MANUFACTURING

MANUFACTURE SMARTER

Selecting a manufacturing partner is one of the most important decisions an OEM or Tier 1 supplier can make. Companies have been choosing The Weiss-Aug Group for 50 years because of our dedication to innovation, technology investment, continuous improvement attitude, and quality-first mindset. You will find working with us that we are very passionate and committed to finding the best way to manufacture your product. We simply manufacture smarter.

PRECISION METAL STAMPING

The Weiss-Aug Group’s foundation in precision progressive metal stamping is the cornerstone of its success in providing cost-effective and quality solutions for metal components and products. Considered widely as one of the most cost-effective, repeatable, and robust ways to produce complex high-volume components, stampings can be found in a variety of applications and industries. From medical devices to automotive busbars and aerospace connectors, stampings are suitable–especially when repeatability and high volume are required.

  • 75+ presses across 7 locations
  • 22 Ton Bruderer to 90 Ton Bruderer high speed stamping
  • 75 to 350 Ton Minster progressive stamping
  • Komatsu and AIDA Servo capabilities from 30 to 100 Ton
  • In-house tooling design and fabrication
  • Materials from .002 to .200

MACHINED PART PROCESS CONVERSION

Many times, complex metal parts are machined with tight tolerances, different heights, angles, and patterns, leading to the conclusion that machining is the only option. This is costly and often slow. At The Weiss-Aug Group we see these situations frequently and, in many cases, can offer stampings as an alternative with little to no design change.

In-Die Processes

The Weiss-Aug Group specializes in optimizing the stamping process to include a variety of processes in line or in many cases in the die.

  • In-die Laser Welding
  • In-die measurement and innovative tooling for on-the-fly adjustments
  • In-die assembly
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IN-HOUSE PROGRESSIVE DIE TOOL SUPPORT AND BUILD CAPABILITY

At each of our stamping locations, we maintain full-service tooling support staff and equipment, with advanced preventative and proactive maintenance programs. From spare component fabrication to launching new builds, we can design, fabricate, groom, and maintain the most complex progressive dies and injection molds.

Insert injection Molding

Complex insert and reel-to-reel molding is a robust process that integrates metal components into a plastic assembly. By encapsulating portions or all inserted components, many common design challenges can be solved with insert molding. The Weiss-Aug group has thermoplastic injection/insert molding capabilities for miniature to medium size applications.

  • Injection and Insert horizontal molding capabilities
  • Arburg, Nissei and Toshiba presses from miniature to 275 tons
  • Engineered thermoplastic resins: PPA, PPT, LCP, PPS, PBT
  • Scientific Molding Principals – RJG Edart System
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Reel-to-Reel Molding

In some applications, the best method for insert molding may be to reel up the part after the molding process. This can preserve the delicate nature of a part, or enhance assembly at a further step. With reel-to-reel, a stamping insert is fed on the same carrier strip used during stamping, into the vertical molding press. Plastic is then injected into the mold cavity around the stamped part, and then cycled to advance the strip continuously through the molding process. The finished part is then coiled up onto the reel and ready for the next step.

ASSEMBLY

Although we started out with producing mainly stampings for our customers, over the years many have reduced direct suppliers and prefer to work with select manufacturing partners. As a result, The Weiss-Aug Group has evolved into a complete assembled product or sub-assembly supplier.

We work to optimize your product for efficiency through the use of automated assembly and reducing process steps. In-house, we can design, build and integrate a multitude of types of automated processes. For lower volume, we can handle that too with the best cost manual assembly at our Monterrey, Mexico Location.

  • Semi-automated systems with robotic loading/unloading, defect inspection and electrical/HiPot Testing
  • Feeder bowl, press fit, staking, singulation, and packaging
  • PEM insertion, orbital and radial riveting, ring staking and tapping in semi-automated to highly automated applications.
  • Assembly systems, secondary process tooling, machinery design
  • Clean environment cost effective manual assembly in Monterrey, Mexico
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Automation and Robotics

Automation selection and proper use are critical to the success of a manufacturing program meeting both cost and efficiency targets. Knowing when to use and how much to automate can be the difference between a solidly cost-effective cell and overly complicated automation that is overkill for the program needs.

The Weiss-Aug Group has full-time automation staff to design, build and maintain automation. We concentrate our concepts on optimal manufacturing process development.

In addition, our Lupine Research Division has a line of specialty automated inspection systems that utilize AI to effectively identify defects.

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Laser Processing

Production Laser Machining encompasses everything from welding to cutting and etching. We can weld similar and dissimilar materials, use etching to create patterns and cut shapes. Laser manufacturing can be the base manufacturing or function as an assembly method, depending on the application.

  • Amada Miyachi laser welding cells for spot and wire attachment applications
  • Trumpf in die stamping laser welding
  • ACSYS continuous cutting and etching
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Vertically Integrated Capabilities

Whether we have a secondary process in-house, or at a preferred sub-supplier, the process is seamless to you. From Abrasive blasting to vacuum heat treating, we provide many types of complimentary capabilities.

Production Machining

Complementing our metal forming capabilities, our JK Tool division located outside of Pittsburgh, PA delivers precision swiss, turning, and milling machining services for a variety of industries.

Heat Treatment

In addition, we are capable of heat treating loose and reeled metal parts. Equipped with furnaces able to reach 650°F and 1100°F, we can harden and anneal various red metals such as phosphorous bronze and beryllium copper.

WELDING

The Weiss-Aug Group offers a variety of welding services separately from our laser capabilities. From MIG and TIG welding to resistance, ultrasonic and percussion welding, we can hand, semi-automatically, or robotically weld.

Resistance and Percussion Resistance Welding

Resistance welding is the joining of metals by applying pressure and passing current for a length of time through the metal area which is to be joined. The key advantage of resistance welding is that no other materials are needed to create the bond, which makes this process extremely cost-effective.

Typically, we will utilize resistance spot welding to weld parts to parts, where parts are fixtured and the weld is performed semi-automatically.

Percussion welding (PEW) is a type of resistance welding that blends dissimilar metals together. Percussion welding creates a high-temperature arc that is formed from a short, quick electrical discharge. Immediately following the electrical discharge, pressure is applied, which forges the materials together. This type of joining brings the materials together in a percussive manner. Percussion welding requires less space than other welding methods and can be used in difficult angles where other types of welding are not applicable.

WELD INTEGRITY

The Weiss-Aug group ensures weld integrity through semi-automated leak testing, which fully tests 100% of production products to give reel time feedback to the welding centers.

Fully Robotic Welding

Robotic MIG welding, also known as Gas Metal Arc Welding (GMAW), is a common high deposition rate process that involves feeding a wire continuously toward the heated weld tip. MIG welding robots are capable of all-position, adding flexibility to the welding system.  (taken from internet)

Applications suitable for this type of welding are often high volume automotive, light & heavy truck, or small engine products where seams must be fully intact. In other areas, we use this technology to assemble rods to mechanical components as well.

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GET IN TOUCH LET US HELP YOU WITH YOUR PROJECT

As the internationally recognized leader in precision metal stamping, injection molding, value-added assembly solutions, and tooling engineering, we have served the medical device industry, automotive industry, and industrial sector for over 50 years. We provide design, prototype, advanced engineering support, and manufacturing services, ensuring a seamless transition from prototype to production.