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Left top: StageRight’s TruBend 7036 cut cycle time in half and doubled the speed of bending small parts. Left bottom:Fabrication Manager Shawn Swartz meets with Paul Rogers. Above: StageRight was able to reclaim floor space bypositioning the laser, chiller and dust collect above the machine.the year,” explains FabricationManager Shawn Swartz. It also leadsto a bit of mischief around the shop.“We regularly see tackling dummiesrunning around the shop. It’s hilarious,especially moving at almost 20 mph!”REACHING HIGHER To supportits manufacturing needs, the RogersGroup purchased two tube laser cuttingmachines, a press brake and a 2D lasercutting machine from TRUMPF in2001. “That changed everything,”asserts Rogers, who especiallyremembers the tube laser’s drasticinfluence. “Our design engineersadapted to it very quickly, adding inslots and fixtures to help with assemblyand error-proof designs.” Since thenone tube laser has been replaced by anew TruLaser Tube 7000. “We processroughly 3 million pounds of tube ayear,” emphasizes Swartz, “and with anaverage batch size of less than thirtyparts, we really utilize the TruLaserTube 7000’s fast set-up and conveyorsystem to handle the changeover. Ourbiggest limitation is in getting thematerial to the machine fast enough.”StageRight recently purchased anew 8kW TruLaser 5030 fiber–themost powerful laser cutting system on10 EXPRESS 2/16the market. “We wanted a fiber laserfor the reduced maintenance costs butlaughed at the thought of that muchpower – until we saw the time study.Not only was it the fastest machine, itwas the cheapest in operating costs byfar,” Rogers explains. “It is unmatchedby any other system both in speedand the available options –the smartnozzle changer, BrightLine fiber,CoolLine fiber, and the Drag&Dropfunction –they are all very impressive.”In replacing its older TruLaser 3030with a CO2 laser, Swartz explained thecompany actually expected to take a hitwhen cutting thicker materials but withBrightLine fiber he claims a win/winsituation. “We cut 0.75 inch material andit’s the best cut we have ever had.” Sincethe TruLaser 5030 fiber requires limitedmaintenance, StageRight designed amezzanine to position the chiller, dustcollector and laser resonator above themachine and added overhead lighting.The reclaimed floor space made wayfor its new TruStore 3030 storage towerwhich, at twenty-seven foot tall, is thelargest TruStore in the country. “Thecombined performance of the storagesystem and the smart nozzle changeris amazing. We can run ten sheets of0.25 inch material and then switchto fourteen gauge automatically. Weestimate a 30% increase in cut time, andinstead of 24/7 production, we run asingle shift five days a week,” he asserts.In addition, the machine operators takeadvantage of the TruLaser 5030 fiber’smobile control app to remotely monitorthe cutting process whilebending parts at a pressbrake fifty feet away.While researching itsnew laser, StageRightnoticed a bottleneckin bending as well asthe waste associatedwith bending smallparts on its ten footTruBend press brake.“By adding a small,electric TruBend 7036,Paul Rogers,we cut cycle time in halfThe Rogers Groupand doubled the speedwhen bending smallparts. This machineenabled the high level of productionwe achieved last year,” Rogers asserts.Swartz also noted, “Man power isin such high demand that findingexperienced operators can be difficult.The press brake takes some of the skillout of forming which we have found tobe a real benefit.”“It is unmatchedby any othersystem both inspeed and theavailable options.”

LASER CUTTINGCustomized builds of professionalstadiums are a StageRight specialty.A STRONG BUILD With the latestfabricating equipment, the Rogers Group iswell prepared for the future. Each businesssegment is strong, including its youngestenterprise, Tranquil Systems, which has beensupplying demountable office walls since 2013.“The more we grow, the more we recognize theneed to organize operations so we can functionefficiently,” says Rogers. This led them to reachout to TRUMPF’s SYNCHRO team. The seriesof 5S workshops commenced this summer withvisual management upgrades and departmentalorganization and are set to continue through2016. “At first we noticed some hesitancy inthe shop, but Nathan and I could attest towhat we saw in TRUMPF’s factory here andabroad. We knew that if we could emulate it, weshould.” With everyone involved and onboard,the company is excited to see how TruTopsMonitor will impact the shop. “We are verymuch looking forward to monitoring our entireprocess to see what takes us the most time,”says Swartz. Above all, the Rogers Group keepsan eye on the big picture. “In every businesssegment, we require the flexibility to adapt tonew products quickly and to handle customjobs, and we can definitely say TRUMPFsupports us in this need.”PLEASE DIRECT YOUR QUESTIONS TO:Laser: Mark.Bronski@us.trumpf.comPress brake: Tom.Bailey@us.trumpf.comAutomation: Tobias.Reuther@us.trumpf.comPRO PERFORMANCEWHO:The Rogers Group. Clare, MI.www.therogersgroup.comWHAT:Six business divisions include:StageRight’s large scale audiencerisers, event staging andperformance products and RogersAthletics’ strength trainingequipment, football trainingaids, tackling dummies and fieldequipment.HOW:TruLaser 5030 fiber (TruDisk 8001)with TruStore 3030, TruLaser Tube7000, TUBEMATIC, TruBend 7036,TruBend V230XStrength training equipment providedby Rogers Athletics.EXPRESS 2/1611

PRECISION FABRICATINGFamily ties: Metal Solutions CEOCathy Thiaville and her brotherpresident Joe Cattadoris Jr.(center) built on their father’sbusiness. Now Joe’s son Jason islearning the ropes.Back on the fab trackMetal Solutions exemplifies what it means to be New York tough.12 EXPRESS 2/16

Joe Cattadoris Sr. was a young sheet metalapprentice in Upstate New York when heenlisted in the Army Air Corps in 1942. Histraining at the Embry-Riddle Aviation Schoolprepared him to lead his “flying sheet metalshop”, stationed in India, on several trips overthe Himalayas during WWII. After the war JoeSr. applied these skills and, with his partner,founded New Hartford Sheet Metal Works toprovide process-related projects and servicesfor the broad array of industry in the MohawkValley. By the time Joe Jr.joined the business in 1983, theregion had begun to decline asa manufacturing powerhouseand business was bleak. As aresult, Joe Jr. branched out intolow volume production, untila unique opportunity changedthe company’s course.“Our investment inTRUMPF technologyin the ‘90s was likemoney in the bank.”FICKLE FABRICATION“In 1995, a transit busmanufacturer needed a localfabricator to support itsimmediate production needsfollowing an acquisition, andwe worked day and night to fulfill them,” recallsPresident Joe Cattadoris Jr. Optimistic aboutthe potential work of a job shop, he took a bigchance and bought the company’s first TRUMPFpunching machine just a few months later. Fivemore machines quickly followed and businessgrew –until the dot-com crash and 9/11 broughteverything to a screeching halt. “Fortunately, ourinvestment in TRUMPF technology in the ‘90sJoe Cattadoris Jr.,Presidentwas like money in the bank,” Cattadoris asserts.“The reliability of the machines we purchasedthen carried us through the rough waters to wherewe could start reinvesting. Had we not chosen tobuild our business with TRUMPF machines, Ibelieve we would not be here to talk about it.”Cathy Thiaville, Joe’s sister and part ownerof the firm, also came on board at this time tohelp the organization get back on track. “Byalleviating some of the managerial burden Joewas faced with, I knew we could restructure,reorganize and recover,” says Cathy Thiaville,CEO. As a CPA and former CFO of a largeenvironmental engineering firm, she broughtgreat value to the business. In addition to herfinancial savvy, she has helped implement anMRP system and scheduling system based onlean manufacturing principles. Applying theTheory of Constraints, the company beganto schedule jobs around press brake capacityand displayed the highly visual schedule soall could track the work that needed to bedone. They also developed a hybrid kanbansystem that enabled the shop to react quicklyto customers with short lead-times andlow quantity parts. Although the big namecustomers had left the area, smaller factionsspecializing in customized and highlyengineered HVAC systems had been leftbehind. By focusing on the hardest tasks, theyquickly became the go-to source for thesecustomers as well as those in mass transit.During this period of revival, the companypurchased two new machines including aTruLaser 2030. “We recognized the clearadvantage of automation even in our volatileEXPRESS 2/16 13

PRECISION FABRICATINGworld, and the TruLaser 2030 was the right machine atthe right price. It was a game changer, and now, with ourincreasingly dynamic mix of products, it is often the onlychoice for processing all the new parts we see every week.”says Cattadoris.THE DAWN OF METAL SOLUTIONS The final stepin the company’s new beginning was a new name. “We hadtransitioned from the old sheet metal house to the modernsheet metal fabrication shop and felt Metal Solutions, Inc.would better reflect our new image,” he explains. While thecompany continued to move forward, many others did not,and in 2012 after years of tepid sales, Metal Solutions sawanother major customer close its doors. “Faced with a makeor-break situation, we again worked to expand our reach andimprove our quality system. With this focus we really beganto gain some traction,” explains Cattadoris. Metal Solutionsnow handles hundreds of small to mid-size orders and up toeighty new parts or revision changes each week. “We builtour workflow management systems around our customers’needs and we continue to adapt as new customers, projectsand challenges come along,” says Cattadoris. “We have alwaysrecognized the value in serving customers with challengingrequirements and dynamic product lines because it createsloyalty and reduces competition.”This most recent growth spurt also led to new investmentsin capital equipment. A TruBend 7036 press brake wasrecently brought in to increase capacity and efficiency inbending. According to Cattadoris, “It certainly has thehighest dollar per cubic inch return on investment of anymachine in our factory.” As the company continues on itspositive path, new laser cutting technology is on the horizonas well. “Our next move will be to add a higher speed fiberlaser cutting system. We realize it will vastly increase ourcapacity, and to keep up with a machine that produces parts14 EXPRESS 2/16at that speed requires our ability to handle them in realtime. Automated loading and unloading will be paramount,”he says.PROUD TO BE WNYSBE In 2015 with Thiaville atthe helm for more than a decade, Metal Solutions wasofficially recognized as a woman-owned business by theState of New York. “The certification was not easy, but shehad been operating in that capacity for quite some timeand we wanted to finally recognize what she brings toour family business,” says Cattadoris. Although this is anexciting accomplishment, the attribute Metal Solutions ismost proud of is its customer service. Whether it is “workall night” or “work all weekend” Metal Solutions’ employeesare willing to do everything necessary to deliver. This hasfostered great loyalty with major customers – some foralmost thirty years. “This success is directly attributableto our dedicated employees,” says Cattadoris. “I thinkour region has a great work ethic, but our employeesconsistently go above and beyond.”PLEASE DIRECT YOUR QUESTIONS TO:Laser: Mark.Bronski@us.trumpf.comPunch: Brian.Welz@us.trumpf.comPress brake: Tom.Bailey@us.trumpf.comTOUGH AS STEELWHO:Metal Solutions Inc. Utica, NY. Founded 1954.www.metalsolutionsinc.comWHAT:A full service sheet metal manufacturer focused onquality and service.HOW:TRUMATIC 190, TRUMATIC 200, TRUMABEND V85,2 x TRUMABEND V130, 2 x TRUMATIC 500-1600,TruLaser 2030, TruBend 7036

FABTECH buyers guideTRUMPF at FABTECH 2016TRUMPF is leading the way in the development of innovativesolutions to keep information and processes connected like neverbefore. As a visitor to the TRUMPF booth at FABTECH, you will beintroduced to TruConnect through the customized production of astainless steel Jeep. Using production process notifications to trackeach Jeep as it travels through the various fabrication steps, wewill demonstrate how our industry-leading products and serviceswork together. With AXOOM as a part of this process, you willalso learn ways to connect your standard sheet metal productionwith the supportive functions and services you need to keep yourbusiness running smoothly. As an open digital business platformfounded by TRUMPF, AXOOM spans the value chain by connectingthe various manufacturers, logistics and service providers together.Get Connected with TRUMPF to define your competitive edge nowand in the future.Booth C35041 / www.us.trumpf.comSpecialGet ConnectedEXPRESS 2/16 15

TRUMPF at FABTECH 2016Booth C35041 / www.us.trumpf.comTruMatic 1000 fiberThe new TruMatic 1000 fiber is the first entry-level punch lasercombination machine from TRUMPF with a solid-state laser. Themachine is revolutionary in its modular design, offering users theability to add to it as business grows. The patented Delta Drivemoves both the electric punching head and the laser along theY-axis while the sheet moves in the other direction. This featurenot only increases machine dynamics, productivity and processstability, it also enables a significantly compact footprint andthe ability to connect with innovative material handling options,including the SheetMaster Compact, to further increase production.The machine’s protective housing, a requirement for safe laserprocessing, is integrated into the system. It automatically movesout of the way when the machine is punching to give operatorsmaximum visibility and accessibility. The TruMatic 1000 fiber willbe on display at FABTECH with a 3kW TruDisk laser which offersfabricators the added flexibility of laser networking.TruPrint 1000The new TruPrint 1000 for additive manufacturing enables users to build metalcomponents, layer by layer, using the process of laser metal fusion (LMF).Any laser weldable metal in powdered form can be used for the build. Thecompact TruPrint is ideal for building complex parts, such as those with internalchannels and hollow spaces, and for manufacturing individual parts or shortproduction runs economically. Its user interface with touch screen control stepsthe operator intuitively through the process. All components, including the laser,optics, process enclosure, filter unit and control cabinet, are integrated withina compact housing making it a perfect fit for a job shop, medical or dentalcustomer, or a R&D lab.TruLaser Cell 3000The TruLaser Cell 3000 5-axis laser machine is available with up to 8kW of laser power. Thesystem was designed for fine laser cutting, precision welding and additive manufacturingand can easily switch between these processes for maximum flexibility. It will be shown atFABTECH with the new laser metal deposition (LMD) technology package which uses thelaser in conjunction with metallic powder to for cladding or to add volume and structuresto existing parts. The TruLaser Cell’s versatility and ability to switch between welding andcutting applications without changing the focusing optics makes it an ideal system for jobshops, automotive subcontractors, medical device manufacturers and others.16 EXPRESS 2/16

TruLaser 3030 fiber with LiftMasterCompact and PartMasterAs a highly flexible and productive 2D laser cutting machine, theTruLaser 3030 fiber easily processes a wide variety of materialtypes and thicknesses, including highly reflective materials. Withthe included BrightLine fiber and Productivity Package, cuttingcapabilities are enhanced even further enabling fabricators tocut stainless steel and aluminum up to 1in with exceptionalquality. The machine will be shown at FABTECH as part of aproductive laser cutting system featuring a 6kW TruDisk solidstate laser, the LiftMaster Compact for loading and unloading,and the PartMaster, which enables an operator to remove partsfrom a processed sheet quickly and with minimal fatigue orwasted motion.TruLaser 2030 fiber withLiftMaster ShuttleThe TruLaser 2030 fiber cuts thick to thin materialswith high accuracy, speed and cut quality. Shownat FABTECH equipped with a 4kW TruDisk laserprepared for laser networking and BrightLine fiber,the machine also features a single cutting headstrategy with collision protection and an automaticnozzle changer. While a pallet changer is perfectfor shorter runs, the machine can also be equippedwith the LiftMaster Shuttle loading and unloadingautomation solution for the added flexibility oflonger runs or lights-out production. With a variety oflayouts available, the LiftMaster Shuttle is the mostflexible automation solution in the industry.TruLaser Robot 5020The TruLaser Robot 5020 provides for cost-effective entry into laserwelding yet it is designed to support both high volume and high mixproduction. Conduction or deep penetration welding, long seamsor corner connections are all easily achieved. The machine’s modularsystem easily clamps components of different sizes and shapes andseveral components can be joined in a single process step, depending onthe size of the part. An optional automatic rotational turntable furtherboosts productivity by enabling set up while the laser is active. TheTruLaser Robot 5020 is also capable of a laser network configurationwhich maximizes the laser’s beam on time while reducing investmentcosts overall.EXPRESS 2/1617

SPECIAL: TRUMPF AT FABTECH 2016TruBend 7036As the most ergonomic press brake on the market, the compact TruBend 7036is ideal for producing small bent parts up to 40 inches. The electric press brakefeatures impressive working speeds and accelerations, a 6-axis lightweightcarbon fiber backgauge, BendGuard safety system and hydraulic upper and lowertool clamping. Programming can be performed offline using TruTops Bend or atthe machine control for maximum productivity.TruBend 5130The TruBend 5130 is the ultimate solution for bending even themost complicated parts with precision and ease. The I-Axis enablesthe machine to shift the die bed from one position to the nextfor hemming, multiple radius tools, or multiple height tools all inone setup. The patented automatically controlled bending (ACB)allows operators to measure the angle on the fly as the machine isbending, and holds an accuracy of 0.3 degrees. The LED positioningaids facilitate quick set-up, greater uptime, and simplifies thebending sequence for the operator. The 6-axis back gauge withcutout “fingers” provides maximum flexibility and precision whenbending complicated geometries.TruBend Cell 7000The TruBend Cell 7000 is an automated bending system specifically designed forextreme productivity in small part forming operations. Featuring a press force of40 tons and an electric torque motor for high speed acceleration, this machineis fast and highly functional. One robot prepares and load blanks and a secondrobot handles blanks during bending and the unloading process. The robots areextremely dynamic and designed specifically to work in conjunction with theTruBend 7036 Cell Edition electric press brake. Available with an automatic toolchanger and conveyor unloading options, the TruBend Cell 7000 is both fastand flexible.18 EXPRESS 2/16

TruMark 5020The fast and flexible TruMark 5020 fiber marking laser features high pulsefrequencies and superior pulse-to-pulse stability. In metal, it shows specialstrength in delivering high quality customized marking or engraving in shortprocessing times. The laser can be perfectly adapted to any application inmetals or plastics, and with high speed and superior edge quality the TruMark5020 excels in any application. It will be shown at FABTECH in a TruMarkStation 5000, an ergonomic workstation which can be operated whilestanding or sitting.Power Tool

chance to see "their car" in action when it raced at Connecticut's historic Lime Rock Park. Each race of the 2016 series is 2 ½ hours long and features a driver change approximately halfway through the race. The TRUMPF #27 car, driven by Britt Casey, Jr. and Danny Bender, is one of three Mazda MX-5s making up the Freedom Autosport Team.