Posts by: Momentum

Engineering: Design for Manufacturability

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Machine Shop

State of the Art Engineering Services

The team at Fusion Fabricating and Manufacturing provides industry-leading engineering and manufacturing services for our many clients. Our ISO 9001:2015 certified shop provides the highest quality products and services to meet the most exacting client specifications. Each team member contributes to our commitment to continuous improvement. Our in-house design and engineering department is here to ensure you get the products you need quickly, efficiently, and with the highest quality.

We provide turnkey sheet metal engineering and manufacturing solutions for diverse industries, from aerospace and military to appliance, automotive, medical, and theater/amusement. Our extensive experience across various industries is why customers choose us to help them develop their custom applications, systems, and processes for both new and existing products. No matter your industry or application, our team has the capabilities to design and build your custom manufactured solutions.

Engineering for Manufacturability Process Highlights

Our engineering team excels in taking customer designs and transforming them using our advanced technology and techniques to streamline the manufacturing process, resulting in improved function, quality, and cost savings.

3D Modeling

We use 3D modeling for a variety of functions:

  • Document/revision control
  • Machine programming
  • Project planning
  • Redesign for manufacturing with our equipment
  • Shop routing
  • Quality control

Every project that comes into our facility is 100% 3D modeled. Using this technology, we can eliminate waste, verify the design, optimize for use with our leading-edge equipment, improve quality, and streamline brainstorming and communication.

Continuous Improvement

Our team never follows the status quo. Continuous improvement is built into everything we do. Our engineers are not just sitting in offices. They are on the shop floor, observing machines, techniques, and processes. This is how they’ve achieved breakthroughs in design, increasing the efficiency, functionality, and most importantly for our customers, the cost-effectiveness of the process and the product.

Smart Design

We are committed to finding ways to error-proof our processes. One of the ways we do this is through smart design. By making the initial investment of time in thoughtful and carefully considered design decisions, we can significantly improve both quality and productivity. It allows our team to meet the most stringent and precise design tolerances.

Software and Equipment

We consistently evaluate our software and equipment to ensure that it meets our extremely high standards and provides the services and results our customers require.

Mastercam

This software is actually a suite of CAD/CAM products. It is the #1 solution for manufacturing companies. It streamlines software testing, component manufacturing, tech support, training, and many other processes.

AutoCAD

AutoCAD ensures our designs are accurate. It is invaluable to our engineers for analyzing and solving design challenges for mechanical parts. A vast improvement over manual drawings, AutoCad allows for very quick adjustments. It can allow us to quickly create 3D models from a basic drawing for accurate prototyping and makes exporting, editing, or printing digital designs easy.

Tebis

This CAD/CAM software is a CNC simulator that allows us to plan, program and verify our NC machining operations with all components. We use it to manufacture individual parts or models, molds, and dies. It saves a tremendous amount of time, effort, and money by simulating complex operations on the digital simulation of the actual equipment.

CNC Cutting Equipment

Computer numerical control cutting machines enables our team to scale production when large quantities of products are needed. It ensures even complex cuts are executed accurately and consistently by executing multiple instructions from a computer program. CNC operations replace engineer-operated equipment with automation that delivers highly precise results. Our CNC cutting equipment is accurate to within 0.005″.

Fabrication Service

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welding

Work with our team at Fusion Fabricating & Manufacturing to identify your fabrication goals and schedule a service. From a single, custom order to a long-term manufacturing relationship, turn to use for cutting-edge equipment, diverse applications and precision engineering.

Applications for Fabrication Services

Fabricating sheet metal typically involves three stages. Depending on your industry and your particular project, your chosen material usually undergoes these three steps before becoming a fully fabricated component:

  1. Remove material: Your workpiece must be cut into the basic shape of your final product. This step can be accomplished with a cut off band saw, jig table, chop saw or drill press. Your workpiece may require multiple cutting equipment, so work with Fusion Fabricating & Manufacturing for complex manufacturing processes.
  2. Form or deform material: Most workpieces are formed into a three-dimensional shape in this stage of the process. This process turns flat sheet metal into a piece that’s ready for assembly.
  3. Assembly materials: Welding and a range of fasteners connect your cut and formed pieces into a complex product. Our Mig and Tig welders create smooth, dependable welds to hold together various components. An assembled workpiece is now ready for final polishing, painting or other finishing steps.

Ask about finishing steps and the optimal products for your particular sheet metal products. Sheet metal can be finished with a powder coat, chem film, anodize, silver plating or other finishes.

Most finishing processes begin with thorough grinding or sanding, which we can perform with our fabricating equipment. Each process has its own pros and cons, so carefully consider your finish requirements and discuss your choice with our team before we begin the sheet metal fabrication process.

Our services are suitable for automotive, military, appliance, aerospace and other industries. Discuss your product specifications to see how our efficient services and affordable rates help you grow your business.

Common Materials

Our fabricating services use a range of sheet metals to create dependable components. Identify the ideal material you need for specific components in your specific industry. Here are some common considerations as you select an alloy for your component:

  • Corrosion resistance
  • Conductivity
  • Strength
  • Weight

These factors should be weighed carefully as you compare steel, aluminum and copper alloys. Selecting your material can affect the ideal cutting and welding equipment used, so our team can assist you in this design step of your process.

Advantages of Industry-Leading Sheet Metal Fabricating Services

You may have in-house fabricating equipment, but there are some projects that are best handled by a specialized service provider. Turn to Fusion Fabricating & Manufacturing for custom components or bulk orders to enjoy these advantages.

Dependable Products

We assist you in sourcing the highest quality of sheet metal for prototypes or end-use fabrication. Innovative techniques and industry-leading equipment come together to give you parts that exceed expectations. From start to finish, work with an experienced company to receive dependable products with every order.

Scalable Business Growth

Fabricating components with sheet metal doesn’t require the same specialized tooling or other setup costs of CNC machining. This allows you to invest in the exact amount of parts you need with minimal additional fees. Scale up your business with sustained growth techniques. Our services start at a single prototype and can reach thousands of parts per order.

Fast Turnaround Times

Delays in fabrication can be costly. Fast estimates and rapid fabricating reduces the time it takes for you to receive your fully finished components. Our rapid turnaround times make our fabrication services a great option if you’re dealing with downed machinery or an unexpected bulk order. Reducing the time it takes to receive fabricated components helps you hit your deadlines and improve your customer relations.

CNC Machining Service

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5 Axis

Our CNC machining offers unique advantages to manufacturing companies of all sizes. Work with our state-of-the-art facility to complement your existing manufacturing line, or outsource your prototyping or end-use production as you grow your business. Review our equipment, capabilities and common materials used in machining applications.

Equipment

At Fusion Fabricating & Manufacturing, we’re equipped with CNC machining designed for versatile projects and high part output. Here are the machines we use to produce your precision components for the automotive, appliance, aerospace, military and other industries.

Vertical Machining

The Fadal 4020 and other equipment at our Sterling Heights location use vertical machining to create traditional CNC components. Vertical machining is a common option to drill, contour, plane, keyway cut and slot components. Turret and bed mills both work to cut and shape your work materials for precision results.

Lathes

Just like a manual lathe, a CNC lathe sheers away exterior layers of a material to create a precision cylindrical part. Use lathe CNC machining to create simple wooden items, like table legs, and can also be used for precision gun barrels and automotive components. Work with our design team to program a CNC lathe for prototyping or end-use production.

Boring Mills

Our boring mill creates or enlarges holes in your work pieces. This service can be used in the rough or finishing stages of your manufacturing process. Thanks to the dynamic tooling and accurate drilling of a CNC boring mill, you can create accurate holes in extremely large or extremely small components.

CNC Machining Service Advantages

Augment your existing manufacturing process or ask about our comprehensive CNC service capabilities. Here are a few advantages you can enjoy when you update or expand your production line with state-of-the-art CNC equipment.

Rapid Prototyping

Other manufacturing equipment requires more time and energy to create a prototype. Because of the versatile tooling and convenient programming capabilities of our equipment, CNC machining is a prototyping solution that offers a low cost per unit.

Efficient Tooling

CNC equipment can operate with virtually any tooling you need for your specific industry. Most CNC machines allow for rapid tool replacement through quick-change tool holders and other fixturing solutions. Reduce the time it takes to retool your equipment to accelerate your production of complex components.

Precision Production

CNC machine precision tolerances are incredibly higher than manual machining and can even outperform more other manufacturing methods. High production precision is not only a critical aspect of some industrial manufacturing facilities, but can reduce the amount of workplace errors and inefficiencies.

Scalable Performance

From a single prototype to a million-part order, our CNC machinery at Fusion Fabricating & Manufacturing is perfectly scalable to your needs. Our equipment can be quickly tooled and prepared for any scale of project. Review our gallery of components to see how our range of CNC machines can create simple or highly complex components.

Common Materials Used in CNC Machining

Our CNC shop covers a significant range of materials for your manufacturing needs. Aerospace, military, automotive and other industry production requires specialized materials, so work with our team to create the custom components you need with these common materials or other, specialized options:

  • Steel alloys: 1018, A36, 4130 and more
  • Aluminum alloys: 6061, 2024, 5052 and more
  • Stainless steel alloys: 15-5, 18-8, 303 and more
  • Copper alloys: 101, C110, 260 and more
  • Titanium alloys: Grade 2, Grade 5 and more

These are just a few examples of the many alloys and other materials that can be used in your manufacturing process. Discuss your options with our team at Fusion Fabricating & Manufacturing to prepare our production line for your particular material.