UpperAxleSeat-1-MeritorAfter experiencing difficulties with production quality from multiple suppliers, we were selected as the single source contract manufacturer for a new and improved design even though our industry-leading customer had significant in-house robotic welding resources available. Working closely with their design team to understand critical characteristics, we implemented high volume production techniques that included progressive die-stamped and precision-formed components, multiple-stage weld fixtures to hold tight tolerances, and dual-arm robotic MIG welding to control weld distortion. This allowed us to produce an economic, precision weldment without post machining or the corrective operations which prior suppliers found necessary.

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Product Description – Axle Seat assembly used in single and tandem Class-8 Semi trailer suspensions.

Market – Commercial and Military Truck Trailer

Materials – High Strength Low-Alloy (HSLA) steels – grade 50 & 80, in 1/8”, 1/4″, and 3/8” coil stock.

Processes – Progressive Die Stamping, Press Forming, Dual Arm Robotic MIG Welding

Overall Size – 9.6” x 9.7” x 10″

Total Weld Length – 96”

Tightest Tolerances – +/- .005″ and perpendicularly to .020”, without machining.

Assembly Weight – 17 lbs

Quantities – Production lot sizes of 200 pc to 12,000 pcs.

Inspection – Dimensional using Faro Arm CMM and part specific Go/NoGo Gauges, Welds to AWS D1.1 and numerous customer specs, AWS Certified inspection – Fillet gauge and visual ND, initial and periodic Macro-Etch.