Using plasma arc cutting to clean-cut stainless steel sheet and plate: Variables to considerTo clean-cut stainless steel sheet and plate, fabricators first must choose the right CNC cutting equipment and then set the correct process-related variables. Precise machine motion controls, torch-to-material distance control, and the correct plasma and assist gases all are crucial to producing weld-ready plasma-cut edges on all stainless steel thicknesses.
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Making plasma cutting easier: Using CNC automation technologyFor many people, the world of plasma cutting is a complex and daunting place, with a cryptic set of rules that can be mastered only by highly trained technicians after weeks of training. For every change of material or thickness being cut, a long process ensues of resetting gas mixtures, tweaking pierce heights and pierce delays, and manually calibrating every last parameter to ensure a reliable result.
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Cutting through the obstacles: The challenges of sawing structural tube, pipe, and solidsOf all the materials that can be cut on industrial band saw machines, structural steels—such as pipe and tubing, plate, angle and channel iron, and I beams—are all among the most common and challenging.
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Cutting to the chase: ArrayArray
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Take the old with the new - Selecting saw blades with new technologies in mindNew methods for cutting tube and pipe have been introduced to welding shops in the last few years—methods designed not only to cut metal, but also to cut costs.
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Cutting to the chase Sawing structural and architectural tubing: Sawing structural and architectural tubingThis article examines common fabrication processes for structural and architectural tube. It specifically focuses on cutting, sawing, miter cutting, bundle sawing, and cambering.
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Exploring complementary cutting methods: Comparing capabilities of laser, plasma, EDM to waterjet technologyThe various cutting methods available to fabrication shops today can be both a little daunting and very beneficial. Choice is good--learn how to make the most of the diversity all your choices offer to you.
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Folding technology makes sweeping changes: New developments in 200-year-old technologySchwenkbiegemachinen, or swing bending machines, have been in use for more than 200 years. European manufacturers began to power them with electrical or hydraulic power after World War II, when an enormous amount of sheet metal was used in the reconstruction of Europe.
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The basic elements of tubular hydroformingMany factors come into play when attempting to execute a production hydroforming operation, among them material selection, friction and lubricants, tube bending and preforming, and equipment. Many companies in the automotive sector are experiencing great success with the process, which can reduce weight, overall costs, and the number of parts per vehicle.
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Successful tube hydroforming: Watching parameters, accurately simulating the process yield good resultsA typical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy).
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Pressure-sequence and high-pressure hydroforming: Knowing the processes can mean boosting profitsPressure-sequence hydroforming can form complex parts as well as forming most ductile metals, including high-strength, low-alloy, and stainless steels with sharper corners, thick-walled tube, and other difficult features.
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Tier 1 supplier builds four-stage competitive strategyF & P Manufacturing Inc., a tier-one automotive components supplier, focused on four areas when it developed a hydroforming line for manufacturing Honda Accord engine cradles. These areas were eliminating end scrap, decoupling the bending machines from the manufacturing line, reducing cycle time, and palletizing parts.
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Tube Hydroforming Design Flexibility—Part IV |
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Tube Hydroforming Design Flexibility—Part V |
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Handling appliance steel: Tips for processing surface-sensitive materialsSavvy stampers are purchasing new equipment or modifying and retrofitting existing equipment to include prefinished materials features. By paying close attention to equipment, tension practices, material processing methods, and material handling, stampers can participate in the market for surface-sensitive materials.
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Establishing an alloy verification process: SOPs help to prevent material mix-upsProduction or fabrication processes can include dozens of stages to convert raw materials into finished goods. Regardless of the raw material or the finished product, one factor is constant - - most metals look alike.
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Stretching metal's forming limits with HSP lubricants: Forming aluminum, high-strength steel without tooling upgrade |
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Keeping pace with today's punching requirements: Advancements in tool design, metallurgy lead to more accurate holes, improved part qualityThis article provides the basics on how the punch, die, and stripper work; how to perform material thickness calculations on various materials; how different applications affect punching quality; how fully guided tooling counters lateral forces; and how metallurgy, coatings, and maintenance affect tooling.
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New tool helps fabricator accelerate part making for small runs: Turret presses with tool perform inline markingCustom metal fabricator Total Metal Products, Dallas, had a need for part marking that would be both accurate and cost-effective for small quantities. The company supplies punched parts in single and small-lot quantities of 200, 300, and 400 on a just-in-time (JIT) basis. Its customers include manufacturers in the telecommunications, aerospace, mass transit, and oil refining industries.
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Material—Is it always a problem?If the problem with your roll forming operation lies in your material, here are some tips in getting to the heart of the problem.
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Selecting the right materials for roll forming—Part 2: How mechanical properties affect productionThis is the second part of a two-part article. Read Part I. If you examine the mechanical properties of several materials, including carbon steel, alloyed steel, stainless steel, as they relate to roll forming, you'll gain an understanding of the influence of some primary metal processes on roll forming.
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Material handling safetyHandling material is a daily function in the workplace. All too often it is a task taken for granted, with little knowledge of or attention to the consequences if done incorrectly. Management and employees need to look at and evaluate how material goods are handled inside and outside their facilities. Whether the operation involves delivering or receiving material, an area should be designated for that purpose.
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Huge possibilities, tiny tools Nanotechnology--the science of small--could change the metals industry in a very big wayNanotechnology is just beginning to blossom as a practical topic of interest for the manufacturing industry. Just how big an impact will nanomaterials have in our lifetimes? We're sure to find out soon.
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Successful stamping: It's a 'we' thing |
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On the road again: Heavy-duty-equipment fabricator ramps upContract manufacturer Morton Metalcraft talks about how it faces challenges in fabricating weldments and assemblies for heavy-duty equipment, including ramping up after a slowdown—with machines, manpower, and material, and revising material flow.
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Protecting surface-sensitive materials in coil processing: ArrayArray
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Installing and maintaining coil cradles and reelsThe installation procedures that can help to prolong the life of coil cradles and reels are outlined in this article. Specific steps to maintain cradles and reels are also included.
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Flatness in coil processing operations: New turns in the leveling processMost flat-rolled coil processing operations use some sort of roller leveling technology. Operations people understand what these machines can do to improve the quality of the product they produce. In the competitive marketplace, customers demand and get more that just flat sheets or slit coils.
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Pairing a servo feed with a pull-through straightener: Applications for noncosmetic stamped partsThis article explores the possibility that servo feeds can be used with pull-through straighteners as opposed to a conventional feed line that uses a powered straightener. Using the servo-PTS (pull-through straightener) can save money on equipment and material. The only limitation may be marking the material so noncosmetic applications are recommended.
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The basics of uncoiling: A review of standard equipmentA review of the basic components of a coil handling system which covers servo drive roll feeds, cradles and reels, straighteners and combination units.
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Getting it Straight: Understanding coil straightening in stamping operationsBefore coiled material can pass through a die to produce an acceptable part, it must be straightened. Coil straightening is accomplished by bending a strip of material around sets of rollers that alternately stretch and compress the upper and lower surfaces so that the material's yield point is exceeded.
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New Features in Coil-to-Coil Slitters: Adapting to the changing coil industry with technologyYears ago it was customary for coil processors to have dedicated slitting lines for specific materials and gauges. Today's larger, stronger, and thinner-gauge coils, however, require service centers to be able to process many materials and gauges on the same machine.
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Slitting ultrahigh-strength steels: Are you ready to process these coil types? |
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Reducing scrap, inventory costs with coil optimization software: Maximize material usageCoil optimization software is a valuable tool that fabricators can use to attack the problems of high scrap and high inventory. It offers the ability to quickly and easily make sound decisions regarding the purchase and use of master coil sizes. By using computers and specialized optimization algorithms, fabricators can minimize manual selection of coil sizes.
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Protecting surface-sensitive materials in coil processing - Three potential danger areasAs manufacturers worldwide strive to reduce costs and streamline their production processes, the market for surface-sensitive materials continues to expand. Surface-sensitive materials include all prepainted steel products and nonferrous decorative materials, such as copper, brass, and stainless steel.
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High-Speed Feeding Techniques - Reviewing the Facotrs that Affect Process SpeedsGripper or roll-type feeds operate on the principle of feeding force, which is a product of the coefficient of friction between the grippers or feed rolls and the material being fed. Reviewing each force as a factor of the feeding equipment or feeding conditions helps in evaluating the feeding process.
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Maximizing a coil fed press: Variables that influence production speed, setupCoil-fed stamping presses are nothing new, but coil feeding processes have changed a lot since the days when press feeders were driven mechanically by crank motion. Influencing these processes are differences between transfer and progressive tooling.
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The importance of the n value in sheet formingStrain hardening is represented by the exponent n in the flow stress equation, which approximates the relation between true stress and true strain during plastic deformation of a metal. The constant n plays a crucial role in sheet metal forming, and this brief article describes its effects.
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Troubleshooting your stamping operationA common thread runs through all effective troubleshooting approaches: the skill of observation. Learn to use it to your advantage.
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Taking the heat, keeping the current: Heat sinks provide thermal conductivity, electrical isolation |
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Virtual tryout: Simulation software simplifies progressive die troubleshooting |
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Stamping out bad partsSheet metal manufacturers are under constant pressure to improve and document quality while reducing costs. Furthermore, original equipment manufacturers are shifting responsibility for quality inspections to suppliers, adding extra burdens. New, complex product designs and rigorous processes, such as deep drawing and the growing use of exotic materials, are placing greater demands on both quality assurance and development departments.
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Filling in the blanks: What to look for in an in-house blank shearing line |
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Key design principles for successful deep drawingSuccessful deep drawing depends on many factors. Ignoring even one of them during die design and build can prove disastrous.
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Controlling flow and obtaining stretch in deep draw operationsAddressing the difficulties in obtaining a wrinkle-free stamped part requires a good understanding of metal flow and how it is affected by draw beads
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Designing progressive dies: Reviewing the basics of progressive toolingDecisions and compromises must be made when designing progressive dies to produce a part. Knowing ahead of time what this process entails just might help you.
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Transfer die design considerations: Questions to answer for successful designA list of basic requirements must be met to begin the design process for a transfer die. You'll probably want to know why transfer dies are used, methods for loading material, the sequence of operations in a transfer press, and the details of manufacturing process before you start.
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Part nesting and die design tips for reducing and utilizing scrap in stamping operationsYou might be able to gain a competitive edge by learning how to reduce the amount of engineered scrap, or that material that was inteded to be scrap rather than scrap created because of defective piece parts.
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Rising expectations spark new approach to draw die development: Reconciling demands for increased quality at lower costsA recently formulated approach to draw die development incorporates simultaneous engineering to identify and address potential problems before dies are built.
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Establishing a die setup recipe for progressive diesSetting up a stamping die is one of the most critical steps in a successful stamping process. It's a fact: More damage is done to a die, especially a progressive die, in the first 10 hits than in the next 10,000 hits. Most die damage happens during initial setup, when the material is being fed into the die. Mistakes such as misfeeds, pilot piercing, double metal, sheared cutting sections, and stock hang-ups often occur.
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Improving blank edge conditionsA blank, stamped in the first station of a progressive stamping operation, usually is subject to subsequent forming processes to form a designated part. If the blank is subject to straining, deformation, bending, stretching, or lateral expansion in later stations, its edge condition should be carefully examined.
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Choosing the proper steel to minimize abrasive adhesive tool wearThe most disruptive type of failure in any tooling application is when the tool cracks. To prevent this type of failure in cold-work applications, it's important to select the correct steel.
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The growing use of orbital tube welding: Quality, repeatability, and documentation drive the technologyAlthough orbital tube welding has been used in aerospace, semiconductor, and other high-purity applications for a long time, general industrial markets just now are beginning to view it as a viable and economical option for joining stainless steel tubing.
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Automotive motives - Tips for cutting per-piece prices for automotive customersToday's automotive industry is more competitive than ever. To compete with the European, Mexican, and Asian markets, the U.S. market must become more aggressive in finding ways to cut costs.
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Notching tube and pipe: Examining three common methodsTube and pipe can be notched with a variety of tools and machines, from saws to plasma cutters. For the hobbyist, the job shop, and the manufacturer, the most common machine tools used for making weld joints are the hole saw, the abrasive-belt notcher, and the end mill notcher.
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Designing an off-road sport truckThe main component in any off-road sport vehicle is the frame. Frames for mass-produced vehicles usually are stamped and welded. These are suitable for most drivers' needs, but for intense off-road driving and competitions, a sturdier frame is necessary.
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Using finite element analysis to roll-form tubesRoll forming is a common method for producing steel tubes. It is a continuous process in which a strip is guided through several sets of rolls that form the strip into the desired shape. After the final shape is achieved, tube edges are welded together to form a closed section. After the welding operation, the tube is sized through another set of rolls to obtain the required diameter.
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Troubleshooting compression bendingYou can achieve nearly trouble-free bending by being aware of the causes of typical compression bending problems and by correctly operating and maintaining the compression bender.
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Producing quality ASTM A249 and ASME SA 249 pressure tubesDetails are everything when you're manufacturing stainless steel pipe to exacting specifications.
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Skiving strip edges for tube and pipe producing: New equipment developments address coil preparation challengesEdge treatment of coil strip before it enters a tube and pipe mill, called skiving, is a rapidly advancing technology. Improving the coil edge before it is welded helps increase the quality of the seam join and helps prevent rejected tube or pipe.
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Exploring the welded tube making process: The basics for fabricatorsThis article is aimed not at tube producers, but at fabricators of tubing, to provide an overview of the process.
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Skelp edge preparation for manufacturing ERW pipePreparing the edge of a metal strip properly before it enters an electric resistance welding tube mill makes a huge difference in the quality of the final product. Make sure your prep methods match your quality requirements.
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Using existing tooling for new product applications: Evaluating the tooling's capabilities and limitationsThe article outlines factors for consideration when changing material type, grade, coatings, efficient speed requirements, specialty shapes, etc. Special consideration is given to the difference in speed between the minor relief angle and the root diameter.
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Inline gauge control in welded tube production: Reducing conversion lossesReducing scrap when converting strip to finished tube is a huge step in bettering your bottom line.
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Cutting to the chase: ArrayArray
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GMAW vs. FCAW for beginners: Choose the best process for your small operationThere are several pros and cons to using the gas metal arc welding process versus the flux cored arc welding process in compact applications.
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Using narrow-gap GTAW for power-generation equipment: Techniques and applicationsNarrow-gap gas tungsten arc welding (GTAW) frequently is used to weld regular and multilayer high-chromium steel for power generation boilers, stainless steel for nuclear power generation equipment, INCONEL® alloy and other high-alloy steels, and thick-wall stationary pipes.
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Welding aluminum tailored blanks with Nd:YAG lasers for automotive applicationsThe increased average power at the workpiece delivered by a 4-kilowatt, continuous-wave Nd:YAG laser source can be used for tailored blank welding of aluminum alloys
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Selecting the right abrasives for your operationWhen it comes to weld preparation, choosing the right abrasive wheel for your grinder can make your job easier. Just grabbing your grinder and cleaning up the weld area can result in poorly prepared joints, cross-contaminated welds, and more wear and tear on the tool and the operator.
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Three optional techniques for beveling: Understanding the advantages and drawbacks of eachMany fabricators use standard plasma cutters and abrasives to create beveled edges. Along with these traditional methods, welders also have the option of using three alternative beveling techniques: punch and nibble, peeling and shearing, and milling and routing. Each has advantages and drawbacks.
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Understanding weld discontinuities |
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Examining electric resistance weld nuggets in tube and pipe: Using the microscope to study weld characteristicsAn in-depth examination of electric resistance welding nuggets as a quality control step in the manufacturing of high-strength tube and pipe used for pressure applications
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Design tips for sheet metal: Bend relief, small holes, hole distortion near bends, and minimum flange widthsThe article discusses making small holes and when to use a punch or laser cutter, inside radius measurements and how they differ depending on whether you are coining or air bending on a press brake, and adding bend relief to prevent tearing material.
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Discovering the limits of press brake toolingOne of the most important aspects of press brake forming is tooling selection. What are the tools capable of? What kinds of loads can they withstand?
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Why should you care about inside bend radii?Operators, designers, and engineers, why should you care about the inside bend radius if the customer doesn't? Because, ultimately, just how easy or difficult it is to produce a part depends on decisions made during the design stage. Misunderstanding terminology, process capabilities, or production methods can lead to mistakes that can make production more difficult. The most common mistake is incorrectly calculating and achieving the correct minimum inside bend radius.
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Adaptive bending: Achieving accurate first-piece bending resultsAdaptive bending allows press brake operators to measure a bend angle during the forming process and feed the information to the numerical control. The article discusses springback and how to determine it and the fact that when air bending, 90 percent of problems result during initial setup, and only 10 percent result from springback. It also discusses using an angle control system, methods of measuring angles, and requirements for angle measurement systems.
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The challenges of laser cutting: Overcoming some common obstaclesLasers can be used to process expensive alloys as well as traditional materials such as stainless steel. However, knowing the strengths and weaknesses of laser processing is the key to determining whether or not a laser is the right choice for cutting.
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Predicting the outcomes of laser thermal forming: How process simulation brought this technology to industry |
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Turning up the power: Using lasers to cut thick plateThe most common power levels ranged between 1,500 and 2,000 watts. However, a statistical survey conducted by the AMT Laser System Product Group indicates a steady increase during the last 12 months of installations for high-power 3,000- to 4,000-watt laser systems and a decline in sales of lasers with power levels less than 2,000 watts.
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Laser cell system gives job shop the home field advantageContract manufacturer CGI Automated Manufacturing Inc., Cicero, Ill., fabricates parts as an outsource resource for vertical manufacturers. The company started out as a stamping operation, then added other fabrication technologies, including welding, press brake forming, drilling, punching, rolling, shearing, and cutting.
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