Facilities and Equipment

Ometek’s 100,000 square foot plant in Columbus, Ohio, is designed to handle virtually every process required for quality metal fabrication. We have a wide range of processing capacity to allow us to cut time and costs, while maintaining control over standards. We constantly invest in new equipment to remain competitive, while helping our clients increase efficiency, reduce cost and gain competitive advantages as a result. Equipment includes laser and waterjet cutting, CNC punching, forming, milling and turning machines, all with the latest computer controls.

Fabrication

Punch Presses

General Fabrication Equipment

• Falls Products Edge chamfering machine.
• Amada S1232 Hydraulic Swing
• Penn Engineering PemSerter PS-100 Hardware Inserter with Modular Autofeed.
• Amada CSHW-220 Corner and Radius Notcher.
• Amada SP-30CNC Single Station Punch Press.
• Fladder-Aut edge de-burring machine, 39” wide.
• Amerecon roller, 4’, 10 gauge capacity
• Wysong 10’ hydraulic shear, straightening arm, back gauge, conveyor
• Gemco 200 sander, 37” wide, wet system
• Togu 3 tool grinder

Press Brakes

• Toyokoki HYB1253-WinnII, 10’ x 137 ton 
• Toyokoki HYB8525-WinnII, 10’ x 93 ton
• Toyokoki HYB1753 - 10’  x 193 ton

All Toyokoki brakes are servo-hydraulic, PC Windows based controller supporting off-line programming and 3D model utilization, 5 axis CNC back gauge, auto-crowning, hydraulic tool clamping [upper and lower], Wilson common shut height tooling [allowing stage bending]

• Amada RG100 Press Brake, 10’ x 100 ton, NC9EX CNC back gauging.
• Amada RG100S Press Brake, 8’ x 100 ton, NC9EX CNC back gauging.
• [3] Amada RG50 Press Brake, 78" x 50 ton, NC9EX CNC back gauging.
• [2] Amada RG35 Press Brake, 4’ x 35 ton, NC9EX CNC back gauging.
• Amada FBD 1030 Press Brake, 10' x 100 ton, NC9EX CNC back gauging.
• Amada RG 80 Press Brake, 8’x 80 ton, NC9EX CNC back gauging.
• Amada SPH60 Press Brake, 3’ x 60 ton. * (5) Haeger Hardware Inserters.
• Wysong MTH 175-144 Press Brake, 12’ x 175 ton, Auotmec CNC2000 control/back gauge
• Hurco PH 123-30 Press Brake, 10’ x 80 ton, Autobend 7 control
• RAS 74.30 folder, 12’, 10’ back gauge, NB9000 Control

Profile Cutting Systems

Amada 3015 laser, 4Kw resonator, 5’ x 10’ sheet size, nesting software, 2 shuttle tables with automated load/unload and automated material handling.

Flow waterjet system, 6’ x 12’, 87000PSI, advanced articulating cutting head for higher cutting speeds while maintaining minimum taper. Capable of cutting virtually any material up to 8” thick. Includes nesting software for optimized material utilization.

Copper Bus Bar Cell

• [2] EHRT Holecut-40-6 CNC punching lines capable of processing 8” wide X 1/2" thick copper bar.[NOTE: For geometries or configurations not matching the capability of the EHRT punch, the water jet and turrets will be utilized to provide the part profile.
• EHRT EB-40 CNC Bending machine capable of processing 8” wide bar with bend accuracy to ¼ of a degree.
• Auto Sert hardware inserter. Equiped with bowls to automatically feed hardware for insertion.
• The cell also consists of a conventional press brake to enable most parts to be fabricated compete within the cell.

Machining Department

Vertical Machining Centers

• [2] HAAS "Mini Mill" Vertical Machining CenterS 16” x 12” x 10”, 10 tool changer, 6K RPM spindle
• HAAS VF-6 Vertical Machining Center 64 x 32 x 24, 32 tool changer, 10K RPM spindle.
• Kitamura Mycenter 3 Vertical Machining Center, travel range of 31" x 19" x 15", 30 tool changer, Fanuc OM controller, 6K RPM spindle.
• [2]Kitamura My Zero, 12”x10”x12”, 16 tool changer, 8K RPM spindle
• Haas VF-3SS, 40”x 20” x24”, 24 tool changer ,30 HP-12K RPM spindle, TR-160 trunnion [4th and 5th axis milling]
• Haas GR-510 gantry router, 60” x 120” x 12”, 20 tool changer, 10K RPM spindle.
• Haas VF-2SSYT, 30”x 20”x20”, 24 tool changer, 30HP-12K RPM spindle, with 4th and 5th axis drives [trunnion ready].

Horizontal Machining Centers

• Mycenter H400 Horizontal Machining Center, travel range of 24" x 20" x 20", 100 tool capacity changer, 10K RPM spindle, Fanuc 15M controller.
• Toyoda FH45 Horizontal Machining Center, travel range of 24” x 22” x 19”, 32 tool Changer, 6K RPM spindle.

Turning Centers

• Dainichi F25 Flash Turn Turning Center, Fanuc OTC control, chip conveyer, automatic tool setter, parts catcher, 7" swing, 21" tool travel, 3K RPM spindle, Space Saver 2000 automatic bar feeder.
• Ikegai TUR-30 3-axis CNC Mill-Turn, 19-11/16” Swing, 40-5/32” Tool Travel, 12 Station Turret w/Live tooling capability, 2.5K RPM spindle, automatic tool setter, Fanuc 18T control.

Saws

• Amada HDA-250 Horizontal Band Saw with NC controller and auto-feed.
• Dake-Johnson V-24 Vertical Band Saw, 24" deep throat x 12" thickness capacity, Auto-feed.
• Kaltenbach SKL 450E Semi-automatic Circular sawing machine, straight or miter cutting, aluminum and other non-ferrous material, 6400 to 12800 RPM blade speed, 17.72” blade diameter, with 16’ Tiger stop positioning system.
• Kalamazoo FS 350SA vertical saw with manual stop.
• IBE Equipment 350 Precision Non-Ferrous Cut-off Saw, 6" x 6" capacity

General Machining

• Clausing 4 spindle drill press with tapping heads
• [3] Flex Arm Drilling and Tapping Machines
• [2] Bridgeport Series I Milling Machines, 9" x 42" tables, Prototrak CNC conversational controls.
• Millport 1840 Gap Bed Lathe, 10" swing, 4’ tool travel.
• [8] Various size Drill Presses.
• Equiptop Automatic Surface Grinder, 12" x 42" magnetic chuck.
• Various disc and belt sanders
• Royson Vibratory Finishing Machine, 6 cubic ft capacity.
• Ultramatic Vibratory Finishing Machine, 3 cubic ft capacity.
• Burrbench Vibratory Finishing Machine, 1 cubic ft capacity.
• Rigid Pipe Threader.

Welding Department

Robotic Welding

• ABB Model IRB 1400 6 Axis Robotic Welding System with Orbit IRBP 250 RAC Servo Positioning System.
• Motoman Arcworld 6200 Duel 6 Axis Robotic Welding System with 2-Sided Servo Positioner. click here for picture

Spot Welding / Stud Welding

• Amada Spot Welder ID40ST Micro Computer Controlled Spot Welding System 80KVA 30,000 Welding Amps
• Sciaky 75 kva Computer Controlled Pneumatic Spot Welder, 36" deep throat, Interlok302 control.
• Southern Studweld CNC Automatic Studweld System
• [5] OBO Bettermann Stud Weld Systems with manual guns, # 4 to # ¼ capacity
• Nelson Stud Weld system with manual gun, 3/16” to 1/2” capacity

Automated Grinding

• Kuhlmeyer BKK2 Cabinet Corner Grinding Machine w/ Dust Collector

Welders

• [5] Miller Syncrowave 250 TIG Welders.
• [5] MillerMatic 250 MP Programmable Computer Controlled MIG Welders.
• [8] MillerMatic 250 Standard Mig Welders.
• Miller 350MPa with XR control
• [3] Miller Delta weld with boom feeds
• (4) Precision Welding Tables, dedicated and modular style setup tooling.
• (4) Precision Adjustable Welding Jigs Dedicated to Cabinet Welding.

Weld Support Equipment

• Demmeler precision weld fixture table [acorn table] 4’ x 8’with modular tooling/fixtures.
• [3] Precision adjustable weld fixtures for specific families of parts. Can be custom configured for specific customer requirements.
• Torit Trunkline Roll-Around FT-500 Welding Smoke Collector.
• (2) Micro Air Roll-Around Welding Smoke Collector.
• (2) Airlux 3000 Portable Welding Smoke Collector.
• Harris 8525-C Oxygen/Acetylene Torch Outfit, braze, solder, cutoff.
• MBA Model Power Peen 4848 – 48” cube sand blast booth
• [3] Mini Max line [stroke] sanders – 2 large capacity 96” long x 35” wide x 23” high and 1 small capacity 65” x 30” x 20” high

Wire Processing

Wire Bender

AIM AccuForm model AFM-3D1-T CNC wire bender. It is capable of bending formed or round wire into complex three dimensional forms via SmartEditor software. Depending on tooling, the bender can process wire from.062” to .350” in diameter.

Finishing Department

In-Line Powder Coating

The in-line powder coating system with the capacity to powder coat and cure a part that is 40” wide, 60” tall, and 89” long. Narrow parts of up to 10’6” in length can be processed.

• 5 Stage stainless steel, insulated, heated pretreatment system [wash, rinse, iron phosphate, rinse, non-chrome seal]
• 450’ of enclosed track conveyor with adjustable drive and automatic lubrication and cleaning system.
• GAT convection cure oven with dry-off section and triple pass cure, 2.5 MBTU burner capable of processing 4000#s of material per hour.
• Ionetc 1615 MPB powder booth with three spray positions, variable drive 8000 CFM air handler, cartridge filter system with auto-pulse cleaning, quick change color cartridge collector.
• [2] Nordson “Surecoat” manual electrostatic spray guns with box feed and electronic controls to improve coverage even in corners.
• [2]Wagner EPG 2007 electrostatic powder guns, vibrating platform for back-up.

Batch Powder Coating Systems

• Rapid Engineering manual Pre-treatment system with spray island.
• Powder X Cure oven, 8’ x 8’ x 20’ long, 750,000 BTUH burner capable of 500 degrees F
• Reliant Specialty manual spray booth, 10’ x 10’ x 15’long
• Eurotec electrostatic manual spray gun with box feed.
• Small parts batch system – includes a 3’x 2’ stand-up booth, a Wagner Cup Gun, and a 9 ft3 electric cure oven.

Screen Printing

• 40” X 48” and 36” X 36” manual screen print tables with 45” micro registration screen clamps
• Atma AT-C100M semi-automatic screen coater
• 44” X 54” Douthitt vacuum exposure table with Olite AL 15 Metal Halide exposure lamp and Olix AI121 light integrator [capable of burning screens to 36” X 44”]
• 72” X 48” semi-automatic screen stretcher table
• Harco IR conveyor oven 24” wide x 11’ long x 10”for curing ink
• Cincinnati conveyor oven, 48” wide x 16’long x 6”tall for curing ink
• 40” X 62” light table for inspection of screens

Engineering/Network Systems

Programming

• [4] Quad Core Intel CAD\CAM Workstations.
• Windows7 Professional Operating System.
• Design software consists of SolidWorks 2010

Fabrication programming software includes Metamation Inc. Metacam software which runs inside Solid works, allowing automated unfolding, flat generation and programming of any brand of turret, laser, laser/punch hybrid, or water jet from a viable engineering model to slash program time and increase accuracy. Bending automation is also provided with automatic tool selection and 3D bending simulation to verify the setup prior to bending the actual part.

We also maintain Teksoft Procad-Procam 2003 2D laser and punch modules for our legacy products.

• Machining programming software consists of Geometrics Technologies CamWorks 2010 which is seamlessly integrated into SolidWorks 2010 with multi-axis support.
• Dedicated laser and color printers.
• Oce’ TDS 400 wide format document printer, copier and scanner.

Network

• File server running Windows Server 2003 networked using Ethernet 10baseT.
• The Local Area Network consists of the file server, a production scheduling server, labor reporting server, (60+) online PC’s, (30) labor and material movement workstations, (6) online Laser printers, HP 240 Gig D.A.T. backup systems (run daily).
• Made2Manage SQL network based multi-user production accounting software.
• Made2Manage Shop Floor Manager real time labor and material movement for the manufacturing floor.
• All accounting, production, engineering, quality ,sales and any pertinent data is stored on the network and backed up daily.
• Network setup for maximum data protection.

Quality Assurance

Mechanical Verification Equipment

• Sheffield Cordax RS70 DCC CMM – 40” x 50” x 40”, with Renishaw AR1probe changer, PH10 head, PH7 probe. CMM manager software with reverse engineering capabilities as well as automated scanning.
• Virtek Laser scanning system – 48” x 48” scan surface for verification of all flats prior to production. Also has reverse engineering capability.
• Z-mike 1220 laser micrometer with 2” diameter capability. Utilized for tight tolerance measurements as well as calibration of pin gages.
• Federal Pocket-surf hand held surface finish measurement device
• All required hand held measurement equipment including calipers [up to 72” in length], inside and outside mics [up to 24”], height gages, thread gages, pin gages, etc. Most are digital with full metric or english readout capability

Powder / Plating Related Equipment

• Datacolor Microflash spectrophotometer for color measurement including software to store standards data.
• Powder verification equipment – can perform impact, mandrel bend, scrape adhesion tests to applicable ASTM standards.
• Tricor Systems gloss measurement meter
• [3]Elcometer Model 345 coating thickness gages
• FischerScope Model 750C-N2 coating thickness measurement system
• DeFlescko Positector 6000 ultrasonic thickness gauge