Low-EAU Part Better Off Fabricated than Stamped

Claiming the project to be the “first fruits of its new fabrication department,” Ultra Tool & Manufacturing, Menomonee Falls, WI, recently saved a customer more than $120,000 in up-front tooling costs to produce a low-EAU (estimated annual usage) part. The part in question: a hydraulic pump-bracket assembly for the Nissan Murano convertible. Progressive dies needed to stamp the assembly’s three parts would have cost $138,000, a hefty up-front investment for an EAU of only 6000.

Instead, Ultra Tool manufactured the parts in its new fabrication department, boasting a Salvagnini L1Ce fiber-laser cutting machine and a Durma 150-ton CNC press brake.

“Typically we look for a maximum 2-yr. payback to justify progressive tooling,” says Matt Schemelin, an Ultra Tool sales engineer. “With such a low EAU, payback for the progressive tooling for this job would have taken more than 8 yr.”

Ultra Tool added its fabrication department during the summer of 2010 to accommodate lower volume orders. Its Salvagnini laser-cutting machine (left) boasts a 60- by 120-in. worktable, 3000-W laser and positioning tolerance of ±0.0004 in. Cutting capacity in steel is 0.70 in., 0.312 in. for stainless steel. The Durma press brake offers a maximum bending length of 120 in., throat depth of 16.1 in. and a 14-in. stroke.

Ultra Tool & Manufacturing: 262/703-0455; www.ultratoolmfg.com

See also: Salvagnini America, Inc.

Technologies: Bending, Cutting

Subscribe to the Newsletter

Start receiving newsletters.