Copper Weld Fixture

Project description: Design and build weld fixtures for customers
The tool shop in our facility here at Penn Metal Stamping, Inc. is a busy operation. In addition to building dies and fixtures for our own internal use, we build and repair tools for outside clients. Designing and building tools and fixtures is a complex process that is managed by a group of individuals with a broad skill set. They use sophisticated software programs to design, refine, and validate functionality, and then use many different types of machines and other equipment to reproduce their designs in metal. Since tools and fixtures typically have very close tolerance requirements, the process of machining, measurement, and inspection is done with diligence and attention to detail.
The weld fixture shown here is an example of one such project we recently completed in our tool shop. Designed for use on an electrode-welding machine, it featured copper construction to promote welding stability. No detail was overlooked during the design phase to ensure the fixture would allow for repeatable accuracy at maximum production rates. We also designed and built this fixture to withstand prolonged stress with minimal maintenance requirements.
Our technicians use our high-tech machining center, wire EDM, and soldering equipment to build and assemble the fixture. When complete, the main body measured 2.0" in length x 2.0" in width. In addition to numerous in-process inspections, we performed a leak test to ensure the fixture was fully sealed.
Through the efforts of our engineering team, tool shop technicians, and quality analysts, we manufactured a single version of this fixture within a very short two-week timeline. Feedback from the customer has been exceptionally positive.