Recently, we had the opportunity to collaborate with a large electrical transformer manufacturer based in Kansas City. They approached us with a unique set of requirements that presented a few interesting challenges, including the need to weld onto a painted product using gas and handling a stud diameter significantly larger than our standard machine capabilities.
Overcoming Challenges Through Innovation
The primary challenge was the large stud size—7/8 inches in diameter. Typically, gas welding isn’t feasible for studs over 1/2 inch in diameter, but the customer was adamant about using gas. To meet these requirements, we developed custom studs and conducted extensive prototyping and testing at our facility in Barrie. This process ensured that we could deliver a solution that met their specific needs without compromising on quality or functionality.
A Trip to Kansas City
Once we were confident in our solution, I personally flew down to Kansas City to oversee the final implementation. Arriving at Kansas City International Airport, I encountered a small surprise at the car rental counter—instead of being handed a predetermined set of keys, I was told to “pick one.” I chose a 2023 F-250, ideal for navigating the rural backroads of Kansas.
Success on the Ground
The custom studs we manufactured worked perfectly, allowing us to begin welding quickly and efficiently. This project was a testament to our commitment to thinking outside the box. We leverage the deep experience of our long-term employees, some of whom have been operating Davenport screw machines for over 40 years, as well as fresh ideas from new industry talents.
Building Long-Term Partnerships
Our collaboration not only solved an immediate technical challenge but also solidified a long-term partnership with the transformer manufacturer. We are proud to say that our products are now helping to supply power throughout the Midwest USA.
How Can We Assist Your Next Project?
This project highlights our capability to handle unique and challenging scenarios in industrial manufacturing. Whether you need a customized solution or expertise in handling unusual specifications, our team is ready to help. Let us know your project needs, and let’s explore how we can bring our innovative approach to your business.