing the screws at the adjustment ring. QuickSet is suitable for both flat and whisper tools – in sizes 1 and 2 and for MultiTool implements.
3.
QuickLoad: Ready quickly for every need
QuickLoad simplifies mounting the tool cartridge. With it, it is possible to place the punch, die and stripper into the tool cartridge, and remove them quickly and precisely. Pneumatic unlocking eliminates any physical exertion.
ASharpening made simple “When we purchased our TruPunch 2020 machine, we decided on the QuickSharp as well and it has been a great resource for us. The TruPunch operates with a lot of different tooling and we essentially use the QuickSharp to regrind all of them. It is an easy and straightforward piece of equipment. Not only do we see quality results, regardless of the tool, the simplicity of the process enables us to train several operators, across different shifts, to use it without any difficulties and with consistent results.” Located in Gorham, ME., Jøtul North America is a subsidiary the Norwegian firm Jøtul AS, specializing in the manufacture of high-end stoves and fireplaces. More information: www.jotul.com/
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Matt Beliveau, Fabricating Department Supervisor, Jøtul North America
TECHNOLOGY
4.
RTC Tool Cartridge: Tool changes in no time at all
Using the RTC Tool Cartridge with TruPunch and TruMatic machines guarantees not only fast and safe retooling, it also maintains order. Weighing just 21 ounces, it lets the machine achieve maximum acceleration rates. Reinforced springs ensure that the tools are held securely while the fiberreinforced plastic chassis protects the machine against overloading. In case of a collision, the chassis will break away first, preventing damage to the punching head. The cartridge’s arms have an additional coating to protect against fretting corrosion and rust –thus extending the cartridge’s useful life. The ergonomically correct grip allows for simple handling.
A
5.
QuickMove: Putting tool cartridges on wheels
The tool cartridge cart makes for quick movement of loaded tool cartridges from point A to point B. The ergonomically correct design enables easy steering, a good overview of the contents, and quick access. It also has numbered positions, oil absorbing matting, a holder for tool set-up plans and job papers, along with integrated holders for the set-up levers and Allen wrenches used for the clamps – all these features make for real convenience.
A
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6.
QuickPad: Never a chance for scratches
The QuickPad mounting device simplifies the process of attaching adhesive pads to punching tools. This helps prevent scratches and impressions during machining. Special press devices for the size 2 die, the intermediate ring and the stripper ensure that the pads are centered exactly on the tool. The elastomeric pressure rings ensure that the self-adhesive pad is secured in place without trapping any bubbles.
7.
Punching Tool Cabinet: Everything in good order
Clearly arranged, space-saving and tidy – the key advantages of this specially designed storage cabinet. Vertical compartments give access from both sides, for fast and easy retrieval of up to seven hundred punching tools. Recesses accommodate lifting forks to make the cabinet portable.
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♥ Express Vol. 2/12
13
PORTRAIT
Herb Stricker (right) and his son Jon turned small opportunities into a successful business.
Hard work N and a little luck Turning a successful business despite a weak economy
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early fifteen years have passed since Herb Stricker took his son Jon’s truck to a neighborhood shop to have a broken windshield fixed. It was a bleak, classically cold winter morning in South Lyon, Michigan. Herb had recently been laid off from a company that served the Big Three in Detroit and as a Prototype Technician in his fifties, Herb was unsure of what to do next. Although there were indications of a recession, this local repair shop was busy and Herb was impressed. Speaking with the shop owner, he found some inspiration, “I had all these little parts that I had produced over the years. I decided to have them sandblasted so I might use them, along with my resume, for job interviews.” Herb was nearly out the door with the finished parts when the sandblaster suggested his brother might be interested in the work. Herb was soon on his way to meet Jeff Trapp of Jeff’s Bronco Graveyard in Brighton, MI.; unaware how this meeting would change his life.
PORTRAIT
Approaching “The Graveyard”: When he arrived, the phones at Jeff’s Bronco Graveyard, a Ford Bronco parts distributor, were ringing off the hook. Handing his sample parts to owner Jeff Trapp, Herb patiently waited. He only had a moment for reservations about this bustling business before Jeff was off the phone. “He took me in back where he had stacks of old parts, all in good order; handed me a box of brackets and asked if I could make them.” When Herb confirmed, Jeff rattled off a lengthy order. Without a place to work or the machinery to complete the job, Herb was less than prepared for his first account. However, he returned home determined and beaming. “My wife, Lorraine, questioned the big grin on my face,” he remembers. Unable to sleep, he developed a plan. “I bought a couple of tools on credit, and with my son, Jon, started working from the basement.” It was such a success, that Herb and Jon Stricker, co-owners of Superb Fabricating LLC., rushed to finish the backyard pole barn in an effort to expand the workshop. Building a business: Traffic to the pole barn began to grow as work continued up to sixteen hours a day. Rather
than upset the neighbors, the Strickers moved to a rental shop in Milford. Kimberly, Herb’s daughter and owner of her own marketing firm, designed a website, and Superb Fabricating was up and running full speed. Superb Fabricating continued to expand in f loor space and fabricating solutions, adding a TRUMATIC L 2520 laser cutting machine and TrumaBend C66 press brake to the operation by 2005. By
“People know that we will supply quality parts, in a timely manner and at a fair price.” 2011 the company had grown significantly and they purchased a much needed larger shop in South Lyon. As the company continued to grow, so did Jon Stricker’s knowledge of ways to combine the traditional metal fabrication he learned from his father, with new technologies. Now, Jon is well versed in applying his understanding of SolidWorks to reduce costs per part. “Together with our experienced design and fabricating team, we adjusted design aspects of the Bronco brackets to run on the TruBend and TruLaser machines instead of reproducing them as stamped parts.” This consideration is not only applied to “The Graveyard” brackets. Over the years, Superb has accumulated customers, priding itself on the quality and expertise it provides to local and startup businesses. “Most of our customers are in Michigan and most are earned by word-of-mouth.” Jon explains, “A lot of our business is in bracket fabrication, Express Vol. 2/12
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PORTRAIT Superb looks to redesign parts for the latest fabricating technologies.
but our customers are diverse – ranging from a local recycling company that supplies collection containers for batteries, to an industrial gas provider who requires cages for gas bottles, to a supplier of roof-mounted solar panels used to minimize heating costs during tough Michigan winters”. Even medical companies have approached Superb for manufacturing assistance. “We recently purchased a TruLaser 1030 with a 5x10 ft. table and the TruBend 7036 electric press brake we saw at FABTECH last year,” explains Herb. These new tools are ideal for the small and medium-size parts Superb often has in production and is a cost-effective investment to prepare Superb Fabricating for future growth.
asked to buy twenty. Herb ran the job immediately and delivered the wrenches so quickly, they were still warm. Local stores readily agreed to sell the wrenches and Herb began to establish an online presence as well. As word spread, he knew he had developed a winner. “I thought, maybe I better get a patent.” Constructed of rust-resistant steel with a rubber handle and available in a variety of sizes, Superb Wrench, a division of Superb Fabricating, patented the Filter Housing Spanner Metal Wrench. Herb recounts, “We made 10,000 handles over a three month period.” The wrenches have been so well received; the company hired a new General Manger; devoted solely to this product. Now, the company looks to expand distribution to include larger hardware stores, in addition to the specialty shops and online opportunities.
Community values: Unlike many companies, Superb Fabricating has grown despite the unstable economy. Now with twenty employees, Herb and Jon plan to hire additional help. “I like doing business in the area and we believe in hiring local workers” Herb affirms. The Stricker family’s dedication to the community is evident. With top-notch attention to their customers, they are able to support and maintain a loyal, local customer base. Herb humbly explains, “People know A wrench in the works: This forward thinking even led Superb to the launch of a that we will supply quality parts, in a timely manner and spin-off business. Born a city boy from Detroit, Herb never at a fair price. That is what makes us successful.” considered the dirt and iron that plagues water outside Superb Fabricating LLC the city. Yet every six months, at the request of his wife, Herb changed the water softener filter in his South Lyon home with a small plastic wrench. When the iron build-up became too difficult, the wrench snapped and Herb was forced to call a technician. Finding little comfort in the technician’s assertion that this was a universal problem, Herb decided, “This wrench was poorly designed. I’m mechanically inclined and even I can’t use it.” He went to work, using the laser to cut a new steel wrench with a longer handle. ”I thought, it can’t be this easy,” but when Herb showed the technician, he
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Who:
Superb Fabricating LLC. South Lyon, MI. established in 1998. www.superbfabricating.com
What:
A complete sheet metal fabrication resource, producing parts from start to finish. Sole producer and manufacturer of Superb Wrench water filter housing wrenches.
How:
TrumaBend C66 (TruBend 3066), TruBend 7036, TRUMATIC L 2520, TruLaser 1030
TRUMPF at FABTECH 2012 Booth C3016
Special Faster to the Finish ‚ FABTECH Buyer s Guide The odds of winning the race increase with the perfect combination of high performance and quick pit stops. At FABTECH 2012, held November 12-14 in Las Vegas, TRUMPF will feature laser cutting machines, punching machines and press brakes that allow quick changeover to keep you running. TRUMPF strives to ensure you make the best technology choice for your application. Stop by the TRUMPF Race Arena to watch a head to head competition between a TRUMPF CO2 laser cutting machine and a solid-state laser cutting machine. Then, take a pit stop at the MyTRUMPF CafÊ to learn more about how TRUMPF technology and services can get you to the finish line ahead of the competition.
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Special Section
Drivers Start Your Engines TruLaser 1030
Equipped with the TruCoax 2500 CO2 laser, the cost effective TruLaser 1030 paves your way into the world of laser cutting. In addition to 25% more laser power compared to its release in 2009, the TruLaser 1030 with TruCoax 2500 features an RF generator integrated in the machine cabinet, replacing the tube generator in the original model. The higher laser power results in cutting speed increases that average 20%. In addition, the RF generator reduces maintenance costs.
The TruLaser 1030 also features low investment and operating costs. As a result of the combination of low power and footprint requirements, the TruLaser 1030 offers the opportunity to easily add laser cutting to in-house services, increasing capabilities.
TruLaser 1030 fiber
The TruLaser 1030 fiber is equipped with the TruDisk 2001 featuring 2.0 kW of solid-state laser power for high speed cutting applications in thin gauge materials. The TruLaser 1030 fiber cuts a wide range of materials that includes not only mild steel, stainless steel and aluminum, but it also cuts non-ferrous materials such as copper and brass up to 0.125 inches thick. Just like the TruLaser 1030 it has considerable price advantages.
TruLaser 1030
Working range: 120 x 60 in. Laser specification: TruCoax 2500 Max. laser power: 2500 watts Max. speeds: 3346 in/min Max. sheet metal thickness Mild steel: 0.6 in. Stainless steel: 0.3 in. Aluminum: 0.25 in.
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TruLaser 1030 fiber
Working range: 120 x 60 in. Laser specification: TruDisk 2001 Max. laser power: 2000 watts Max. speeds: 3346 in/min Max. sheet metal thickness Mild steel: 0.5 in. Stainless steel: 0.25 in. Aluminum: 0.187 in. Copper: 0.08 in. Brass: 0.125 in.
TRUMPF at FABTECH 2012 Booth C3016
TruLaser 5030 fiber
Working range: 120 x 60 in. Laser specification: TruDisk 5001 Max. laser power: 5000 watts Max. speeds: 9252 in/min Max. sheet metal thickness Mild steel: 1 in. Stainless steel: 0.75 in. Aluminum: 0.75 in. Copper: 0.375 in. Brass: 0.375 in.
Determining which TruLaser 1030 is the right choice for you is dependent upon several factors. Visit the TRUMPF “Race Arena” at FABTECH and watch the TruLaser 1030 and TruLaser 1030 fiber battle it out cutting various parts and materials side by side to help you determine which machine will power your company past the competition.
TruLaser 5030 fiber
TRUMPF’s TruLaser 5030 fiber now features the 5kW TruDisk 5001, making it the highest powered solid-state 2D laser cutting machine on the market. The added power of the 5kW disk laser results in increased cutting capability in material thickness and speed. The machine significantly reduces the cost of production for sheet metal fabricators who specialize in cutting thin sheet material. The TruLaser 5030 fiber offers cost
effective cutting in mild and stainless steel and aluminum, as well as non-ferrous metals such as copper and brass up to 0.4” thick. To keep processing time as low as possible, the TruLaser 5030 fiber features TRUMPF’s single-cutting head strategy and automatic nozzle changer. At FABTECH the TruLaser 5030 fiber will be equipped with the LiftMaster Compact and PartMaster automation components to achieve maximum performance. Capable of handing material while the machine is in production, the LiftMaster Compact achieves high-speed material handling in a minimal footprint. With the PartMaster, processed sheets are automatically transported to the sorting station, increasing sorting productivity by 30%.
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Special Section
TruBend 5130
TruBend 7036
Representing the TruBend Series 5000, the TruBend 5130 combines innovative technology with TRUMPF precision to reduce cycle times by up to 30 percent. With a press force of 141 tons and six-axis back gauge solutions, the press brake features a hydraulic system for precise bending of a wide variety of parts in various sizes and material thicknesses.
The TruBend 7036, is not only the fastest press brake in the world, but it is also the most ergonomic. Its world’s speediest brake claim is achieved through high speed and acceleration values of the beam and back gauge. And, features like its adjustable arm and foot rests, pivoting control panel, and seated operation, support its industry leading ergonomics.
Whether the parts are large or small, complex or simple, ACB (Automatically Controlled Bending), the patented measuring technique, ensures first part accuracy, minimizing downtime and reducing scrap. Programming can be performed with TruTops Bend software, or right at the machine control. The optical LED and positioning visually assists the operator, facilitating quick set-up and bend sequencing. The 4-cylinder technology ensures uniform pressure distribution over the entire length of the ram. Other features, such as the ability to bend up to 127 inches, the quick-change tooling system and an installation height up to 24�, provide additional production support.
Typical applications include sheet metal parts used in the production of vending machines and electrical equipment as well as in the telecommunications and aerospace industries. It is an especially cost-effective solution for bending small and medium-sized parts up to 40 inches. Optional TRUMPF LED lighting illuminates the bending area without unpleasant radiant heat. And, a laser line projects the bend line onto the sheet metal part surface indicating precisely where it will be bent, enabling the operator to verify that the work piece is in the correct position.
TruBend 7036 TruBend 5130
Press force: 141 tons Bending length: 127 in. Rapid approach & return: 520 in/min Working speed: 24-48 in/min Installation height: 15 / 24 in. Stroke: 8.5/17.5 in. Throat depth: 16.5 in.
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Press force: 40 tons Bending length: 40 in. Rapid approach & return: 520 in/min Working speed: 24-59 in/min Installation height: 12 in. Stroke: 4.75 in. Throat depth: 6 in.
TRUMPF at FABTECH 2012 Booth C3016
TruPunch 3000 Working range: 100 x 50 in. 120 x 60 in.* Punching force: 20 tons 20 tons Max. simultaneous speed (X and Y): 4252 in/min 4252 in/min Tool change time (MultiTool): 0.3 sec. 0.3 sec. Max. stroke rate (punching): 1000 1/min 900 1/min Max. sheet thickness: 0.25 in. 0.25 in. Tool stations: 18 (180 with MultiTool) 17 (170 with MultiTool) *With repositioning
TruPunch 3000 The TruPunch 3000 is the first punching machine in the world designed for skeleton-free processing. This innovation reduces material requirements by an average of 10%, increases process reliability, is extremely userfriendly and features increased safety. The TruPunch 3000 has an electric punching head and an average electrical consumption of about 5 kW, which makes the machine very energy efficient. Fabricators benefit from its high resource efficiency, skeleton-free processing, virtually scratch-free material handling up to 0.25 inches thick and its small machine footprint. At FABTECH the TruPunch 3000 will be equipped with the SheetMaster automated load and unload system. Enhanced process reliability can be achieved with the double sheet detector, accurate suction cup positioning and minimum part pick up size of 2 to 4 inches. The Sheet Master can be easily equipped with a automation options such as carts to make ideal use of available resources like manpower and space.
TruMark 3020
Wavelength: 1064 nm Laser medium: Nd: YAG Pulse repetition frequency: 1 kHz - 100 kHz Max. marking field: 4.3 x 4.3 in., f=6.3 in.
TruMark 3020 / TruMark Station 5000 The TruMark 3020 marking laser, a diode-pumped solid-state laser with a wavelength of 1064 nm, provides high mark quality with unique energy efficiency that results in an approximate 80 percent reduction in power consumption. Its excellent beam quality, a recognized TRUMPF laser marking standard, provides remarkably high peak power. However, its real forte is the cost-effective processing of metallic surfaces and plastics. Like all lasers in the TruMark series, the convection air-cooled TruMark 3020 stands out due to its modular and compact design. Scanner, laser head and power supply are connected through a hybrid cable so that the marking laser can be easily integrated into existing production systems. At FABTECH 2012 the TruMark 3020 will be housed in a TruMark Station 5000. The extremely compact TruMark Station 5000 offers long traverse paths and high travel speeds in the linear axes, which are available as a complete module that can be installed in just a few steps. Additional features include a powerful suction unit that enables marking processes with strong materials removal and ergonomics designed for operator comfort and optimal efficiency.
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Special Section
Performance Leaders Manufacturing lasers since 1971, TRUMPF has more than 4 decades of experience with industrial lasers and their applications. As the biggest industrial laser company in the world with the largest laser installed base of any manufacturer, TRUMPF has the most comprehensive product portfolio ensuring the right tool for the job.
TruFlow Over many years, TruFlow CO2 lasers have become well established in laser materials processing, and are known for their reliable and robust beam sources. Tens of thousands of beam sources worldwide have proven this laser consistently dependable as a universal cutting and welding tool.
TruCoax Diffusion-cooled CO2 lasers are impressive due to their compact and lightweight design. And with a high beam quality, they are optimal for thin sheet processing.
TruDisk With power outputs of up to 16 kilowatts and beam qualities starting at 2 mm*mrad, disk lasers offer unrivaled robustness - for highly productive thin sheet cutting, fine welding, remote welding, deep penetration & hybrid welding, as well as for laser metal deposition.
TruDiode The direct diode lasers are extremely energy efficient and particularly well suited for welding, brazing, laser metal deposition and heat treating applications.
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TruFiber Fiber lasers are impressive due to their high processing speeds in the lower output range. With laser outputs between 200 and 400 watts in fundamental mode beam quality, they are ideal for precision processing.
TruPulse With short high-energy pulses at a higher pulse output, pulsed solid-state lasers are ideal for spot or seam welding as well as cutting.
TruMicro Short and ultra-short pulse solid-state lasers are used in micro-production and photovoltaics for structuring, material removal, edge stripping, cutting, and drilling.
TruMark With beam sources in all relevant wavelengths (infrared, green, ultraviolet), marking lasers mark metals, plastics, glass, ceramic and organic materials.
TRUMPF at FABTECH 2012 Booth C3016
TRUMPF’s Portable Power Tools Put the Power of TRUMPF in Your Hands TRUMPF has more than three-quarters of a century of experience in designing rugged, precise portable power tools for the HVAC, metal shop, construction and other related industries.
Shears/Double Cut Shears A complete line of shears that is ideal for cutting jobs where material loss through chips must be avoided.
Nibblers TRUMPF nibblers are easy to guide and cut distortion-free through a variety of thin and thick (0.375 in. in mild steel) materials including stainless steel and aluminum.
Fasteners/Seam Lockers Facilitate production of standing and angular seams at tight angles, as well as closing Pittsburgh Seams.
Bevellers Provide clean, accurate edges that help guarantee good weld quality; TRUMPF bevellers can start a bevel at any point with no structural damage to the material.
Chamfer/Deburr TRUMPF chamfering and deburring machines create cuts with excellent surface quality, which is important for large visible welded edges.
Slat Cleaner Removes slag build-up on support slats without interrupting production. It is a simple and cost-efficient alternative to manual slag removal or complete slat replacement.
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Special Section
TRUMPF at FABTECH 2012 Booth C3016
TruTops Software Machine Intelligence TruTops Software TRUMPF software products and solutions provide idea support for all of your sheet metal processing needs. In addition to solutions for sheet metal design, programming systems and proposals for complete production control, we offer custom products to match your specific requirements.
Design Software With numerous functions geared toward sheet metal processing, TRUMPF design software is a time-saver. Integration of TRUMPF bending factors ensure precise production and the modular principle results can be adapted to your needs. It is also coordinated perfectly with TruTops programming systems.
Programming Systems
The perfect mix of productivity and process reliability gives you complete control of part processing. It features a seamless modern operating concept focused on ergonomics and efficiency. Programming systems are integrated into the total TRUMPF concept from design to production planning.
Production Control
With TRUMPF production control software you have a constant overview of your production situation enabling quick response to interruptions. Production sequences and processes are optimized, which assists in controlling costs.
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FINANCE
TRUMPF Finance: Advantage Lease Keep your TRUMPF equipment technology current
As a shop manager or production supervisor, the challenge is always to keep manufacturing cost low enough to be competitive while producing parts as quickly as possible. Two main factors that can positively influence this are minimizing labor cost and maintaining highly productive machines with the latest, most state-of-the art technology. Wouldn’t it be nice to know that in 3 to 5 years you could have the choice to upgrade your equipment to the most current technology or keep what you have, based on your manufacturing needs? At TRUMPF Finance, an Advantage Lease is one method to help you manage changes in your manufacturing environment. In most cases, an Advantage Lease can provide a lower monthly payment that also includes warranty and preventive maintenance visits for the term of the lease. A lower monthly payment translates into a lower operating cost for machine time and an increase in cash flow. This allows you to be more competitive in capturing and increasing business. The difference in monthly cost can be significantly less than that of a conventional loan. In addition to monthly cost savings, TRUMPF Finance’s Advantage Lease provides the flexibility to return the machine at the end of the lease. This allows you to decide whether to retain your valuable TRUMPF machine or replace it with one of TRUMPF’s newest technologies. The buy-versus-lease question is one of the most common in the business world. There are considerable tax and income advantages and disadvantages on both sides which you should discuss with a qualified financial advisor. But if want to have more flexibility in your equipment based on your manufacturing needs, an Advantage Lease can be a perfect solution.
TRUMPF Finance: At a glance* $1-Option-Lease TRUMPF Finance’s most common offer, featuring level monthly payments for 36 to 72 months. Finance Lease with balloon Level payments for 36 to 72 months where monthly payments are lower than the $1-Option. At the end of the lease machine purchase is completed with a final balloon payment (i.e. 20% of the price of the machine). Delayed Payment Lease No payments for a period of up to 3 months, providing time for machine installation and programming. This option assists customers in generating revenue before making payments on the machine. Interest Only for 1 Year Begin with a 15% down payment and interest only payments, if you qualify, during the first 12 months of the financing. This is followed by regular principal and interest payments. Ramp-Up Program With no payment for 3 months, this option eases into monthly payments as follows:
n 25%
of a normal payment for months 4-6 of a normal payment for months 7-9 n 75% of a normal payment for months 10-12 n Normal principal and interest payments for months 13+ n 50%
Additional information: mike.morissette@us.trumpf.com *Products are available based upon credit approval by TRUMPF Finance.
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Portrait
David Bridges knew Lise Baker had all the tools to take over and lead the business
Diversification & Relationships An unbeatable combination for Champ Industries
D
avid Bridges had always been a bit of a cowboy. He often walked the shop floor dressed in blue jeans, a cowboy hat, shirt and boots. Certainly, he wasn’t your typical businessman. But he knew metal fabrication inside and out. He also realized the value of relationships and diversification. The Canadian company that evolved into Champ Industries began as a manufacturer of glass washing machinery for restaurants and bars. Before Bridges bought the company in 1992, he was one of five employees. The company manufactured excellent products, but not in high volumes. The business needed to branch out. Bridges turned to an acquaintance who worked for a local original equipment manufacturer. Through the relationship they developed, Bridges gained the opportunity to do work for the large manufacturer. He delivered high-quality work in such a timely, cost-effective manner that the company gradually gave him more and more jobs.
Growing Relationships As the work grew, so did Champ Industries and its relationship with the large OEM and other local manufacturers. Champ needed laser cutting machinery to keep up and turned to TRUMPF Canada. Another mutually-beneficial relationship formed. By 2004, 26 Express Vol. 2/12
Portrait
Champ was humming with TRUMPF lasers, punching machines, and press brakes. The company was expanding rapidly. That’s when Bridges asked his stepdaughter, Lise Baker, to join the organization. Bridges wanted someone he trusted to lead the growing business. A nurse for seventeen years, Baker had proven leadership skills, running an adult mental health program at a large teaching hospital. “We have sheet metal experts,” Bridges said, “You just need to know how to lead people and provide them with the tools that they need to do their jobs well.” Technology to Meet Needs New TRUMPF technology facilitated the quality work done by Champ employees. Champ’s bond with TRUMPF was so strong that as Baker moved into a leadership role, Bridges made sure she understood the value of TRUMPF equipment in maintaining quality products. Baker concurs, “TRUMPF technology plays a huge role in our success. It helps us stay one step ahead of the competition by fabricating parts with greater speed, precision and cost-effectiveness.” A TruLaser Tube 7000 is among the newest tools that Champ employees use to ensure customers get what they need done. The tube laser machine trimmed the time and labor required for one particular job from three hours to seven minutes. Additionally, the machine allowed Champ to expand beyond flat sheet laser work and to diversify into the tube market. “The tube laser was a calculated risk, but the speed, precision and ability to redesign parts to reduce costs were worth it,” explains Baker. “We were one of the first job shops in the area with laser tube cutting technology. It gave us a tremendous opportunity to diversify and cultivate many new customer relationships.” Maintaining the Legacy Although Bridges died in 2007, Champ employees still embody his spirit – ready for a challenge and having fun, but serious about work. The growing staff of one hundred and seventeen employees is busy covering what will become a 24-hour, seven days a week schedule. Champ typically has parts ranging from half-inch brackets to large welded assemblies for the transportation, commercial and agricultural equipment markets. “We always try to honor customer requests and do whatever we can to meet the urgent needs of our customers,” Baker emphasizes. “Our growth and success is largely attributable to our skilled employees going above and beyond to satisfy the customer. If a loyal customer says, ‘I’m in a jam. I need this part or I’ll have to shut down the line tomorrow,’ we do what we can to be as responsive as possible. There is a long list of employees who’ve worked during a vacation or in the middle of the night to ensure a job gets done.” Flexibility to Adapt The company continues to cultivate strong customer relationships with a variety of local OEMs. For Champ, adapting to customer requirements has meant advancing technology and software, gaining ISO certification ten years ago, and even adding a new facility in the United States. Champ prides itself on having the flexibility needed to fit urgent customer jobs into the production schedule. “Our equipment,
for example the TRUMPF press brakes, allows us to do timely and rapid tooling changeovers to accommodate urgent customer needs,” Baker explains. To meet the increasing US content requirements of one of its largest customers, Champ opened a 10,000 square foot facility five hours away, across the border in Jamestown, North Dakota. The US-based operations
Champ largely attributes success to the skill set of its employees
expanded into a 37,000 square-foot facility just three years later. “It was a big risk, but we recognized it as a stepping stone toward further diversification opportunities,” says Baker. As in Winnipeg, the North Dakota facility is filled with TRUMPF laser cutting, bending, automation and punching technology to ensure company standards are met. The North Dakota production manager upholds Champ’s dedication to quality, responsiveness and cultivation of strong customer relationships. Symbiotic Relationships Champ Industries realizes the symbiotic nature of their relationships with customers and suppliers. “Our investment in new technology, such as the tube laser, and our diverse and growing customer base reduces our risk and strengthens the company,” Baker says. Business is booming and Champ Industries expects continued growth from their loyal customers and new business in Winnipeg and North Dakota. Thanks, of course, to the dedicated staff and advanced technology which help Champ continue to meet customer needs. Champ Industries Who: Champ Industries, Winnipeg, MB. Canada, established in 1992. www.champstainless.com What: Provider of quality metal fabrication How:
TruLaser Tube 7000 with automation, TruMatic 6000 with automation, TruLaser 5040, TruLaser 3030, TruPunch 2020, TrumaBend V85 (TruBend 5085), TrumaBend V200, TruLaser 3030, TruBend 7036. Jamestown, ND: TRUMATIC L4030 (TruLaser 3040), TruPunch 2020, TrumaBend V130 (TruBend 5130), SheetMaster
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PROFILE
A family tree rooted in fabrication A focus on new and diverse technology works for Eaton.
W
hen Lloyd Roach Jr. was sixteen years old, he began working alongside his grandfather, father, uncle and cousin at the family business, Eaton Fabricating Co. Inc. Throughout high school and college, his interest in sheet metal fabrication grew as did his knowledge and understanding of the maintenance, repair and other basics of the equipment in the shop. Now as Production Manager, Lloyd is well versed in the company business and in keeping ahead of the times. When asked how it is to work with so many family members, Lloyd gives a little laugh. “We don’t always agree but we always find a way.” The family business was established in 1963 when Cecil Roach and his brother Ray set up a rose-bud torch and an arc welder in Cecil Roach’s one-car garage. Their first work was mainly fabricating ornamental hand rails and mending farm equipment for local patrons. The Roach brothers’ business took off, necessitating an increase in manufacturing space. Eaton Fabricating moved shop several times as they grew but ultimately purchased land in Grafton, Ohio. Construction was completed on the company’s first building in 1976. Since then, the business has grown to occupy 110,000 square feet of space on the property.
Production Manager Lloyd Roach, Jr. ensures part precision and tolerance is met for his customers
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Evolving and investing Over the years, Eaton Fabricating found the best way to drive their business further has been to invest in technology. In 1987, they bought a TRUMATIC
PROFILE
240 Punch Press to help meet production requirements. While the company also had a TRUMPF CN 75 nibbler, this was the first new TRUMPF machine the company purchased. It was only the second machine of its kind in the country; however, this did not deter the company from the It’s a Roach family affair for (L-R) Ray Jr., Ray, Lloyd, and Lloyd Jr. investment. Instead, the family embraced the new equipment and in 1990 when an axel fabrication project started to percent of the work is produced within our facility and the customer has die down, Eaton Fabricating again looked to expand their offerings and only to integrate the remainder and perform the test fire.” enhance the business. With a wide range of offerings, the company maintains a diverse This time, the Roach family decided on the TRUMPF TC 260A Rotation; portfolio of clientele, manufacturing products such as coatings equipment, eventually known around the shop simply as Herman the German. They turnkey washers and batch ovens, and even Humvee chassis for a bought the new punch “sight unseen” from Germany and once again, it simulation program used by all branches of the military to help train was the second in the United States. Lloyd recounts the memory of the soldiers before they are shipped out. “Our work and our customers rotate installation, as learned from his uncle, Ray. “A service technician from which keeps us active when others are experiencing slow times and we Germany practically lived in the shop, working to adjust for dirty power have also been able to pick up business when others unfortunately, must coming in from off the poles. Achieving consistent results took work and close their doors.” Lloyd speaks of a customer in Florida who came to it ultimately influenced installation for the machine moving forward.” Eaton simply because it could not find a vendor capable of building its Eaton Fabricating maintained this forward thinking as it continued military product to the standards required. “While we receive requests to evolve. In 1993, when the company decided to purchase its first laser for work from our website and the internet, word of mouth is the biggest machine, very few fabricators offered laser processing of heavier plates. contributor to our growth.” Lloyd explained, “We were looking to separate ourselves from the shops With such a solid grasp of manufacturing for a wide range of customers that provided plasma cutting. With the laser, we could give the customer and a clear head on how to diversify, the bigger challenges might be the precision products they wanted to see; cutting half inch plate at the 5 outside the shop. Lloyd jokingly admits that since Eaton Fabricating is thousandths tolerance nobody else could guarantee.” such a family business, “There is a lot of shop talk, all day long and the moms and wives don’t always appreciate that.” Filling the needs “Our business is driven by our ability to keep ahead of the times. We look to provide the best speed, precision and a tolerance we can maintain.” Eaton Fabricating Co. Inc. says Lloyd. The ability to provide when others cannot has established Eaton Fabricating as a premier partner not just in the Cleveland area but Who: Eaton Fabricating Co. Inc., Grafton, Ohio, established in 1963. across the United States. “We have maintained a system of purchasing new www.eatonfabricating.com equipment roughly every-other year,” Lloyd explains, “and our decisions regarding new machines are often driven by product lines.” For example, What: Precision sheet metal fabricators Eaton Fabricating is part of a joint project to provide power grid cabinetry How: TruLaser 4030, TruLaser 5030, 3 x TC 500, TrumaBend V320 used to generate power overseas and on military ships. “We manufacture (TruBend 5320), TruBend 5170, 2 x TrumaBend V85 (TruBend 5085) the housing and perform a portion of the assembly. Approximately eighty Express Vol. 2/12
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CHARACTERS: PEOPLE AND SHEET METAL
”Working in this environment gives me such unbelievable perspective.”
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Deedee Morrison knows the fine art behind forming sheet metal
CHARACTERS: PEOPLE AND SHEET METAL
A
cross America, in parks and outside libraries, you’ll find artist Deedee Morrison’s remarkable steel sculptures - beautiful towers of silver sheet metal that glow from within like a firefly after sunset. Grand as they are, these beautiful structures have unexpectedly humble beginnings at Deedee’s studio in Birmingham, Alabama. Her studio space is located in what was formerly Republic Steel Mill, situated just outside of an active rock quarry. At one time, the steel mill was an integral part of Birmingham’s industry, and that significance is not lost on Deedee. “Working in this environment gives me such unbelievable perspective.” She also enjoys the hustle and bustle of the quarry nearby. “I can hear trucks coming and going, dynamite being blown, the quarry walls falling in.” The path Deedee took to attain her studio near the rock quarry has been a fascinating journey. An economist by trade, Deedee was living and working in London when she began taking sculpture classes. Back then, her medium was clay, and art was merely a hobby for her. After moving back to the United States, she picked up a welding gun and enrolled in a two year certification course at a local technical school. Though it was quite a different experience compared to a traditional art program, the welding course played a large role in her evolution as an artist. “I’ve always wanted to be a welder, I have no idea why,” Deedee laughs. “I love working with metal. It suits me.” Deedee’s studio is equipped with a plasma cutter, but by working with local fabricators she is able to expand the size of her projects and take on new challenges with her art. The ability to fabricate larger pieces has evolved the more she has learned, and with access to laser
The art of melding nature with industry Artist Deedee Morrison adapts lasers and light for public works of art.
cutting technology she is able to achieve more intricately detailed patterns in her pieces. “It is a pleasure to work alongside people who understand the material and its nature better than I do. I’m still learning; I learn every day.” Deedee continues, “The more I learn the more I understand how I can create – how to make the material bend, how to get what I want out of it or what more I can ask from it.” As a public artist, Deedee is committed to using her artwork as a platform to relate a message of environmental awareness. Her greatest inspiration is nature, and her studio’s location helps her connect with the earth in a significant way. “I love the heat in the summer; the cold in the winter; being exposed to the elements and that close to the earth. I love working in such an organic yet industrial setting. At the bottom of the quarry, I’m standing in 600 million years of history.” In her Charms series of sculptures, Deedee incorporates limestone rocks she has collected from the quarry’s perimeter with her signature sheet metal to embrace this geological history she admires. Deedee is dedicated to using environmental efficiencies in her art as much as possible. “Our understanding of renewable energies is limited only by our lack of knowledge,” she explains. Exploring these renewable energy sources has encouraged her growth as an artist. Some of her earlier pieces are lit with highly efficient LED lighting while her more recent pieces go a step further and utilize solar power. Seed Pod, located in Chattanooga’s Renaissance Park, is one of her first and greatest practical applications using solar energy. Deedee likens the technology to the process of photosynthesis. “A plant sits outside and absorbs enough energy to build new life,” Deedee marvels. “Seed Pod is a great example of how you can harness the resources of the sun. It is one solar panel that powers itself every day, without fail.” Demonstration pieces such as this are aweinspiring ways to introduce alternative energy to a community in a profound yet understandable way from a very unique artist. Express Vol. 2/12
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stories in sheet metal
CREDITS
Steel Shelters
TRUMPF Express 2/12 Magazine for Sheet Metal Processing
Through wars and beyond, the Quonset hut served as more than a military shelter.
Published by
TRUMPF Inc. Farmington, CT 06032 www.us.trumpf.com Responsible for the content
Sheila LaMothe Editor-in-Chief
Susan Grohs 860-255-6104 susan.grohs@us.trumpf.com Editorial Staff
Katelyn Ercolani Mike Gordon Susan Grohs Sheila LaMothe Amy Leblanc Taryn Murphy The prefabricated Quonset hut could be used virtually anywhere. Here, it served as office space for the 598th Engineering Base Depot, 1947-48, post-WWII Japan.
World War II created a need for an all purpose building that was easy to assemble, ship, and maintain. Inspired by the British World War I building known as the Nissen hut, the United States Navy began to design its own semicircular building covered by corrugated galvanized steel, known as the Quonset hut. The Quonset hut was first manufactured at the United States Naval Base in Quonset Point Rhode Island. The first prototype was constructed using steel arch rib T sections covered in corrugated steel with two plywood ends to supply doors and windows. Unlike its predecessor, the Nissen hut of WWI, the Quonset hut featured insulation, pressed wood lining and a wood floor. No skilled labor was required to assemble the prefabricated building which measured 16 by 36 feet. While the prototype fit the guidelines in terms of ease in shipping and assembly, there were still improvements to be made. The biggest complaint was the semicircular design left little to no wall space inside. To rectify this issue the Navy modified the steel arch ribs by welding two lightweight channels back to back, providing a grove for nails. The redesigned Quonset hut now supplied an additional 4 feet of vertical wall. Eventually the Navy again reformatted the Quonset hut to reduce shipping space and 32 Express Vol. 2/12
tonnage. This third design incorporated lighter corrugated galvanized steel sheets and lighter plywood floors. Using the new materials the Navy was able to decrease the amount of steel needed by half a ton and reduce the shipping weight – all while increasing the overall size of the hut to 20 by 48 feet. The resulting Quonset hut was extremely functional. The Navy found a multitude of uses for them such as for hospitals, barracks, latrines, offices, and kitchens. They could be placed on concrete, stilts or the bare ground and in different climates steel overhangs could be added to the body of the building to protect the doors and windows from driving rains or strong sun. Now, the Quonset huts are most often found in museums or as memorials featuring WWII memorabilia, however some are still actively used by the U.S. Military in locations such as South Korea. After WWII the U.S. Military also sold surplus Quonset huts to the public. Across the U.S. these huts can occasionally be found adapted for commercial use, or as housing like Michigan State University’s Quonset Village where they once served as dormitories for students. en.wikipedia.org/wiki/Quonset_hut www.history.navy.mil
Design and production
John Mik, MIK Advertising & Design Printing and assembly
Paladin Commercial Printers, LLC Contributors
Flynn Ink pr + co. GmbH, Stuttgart Photographs
Steve Adams Photography Blue Sky Photography Michael A. Foley Photography Follett Corporation Jazen Photography Deedee Morrison Monahan Design Nautel SIGN Fracture Care pr+ co. GmbH, Stuttgart
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Manufacturing High Quality Careers In the United States, TRUMPF employs 130 women in a wide variety of departments and positions including: Contracts Engineering Finance & Administration Human Resources Information Technology Laser Assembly Logistics Machine Assembly
Management Manufacturing Marketing & Communications Sales Service Software Spare Parts Training
We salute the Women of TRUMPF for their dedication and contributions towards making us the world’s largest manufacturer of fabricating equipment and industrial lasers.
us.trumpf.com
Cool innovation Ice is an element of convenience, fully integrated into our daily lives. Yet producing ice and keeping it free of contamination is not always so transparent. Follett Corporation knows how to bring all the ingredients together to deliver more than just blocks
of frozen water. With the help of its TRUMPF fabricating equipment, Follett provides innovations such as ChewbletŽ ice; a crunchy, chewable amenity t hat complements our lives – because no one keeps ice on hand better than Follett Corporation.