Case Studies

Precision Antilock Brake Assembly

One customer required a precision assembly to encase a critical sensor to monitor wheel movement.

Cost Effective Water Valve Components

The Vulcan team can produce a variety of customized, internal parts for water valves. Look at this case study to see how we accomplished this for one of our clients.

Cost-Effective Welding of Dissimilar Materials

A leading lithium-ion battery manufacturer needed help to weld dissimilar materials and reduce cost.

Cont. Impv.

Experts at identifying and resolving manufacturing inefficiencies, we helped a customer minimize recurring defects from our tubing supplier.

Cost-Efficient Tube Forming Process Improvements

Tooling redesign increased our output by 80% while significantly reducing our customers’ costs.

Successful Fueling System Development

We helped the world’s largest manufacturer of heavyweight motorcycles develop two products for use on new models.

Lower Cost Stainless Steel Spindle Assembly for Eaton Cooper Power Systems

We helped a prominent manufacturer of vacuum fault interrupter switchgears reduce their parts requirements, and consequently, assembly costs.

Cost-Efficient Increase of Tube Feed Cell Production

To increase tube feed cell production capacity in a cost-efficient manner, we developed a manufacturing cell capable of forming multiple sizes of steel or aluminum tubes.

New and Improved Battery Busbar Assembly

Utilizing our tooling expertise, we assembled a newly-designed product for our customer in a cost-efficient manner.

Higher Quality, Lower Cost Spring Cover Assembly

Using our engineering expertise, we helped the world’s largest manufacturer of heavyweight motorcycles improve product quality while reducing assembly costs.

Softail Footboard Manufacturing Improvements

We re-engineered an assembly fixture to reduce operator fatigue and provide our clients in the motorcycle industry with faster turnaround and enhanced quality.

Design and Assembly of New Lighting System

We assisted a manufacturer of independent living aids with design improvements for enhanced quality and performance.

Laminated Plunger Manufacturing Process

We designed a cost-effective, alternative manufacturing process to help a customer produce high-quality actuator plungers with standard steel.

Automating Pushrod Tube Polishing for Harley Davidson Motor Co.

A market leader in the power sports industry needed help automating their metal polishing process and increasing their production capacity.

Automated Laminated Actuator Frame Assembly

We helped a leading power distribution and circuit protection manufacturer resolve their existing quality issues.

Design for Assembly

A container Kanban system was implemented to provide complete tested assemblies as required using weekly Customer pickups.

Cost-Effective EMS Mechanisms

We helped a global leader in the power distribution and circuit protection vertical develop two new cost-effective EMS mechanisms.

High Speed Stamping

Design a stamping die to produce a part with multiple features such as trimming, coins and forms in a single progressive stamping die.

Robotic M.I.G. welded Powertrain Component

Develop a robotically M.I.G. welded joint that would eliminate an assembly operation, reduce freight costs, lead time and inventory.

Automated Tube Cut Off and Forming Project

Design and build new tooling that combined several forming operations into once cycle and develop an automated feed system.

Welded Metal Stamping Assembly

Using low carbon spring steel and subsequent heat treating process we were able to robotically fillet weld the two components