MANUFACTURING SOLUTIONS FOR FORMING, JOINING AND ASSEMBLY AEROSPACE APPLIANCE AVIATION AUTOMOTIVE BEVERAGE DEFENSE ENERGY HEAVY EQUIPMENT

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1 MANUFACTURING SOLUTIONS FOR FORMING, JOINING AND ASSEMBLY AEROSPACE APPLIANCE AVIATION AUTOMOTIVE BEVERAGE DEFENSE ENERGY HEAVY EQUIPMENT Manufacturing Your Success

2 WHAT WE DO Coldwater Machine Company is a leader in the design, build and integration of specialized equipment for discrete manufacturing with extensive precision-machining capability. We apply our breadth of experience across metalworking, materials science and manufacturing processes to develop effective solutions that improve production operations. If you are looking for a company committed to aligning value-driven solutions with customer service, Coldwater can provide you that partnership. PRODUCTION SOLUTIONS PRECISION MACHINING & ASSEMBLY We design and build inventive manufacturing equipment and assembly systems that deliver optimal performance. We manufacture high-precision parts and assemblies used in a wide range of applications and industries. ENGINEERING SUPPORT SOLID STATE JOINING We provide industry-leading solutions that join similar, dissimilar and exotic materials through our Solid State Joining Center. We offer full engineering services to enhance your product design, manufacturing processes and repair operations. Our mechanical, electrical and weld engineering teams employ the latest 3D design and documentation tools. OUR FACILITIES Coldwater Machine s 115,000 sq ft. climate-controlled facility features over 40 machine tools and includes 39,000 sq. ft. of space for full production line assembly. In addition to a full Metallurgical Test Lab, we have inspection and test equipment to support our internal machining needs as well as our customer s build-to-print activity for precision parts.

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4 AUTOMATED WORK STATIONS Coldwater Machine has extensive experience in developing innovative solutions for automating manufacturing processes for a variety of industries and applications such as welding, inspection, material handling, forming, fabrication and others. We work closely with you to design, develop and build a costeffective and efficient solution specific to your needs. Some examples of what we ve developed include: Weld Cells using: Fiber Lasers CO 2 Lasers MIG (GMAW) Direct Drive Friction Welders Resistance Welders Piercing Stations Blade Removal Machines Forming Machines Robotic Welding Cells Robotic Weld and Extrude Cells Robotic Tube Forming and Cutting Cells Vision Inspection Cells Pallet Indexer Machines Fully Automated Manufacturing Lines Assembly Lines

5 SIZE & FORM TUBE CELL Our customer had a new product that required five operations a combination of bending, sizing, crush-forming and retrimming. This initial processing approach also required additional material to accommodate the retrim prior to bending. Coldwater s solutions replaced all of these operations with a single-stroke hydraulic press cycle as well as eliminating the need for extra material. Result: Time savings, floor space savings, and approximately 75% reduction in system cost as compared to the original approach.

6 AUTOMATED ASSEMBLY AND FAB At Coldwater Machine we apply our innovative thinking to your manufacturing needs, looking for the best way to help you improve process efficiency and profitability. We offer design and build of lean assembly and fabrication solutions from single cells through fully automated turnkey lines that provide any number of processes such as laser or spot welding, stamping, roll forming, and inspection. If you are looking for a solution to a unique assembly challenge or a way to optimize your production operations, you can rely on Coldwater to provide an effective approach. Some examples of assembly systems we ve provided include: Washing Machine Line Cabinet Line with robotics, toggle locks, spot welding, and stamping operations Conveyor/Track Assembly Stainless Steel Panel Lines with destacking, embossing, notching, piercing, bending, and louvering Drum Line with robotics, laser welding, stamping, roll forming, assembly and inspection Transmission Component Cells with assembly pressing and laser welding

7 RICATING SYSTEMS AUTOMATED TUBE FABRICATING SYSTEM Our customer had been processing its tubular parts, specifically window regulators, using four manual cells requiring one to two operators at each cell. Coldwater developed an automated, programmable line that decoils, mills, cuts, loads, and bends, which was capable of processing 40 different high volume parts with approximately 250 different SKUs. Easy programmability for quick part changeover allowed the customer to also move low volume parts to this line. Result: Three of the manual stations were replaced by this one line. Faster changeover, improved part consistency, equipment reliability, labor savings.

8 WORKHOLDING & TOOLING When it comes to holding, supporting and locating the workpiece, we are specialists in high tolerance, precision applications. Our engineers are experts in resolving difficult part holding applications, enabling you to deliver the level of accuracy and repeatability required for your particular processes. This high level of quality can help make you more efficient, productive and cost-effective. We provide precision tools, jigs and fixtures for: Assembly Inspection Repair Welding Machining

9 PRECISION, PRODUCTIVITY AND PROFITABILITY We design workholding precision into every piece of equipment we build. We also provide build-to-print tooling solutions for all types of tight tolerance operations. The quality of these solutions can contribute to increased production and profitability of manufacturing facilities. For example, an engine jig we produced enabled the client to set-up and pre-assemble piping without idling the high-cost jet engine.

10 PRECISION MACHINING Coldwater offers a variety of precision metal machining services ranging from prototype development through contract manufacturing of demanding applications. We are able to produce highly complex components and assemblies based upon your supplied specifications or we can employ our engineering team to assist in your design. We consistently deliver machining tolerances of.0002".0004", helping to achieve your required quality standard. This level of precision is enabled by our highly skilled engineers, our CNC machining experts, our experienced skilled tradesmen and our state-of-the art equipment. Processes Milling, turning, boring, EDM, grinding Materials Stainless Steel, Aluminum, Inconel and other exotic metal alloys Value-Added services included, but not limited to: Assembly, Painting, Deburring Quality & Inspection NDT, CMM, 3-D portable laser tracking, ISO 9001, load-testing

11 Our newest horizontal machining center offers outstanding machining performance for large workpieces (57 in. x 57 in.) and difficult-to-cut material in the construction machinery, aircraft, ship, and energy industries. DEPENDABLE ACCURACY One of our customers had been experiencing heavy re-work costs of a large machined component due to deep bore and bottom plate out-of-tolerances. Turning to Coldwater s precision machining department for assistance, we assured them we could achieve higher accuracy. Result: Holding the stricter tolerances, we were able to deliver an improvement of about 10% over the previous method, allowing our customer to save nearly 20% of the total costs they had been investing.

12 Weld consistency Forge-quality welds Leak-tight joints No spatter, smoke, or radiation No consumables FRICTION SPIN WELDING Through its Solid State Joining Center, Coldwater has developed its SPINMeld TM technology, which uses rotational friction to heat the materials along with pressure to create a solid state welded joint. In friction spin welding, one part is held stationary while the other piece is rotated on a spindle until the heat of friction between the parts softens the material to a plastic state, creating a solid state weld in fractions of a second. Coldwater offers pre-production, prototype and low volume friction spin weld part production using its SPINMeld machines, which can join like or dissimilar materials including aluminum, magnesium, brass, steel and carbon fiber composites. SPINMeld machines are available to customers for integration into their work cell or as part of an automated processing line.

13 PART AND PROCESS DEVELOPMENT Our customer was interested in replacing clinch nuts with friction welded nuts on an automotive aluminum panel. Through a series of design iterations, verified by weld lab testing, we developed an M6 nut size and nut driver that would automate pickup and welding during production. Result: After verifying the optimal nut design and process, Coldwater developed a two-machine solution that friction welds nuts on the same part on different ends, which enabled our customer to meet the OEM s 11.6 second part-to-part cycle requirement.

14 Joins aluminum, magnesium, non-ferrous and dissimilar materials Flexible sheet thickness in one operation Weld near-original material strength High energy efficiency No consumables FRICTION STIR SPOT WELDING Coldwater is on the forefront of spot welding solutions for lightweight and dissimilar sheet materials. Its SPOTMeld TM Refill Friction Stir Spot Weld system enables spot welding of aluminum ( series), magnesium, non-ferrous and dissimilar sheet materials. This technology uses rotational friction to heat the materials along with pressure to forge together the parts using wear-resistant tooling to join two or more surfaces. Heat is generated between the tool and material, creating a soft region. Pressure is then applied, resulting in a solid state joint. Customers can employ Coldwater to run prototype and feasibility tests at its Solid State Joining Center or have a SPOTMeld system built to specification for use on their production floor.

15 Step 1: Tool is closed Step 2: Initial friction phase Step 3: The sleeve advances into the aluminum Step 4: The sleeve and pin return to a level, home position Step 5: The tool opens

16 Coldwater Machine Company has a 50+ year history of providing quality manufacturing solutions and services to OEM and Tier suppliers who require precisely machined components or solutions for assembly, fabrication or maintenance of components with tight tolerances. We are recognized for developing effective solutions that improve production operations whether it be dies, fixtures, gauges or special purpose automated metalworking and assembly equipment. All our solutions are engineered and built to be durable, reliable and maintainable. ColdwaterMachine.com CORPORATE OFFICE 911 North Second Street Coldwater, OH Tel. (419) Fax (419) MIDWEST OFFICE 100 W. Big Beaver Rd. Suite 200 Troy, MI Tel. (248) Copyright 2016 Coldwater Machine Company Designed by Industry-Scope.com

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