For close tolerances and parts that fit the first time every time, industries look to precision metal fabricators. Metal fabrication involves cutting, bending, welding and assembly. Precision fabricators use advanced and innovative techniques and equipment to manufacture products to exacting specifications.
Plasma and laser are two methods at the forefront of metal cutting technology. Plasma cutting, the more mature process, works by firing gas out of a nozzle. Plasma formed by an electrical arc can cut through any type of metal up to 3.15 inches thick.
Lasers cut thin sheets of metal but can be employed for a variety of other purposes, including engraving, welding and drilling. Water jet cutting can also be used, particularly in temperature-sensitive conditions.
What's new in precision metal fabrcation?
Three trends are on the horizon for plasma cutting machinery. The first is the integration of biochemistry with the equipment, to inhibit bacterial growth in cooling fluids. High-definition plasma systems exploit ethernet connections for automation and the employment of PC-based controls. These configurations offer instant troubleshooting.
Several organizations are looking at Android-based systems that can interface with computer numerical control (CNC) equipment. These configurations will allow mobile control of machines and remote transfer of programs. Productivity is expected to increase, as employees will be able to complete tasks away from the manufacturing line. As information technology expands, capabilities of precision metal fabricators do as well.
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Equipment, specializations and certifications vary among fabrication shops. Additional services may also be available. According to data gathered by IndustryNet from 27 companies providing 1,638 jobs, the following top firms offer examples of what is available to customers.
Top Companies by Employees
Within a modern facility featuring the latest CNC, robotic and automated equipment, Inland Metal Inc., employs 300 workers in Hayward, California. A barcoded system tracks jobs from purchase order to delivery. Inland is certified to AS 9100:2009.
Roadmaster Inc. in Vancouver, Washington, is a leading supplier of automotive products. Two hundred employees produce offerings, including towbars and baseplates. Roadmaster's brands include:
• StowMaster
• Falcon 2
• Sterling
• InvisiBrake
• FuseMaster
• BrakeMaster
• Even Brake
• Davis TruTrac
• Voom
• Wheel Masters
• Reflex
Serving the agricultural, construction and industrial manufacturing industries, Iowa Laser Technology, O'Neal Manufacturing Services Division employs 185 workers in Cedar Falls, Iowa. The company is ISO 9001:2008 certified. It specializes in laser-based sheet steel and tube fabrications.
Since 1948, Mech-Tronics has been serving customers in Melrose Park, Illinois. The company provides 110 jobs at their facility incorporating CNC, sheet metal scanning equipment, metal stamping and metal forming. Mech-Tronics is certified to ISO 9001:2008, AS 9100:2009 and Nadcap standards for chemical processing and heat treating.
A family-owned business established in 1927, Columbia Machine Works Inc. in Columbia, Tennessee, offers both fabrication and machine rebuilding services performed by a workforce of 90 employees. Its high definition plasma cutter can handle any size steel or plate, allowing it to accept jobs large and small. The company also supplies finishing and testing services.
With 30,000 shipments per year, Laser Precision LLC delivers 99.92 percent on time. With 80 employees in Libertyville, Illinois, it provides laser cutting, forming, machining, welding and assembly. Finishing services such as powder coating are also available.
Humanetics II Ltd. in McAllen, Texas, has taken a step into the future with information technology. Its staff of 75 employs data analytics throughout the plant. The company houses data in an off-site center allowing it to utilize the advantages of the cloud.
For 40 years Screen-Tech Inc. in Livermore, California, has prided itself on providing quality products on-time and at a value price. Among the industries its 65 employees serve are electronics, semiconductor, medical, food processing and telecommunications. Its facility features a laser cutting and punching combo and is certified to IS0 9001:2008 and by UL and CE.
Spincraft in Billerica, Massachusetts, is a single source supplier of metal formed products. Its 65 employees apply innovative technologies to meet the needs of aviation, defense, energy, medical and space systems. In addition to forming, Spincraft's capabilities include machining, heat treating and welding.
Leading-edge equipment at the New Holstein, Wisconsin, facility of Metko Inc. allows its staff of 65 to produce virtually any metal shape. Its capabilities include lasering, CNC forming, turret punching and robotic welding. Unique to Metko's facility is a proprietary in-house nitrogen generation system.
Top Companies by Square Footage
The following companies lead both in area and number of employees, as referenced in the previous section.
• Roadmaster Inc.: 225,000 square feet
• Iowa Laser Technology, O'Neal Manufacturing Services Division: 156,000 square feet
• Laser Precision LLC: 130,000 square feet
• Humanetics II Ltd.: 100,000 square feet
• Spincraft: 100,000 square feet
• Inland Metal Inc.: 92,000 square feet
Other Leaders by Plant Size
Established in Dayton, Ohio, in the late 1800s, Dayton Mfg. Co. is a witness to the history of the development of precision metal fabrication technology.
In its 50,000-square-foot facility, it incorporated modern equipment, including laser cutting and waterjet cutting as the evolution of the industry took place. The industries Dayton serves include aviation, food, railroad and electronics.
With a plant covering 94,000 square feet in Portage, Michigan, Unifab Corp. specializes in custom fabrication and the biomedical industry. The company manufactures cages, cabinets and enclosures. Specialized characteristics of its products include mobility and storage areas for hazardous materials.
C.O. W. Industries Inc. is a low-volume contract manufacturer. The company was founded in 1911 as Central Ohio Welding. This 100 percent employee-owned business occupies an 80,000-square-foot facility in Columbus, Ohio.
The construction and agricultural industries are served by Ray-Mac Inc. in its 75,000-square-foot facility in Gwinner, North Dakota. The company offers services, including engineering, machining and welding. Backhoe accessories comprise a significant portion of its products.
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