January 2007 Edition

Job Shop Showcase

Waterjet Technology Doubles a Small Shop’s Sales in the First Year of Use

Innovative use of mature technology helped a job shop weather the economic storm after 9/11

Trim Tool & Machine uses its waterjet system to cut up to 9"-thick steel

When it comes to the cutting edge, Trim Tool & Machine, Cleveland, knows its business. A traditional “mom and pop” job shop employing eight has become a specialist in cutting thick materials with a waterjet system.

Best known for cutting thin materials, Trim Tool & Machine routinely uses a waterjet to cut thick, hardened metals, such as 9" thick 4140 heat-treated steel.

“We typically cut 4" to 6" all day long,” owner Dane Willis said. “Often, someone comes in and says ‘Wow, you cut thick.’ We cut more thick steel than anybody. We design around it.”

In business since 1999, Trim Tool & Machine offers abrasive waterjet cutting, CNC milling, stamping and die-cast tooling, and machine building. The company serves industries from automotive to arts and architecture. Willis said the firm prides itself on its ability to turn around work within two to three days of an order, or even provide same-day service, if necessary.

Quick Turnaround

“We turn work around,” Willis said. “We get it in there and get it done. If the customer needs it today, we get it done. I will stay late and operate the equipment myself. We do the job when we say we are going to do it.”

Trim Tool & Machine specializes in gages, fixtures, trim dies, special machines, custom metal art, and repairs. It is known as one of the largest producers of steering wheel trim dies in the U.S. In fact, the company produces trim dies used by almost every U.S. auto manufacturer.

Trim Tool & Machine uses a waterjet system to produce trim dies used by almost every U.S. auto manufacturer

A trim die is a stamping tool made of thick, hardened steel that trims away excess metal from castings, creating precise and consistent parts. While many companies use EDM to cut trim dies, Willis said his company uses a Jet Edge abrasive waterjet system because it is faster and more cost-effective.

“That gives me a competitive edge,” Willis said. “Waterjet costs from $3 to $5 to cut one inch versus $10 to cut with wire. It’s possible to use waterjet for about 85 percent of the die.”

Set Apart

To set himself apart from the competition, five years ago Willis invested in a 4'×8' precision high-rail gantry waterjet system by Jet Edge, St. Michael, MN. The machine is powered by a 50 hp Jet Edge intensifier pump, producing water pressure up to 60,000 psi. Willis equipped his system with a 5'×13' tank for future expansion.

“I bought the largest and best one I could,” he said.

Willis researched numerous waterjet systems for several years before deciding on Jet Edge. The system’s bridge-style overhead gantry appealed to him, as did the company’s customer service.

“I was a one-man show, and Jet Edge was one of the only companies that talked to me,” he recalled. “It looked like it was constructed better. Upon researching it, everyone raved about the pump.”

Willis said the waterjet exceeded his expectations. When a friend asked him what waterjet system he should buy, he told his friend he could recommend only three manufacturers, but that he should choose Jet Edge because of the company’s support.

The Jet Edge waterjet system has helped Willis increase productivity and reduce costs, saving customers’ thousands of dollars and enabling him to expand his business.

“We have been able to maintain the cost of tooling despite the steel increase, because we are using waterjet,” he said.

Tackling the Hard Stuff

Best known for cutting thin materials, Trim Tool & Machine routinely uses a waterjet to cut thick, hardened metals, such as 9" thick 4140 heat-treated steel

Willis recalled one project where a customer needed to have 28 0.281" holes cut in 0.50"-thick, hardened A-2 steel. He was able to do the project for $90 with the Jet Edge system.

“For someone to burn it or carbide it, it would have been hundreds of dollars,” he said. “Waterjet can tackle hardened steel.”

Trim Tool & Machine also saves stamping industry customers money, using the waterjet for cutting stamping strips these customers need for sample hits prior to final adjustments for die cuts.

“It saves them thousands of dollars in tryout time,” Willis said. “The waterjet mimics the stamping process. Laser and plasma leave a case-hardened edge where a waterjet doesn’t. When I talk a customer into waterjetting, they never go back to laser or plasma.”

Willis noted that his waterjet system resulted in a business boom for the firm. His company’s sales doubled the first year after he bought the waterjet.

“At that point I was able to start hiring people,” he said. “I believe I would not have survived the post-911 industrial crash if I hadn’t had the waterjet. Without the waterjet, there is no way we would have been able to grow.” Jet Edge

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