Process Engineering

Over 60 years of manufacturing innovation, supported by the latest in advanced engineering tools results in our on-time, high quality products. To improve accuracy and reduce trial and error, we utilize advanced engineering tools, such as stamping simulation, solid modeling, FEA simulation, and CNC machine coding.  Our expertise in each of these processes helps us meet the challenging standards of the aerospace and automotive industries and deliver on-time, on budget programs for our customers. Our vertical integration supports a rapid response from concept to functional model.

One of our specialties is engineering the manufacturing process so it is as efficient as possible.

Working with numerous design programs, we are able to virtually assist you with your process engineering needs. We have the ability to receive all customer designs in native format through a large investment in several CAD systems, including Unigraphics and CATIA.

Our engineering tools include:

• Unigraphics/NX
• CATIA
• Solidworks
• Autoform die simulation
• Omnicad morphing
• Cenit OLP for robotic processing
• Fastsuite OLLP for laser cutting
• Work NC OLP for machining

The ability to work with this wide array of design software provides many benefits for your program and allows us to provide assembly or process engineering, FEA process, and product design, among other compressive solutions. Autoform, formability software for the engineering, evolution, and improvement of the sheet metal forming process, is used for spring back and finite element analysis, as well as die form simulation, both prior to design and during die manufacturing. This ensures that even the smallest design details are managed efficiently. 3D laser scanning assists reverse engineering support while also supporting your R&D efforts.

We use our experience to help you create a better product. If you do not have the resources available, we can work with and refine your design ideas. We are able to design highly efficient processes with multiple stages and varying complexities. Our in-house capabilities allow us to develop custom assembly work cells to standardize processes and ensure consistent quality through the life of your program. Our team manages the master data files, incorporates working data files, and provides updates to all process documentation. Rapid execution of product and process revisions keeps your program on schedule. We also create product development and design documentation, including design validation plan and report (DVP&R) and process validation plan and report (PVP&R).

Upon receiving your existing designs or native data, we begin a detailed study of your processes and develop a customized engineering plan. Our engineering and estimating team develops a manufacturing process that is unique to your program requirements, including simulations, robotic weld programing, press sizes required, weld cells needed, and other specialty equipment essential to your program. For stamping programs, this will include the number of operations needed, while for assembly programs, it will include the number of fixtures, loading order, and cycle time.

We also utilize virtual assembly solutions for weld designs to ensure the robots will operate as needed without obstacles. Robotic swing circles allow for weld gun reach and robotic clearance studies to plan multiple joining technologies such as adhesives, glues, and welds (SPR and RSW).

One of our specialties is creating virtual stamping simulations for both hot and cold stamping, applying a scientific approach to a traditional manufacturing process. Utilizing our cross-functional teams and their areas of expertise, we develop the right process before any work is started. Using your deliverables, we review your part along with our stamping simulations as we develop the die to predict any issues that might happen during stamping, such as spring back and wrinkling. This helps avoid surprises during production, having already proven the process on the computer before manufacturing commences. This reduces cost and try-out time, allowing us to get you to market faster.

If you do not have the resources available in-house, we can work with and refine your design ideas, from concept to reality.

Computer simulations and virtual assembly solutions allow us to manufacture your parts without wasting material or excess time. Your program benefits from these simulations in a number of ways, including:

• Increased cost savings and production efficiencies
• Reduced weight and cost services
• Reduced try-out time, allowing us to get you to market quicker
• Design for manufacturability assistance and improvements

We also utilize off-line programming to virtually program robots to weld, as opposed to the traditional manual programming process. Off-line programming allows us to engineer the robotic weld strategy while the fixtures and parts are being built, reducing overall program time.

We have more than 60 years of experience in sheet metal manufacturing and can use it to assist with your design for manufacturability. We aren’t simply a stamp and ship shop. Using your native data and our experience, we are able to provide industry leading engineering recommendations and changes and deliver a quality finished product. Using up-front engineering, we review your virtual stamping solutions, focusing on how to reduce costs, number of hits, and manufacturing time. As the industry leader, let us help make your next program best-in-class.