Metal Fabrication Case Study for an Automotive Aftermarket Customer

Metal Fabrication Case Study

Customer:   Automotive Aftermarket

Product:  Metal Bracket

Type of Fabrication:  Laser Cutting, Press Brake Metal Forming, Powder Coating, Packaging & Shipping

Problem:  Needed a heavy duty bracket with a lance and formed area which would include a square hole for a carriage bolt

Noble Industries solution:

One of our automotive aftermarket customers came to us with a need for a bracket with a lance and form section to allow a carriage bolt to be used with the part.  A lance and form tooling can be purchased for a punch press or for a brake press.  For our application we created tooling for an Amada press brake form operation.  This part also has an offset and 90 degree bends around the lance and formed area and the part number stamped into the part.

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Commonly Used Materials in Metal Fabrication

COR-TEN A is a premier high-strength, low alloy steel, with its combination of greater strength and exceptional resistance to corrosion (5 to 8 times carbon steel for COR-TEN A and 4 times carbon steel for COR-TEN B).  This high strength steel is ideally suited for applications where weight reduction or long term maintenance fees are key considerations.

ASTM A-36 is a structural quality carbon steel which can be used in riveted, bolted and welded metal parts needed for structural purposes and general purposes where strength is needed.  A-36 does not come in light gauge materials.

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Reasons to use Powder Coating for metal parts!

Powder Coating offers substantial advantages over wet paint or plating.

  • No solvents
  • If you have a clean room and an oven it is easy to apply
  • Unpolluted operational area making better work environment
  • The above items make for an environment with virtually no pollution
  • Only one coat is required to give a superior finish with excellent coverage in holes, corners and edges
  • Once baked on a clean surface it is resistant to scratches & chipping
  • With a good operation you will have savings in overall coating costs

Our new Mazak FMS system is up and running!

Advanced Laser Cutting FMS system

Flexible Manufacturing System by Mazak added at Noble Industries

The Mazak FMS system has a material storage tower that can hold 10 different sheet metal material.  It also has a pneumatic load system to accurately position the sheet on the laser and automatic unload capability.  Laser cutting jobs are loaded into the computer.  While both lasers are cutting the parts of the material already loaded, the FMS system automatically locates the material for the next job and has it waiting.  Once the machine has finished laser cutting the parts on the laser, it will call for the FMS system to unload that sheet and load the material for the next job.  The FMS system continues to get the material ready for each job while the machine cuts metal parts.  This allows the same number of operators to run twice as many lasers at one time.  It can also be scheduled to run parts in the “lights out” mode so that employees can go on a lunch break and machines continue to run.

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Metal Fabrication Case Studies – Retail Point of Purchase Freestanding Display

Metal Fabrication Case Study

Customer:   Retail Point of Purchase

Product:  Freestanding Display

Type of Fabrication:  Laser Cutting, Welded Wire Mesh Grid, Press Brake Metal Forming, Welding, Powder Coating

Problem:  Taking a new design from the concept to production

Noble Industries solution:

Noble Industries has several customers who design all types of store fixtures for the retail industry.  Many things are considered before a prototype is scheduled.  Our customers will send conceptual drawings or models with all the factual information included such as the material they wish to use, dimensions, views from the front, back, side and top, specific hardware requirements, what powder coat color or colors they want and much more.

Our process engineers will review the design for manufacturability and give any comments or concerns to the customer.  If everyone agrees on the concept, then our customer will detail each individual part.  For this particular metal fabrication case study, we had a project to fabricate for Point of Purchase during the holiday season.

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