Frequently Asked  

Questions

Branch Manufacturing Company is a metal stamping and fabrication job shop that specializes in building large draw operations, progressive dies, and sheet metal parts. They focus on tooling design, precise testing, and short- or long-run production, emphasizing innovative technology and customer service.

The company is headquartered at 6420 Pine Street, North Branch, MN 55056, in a 66,000-square-foot production facility less than an hour north of the Twin Cities.

Branch Manufacturing was founded in 1952 and has been operating as a family-owned business ever since.

They provide CAD/CAM design, grinding, laser cutting, metal stamping, inspection, sheet metal fabrication, and tooling building. Services include rapid turnaround with just-in-time delivery and a focus on both innovative equipment and personal customer partnership.

Yes, Branch Manufacturing is ISO 9001 certified, ensuring high standards in quality management for their manufacturing processes.

You can reach them by phone at (651) 674-4441 or fax at (651) 674-4442. For inquiries, contact Troy or Dan Fairbanks. Their website is www.branchmfg.com.

While specific industries are not explicitly listed, they produce metal stamped and fabricated parts suitable for sectors like consumer products, automotive, and general manufacturing, serving customers primarily in Minnesota and beyond.

Branch Manufacturing employs between 1 and 50 people, operating as a small private company with a focus on a clean work environment and family-owned management.

Yes, they hire for roles such as design engineers, tool room machinists, and production workers. Employees report a 10-hour workday in a clean, friendly environment. Check their website or sites like Indeed for current openings.

They stand out due to their long history of customer-focused service since 1952, advanced technology integration, and commitment to safety and rapid production methods, making them a reliable partner for custom metal parts.

Deep draw metal stamping is a metal forming process where a flat sheet or blank of metal is drawn into a die using a punch to create a hollow, seamless part, often cylindrical, where the depth exceeds the diameter. It involves pulling the material through a series of operations to reduce its diameter and increase its depth.

Common materials include deep draw quality (DDQ) metals such as low carbon steel, stainless steel, aluminum, copper alloys, brass, and specialty metals like gold, silver, or titanium. These materials are chosen for their high ductility and ability to withstand deformation without cracking.

Advantages include material savings through reduced scrap, high repeatability for consistent parts, superior cosmetic quality, work hardening that may eliminate secondary heat treating, higher production rates, and the ability to create seamless, strong components compared to methods like extrusion or machining.

The process commonly uses a transfer press or eyelet press, which transfers the workpiece through a series of punch and die stations to progressively form the part. Progressive stamping presses may be used for shallower draws, but transfer presses are ideal for deep draws.

Deep draw stamping creates parts where the depth is greater than the diameter, using a transfer or eyelet press with multiple stations. Shallow draw stamping involves parts with shallower depths, typically produced in a single progressive die press.

Key factors include material mechanical properties, relative thickness, number of drawing stages, die fillet radii, surface smoothness, lubrication, drawing speed, and clearance. Wrinkling and cracking are common issues if these are not optimized.

Deep drawn parts are used in items like battery cases, cans, sensor housings, pacemaker shells, connector shields, earphone cases, hearing aids, and automotive or aerospace components requiring seamless, hollow shapes.

Sizes vary by manufacturer, but examples include maximum lengths up to 5.44 inches with a 0.400-inch diameter, or maximum diameters up to 1.562 inches with a 0.700-inch length. Minimum parts can be as small as 0.090 inches long and 0.080 inches in diameter, with material thicknesses as thin as 0.006 inches.

While primarily for circular or cylindrical parts, deep drawn stampings can incorporate square, rectangular, round, or slotted openings. However, fully square or rectangular deep draws are less common and may require additional processes.

The process includes stages like initial drawing, redrawing to increase depth, reverse drawing to alter shape, and thinning/drawing to reduce diameter. It progresses through local deformation, main deformation, and pushing stages.

Hydraulic metal stamping is a manufacturing process that uses a hydraulic press to shape, cut, or form metal sheets or plates into specific designs by applying controlled hydraulic pressure. It relies on fluid mechanics to generate force, making it ideal for precise and high-force operations.

A hydraulic stamping press operates based on Pascal's law, where force applied to a small plunger in a fluid-filled cylinder is transmitted equally throughout the system, amplifying it through a larger ram to press the metal against a die. This allows for adjustable speed, pressure, and stroke length during the operation.

Hydraulic stamping offers greater versatility for complex shapes and deep drawing, full tonnage at any point in the stroke, adjustable stroke lengths, and better control over pressure and speed. It is also more energy-efficient and durable with built-in overload protection, though it may be slower than mechanical presses for high-volume simple parts.

It is commonly used in industries like automotive, aerospace, appliances, and electronics for tasks such as deep drawing, blanking, punching, forging, bending, embossing, and forming structural components or body panels. It's particularly suited for creating complex, deep-formed parts.

Common materials include aluminum alloys (e.g., 1100-O, 5052), carbon steels (e.g., 1008, 1018), stainless steels (e.g., 304, 316), copper (e.g., C110), and brass (e.g., 260). The choice depends on the required strength, corrosion resistance, and formability for the application.

Hydraulic presses use fluid pressure for adjustable motion and full force throughout the stroke, making them better for complex, variable tasks and slower speeds. Mechanical presses convert rotational energy for fixed strokes and higher speeds, ideal for high-production of simpler parts, but they deliver full tonnage only near the bottom of the stroke.

Capacity is determined by factors like tooling requirements, part size, material thickness, and operation type. Key specs include tonnage (force in tons), bed and slide size, stroke length, die height, and speed. Consult a toolmaker with product drawings to calculate these, as they influence cost and lead time.

Key components include the frame, hydraulic cylinder, fluid reservoir, pump, valves, piston rod, pressing plates, pressure gauge, and hoses. These work together to generate and control the hydraulic force applied to the metal.

Regular maintenance involves checking hydraulic fluid levels, inspecting hoses and seals for leaks, monitoring pressure gauges, and ensuring the overload protection system functions properly. They require minimal upkeep due to their durability, but periodic servicing helps prevent downtime and extends lifespan.Regular maintenance involves checking hydraulic fluid levels, inspecting hoses and seals for leaks, monitoring pressure gauges, and ensuring the overload protection system functions properly. They require minimal upkeep due to their durability, but periodic servicing helps prevent downtime and extends lifespan.

Lead times vary but often include 1-3 weeks for quoting, 6-12 weeks for initial samples in economy options, and 16-20 weeks for domestic production. Additional time is needed for tooling fabrication and full production after sample approval, depending on complexity and volume.

Laser cutting uses a high-powered laser beam to cut and shape various materials, such as metal, plastic, wood, and fabric.

Mirrors direct the laser beam and focus the light through a lens on a specific spot on the material. The heat generated by the laser beam melts, vaporizes, or burns the material, while compressed air blows away the debris.

Lasers can cut a wide range of materials, including metals, plastics, wood, fabrics, leather, and paper.

Laser cutting offers precise and accurate cuts, can handle complex shapes and designs, reduces material waste, and minimizes the need for secondary finishing.

CO2 and fiber lasers are the most common types used for cutting steel.

The thickness depends on the laser's power and the material. CO2 lasers can cut up to about 1 inch thick, while fiber lasers can cut up to about 1/2 inch thick.

Yes, a properly outfitted CO2 laser can cut metal with relative ease, especially with specialized options designed for this purpose.

The accuracy depends on the machine and material, but typically, it can achieve tolerances of +/- 0.005 inches.

Yes, laser cutting is generally safe with closed operations producing less dust and noise compared to methods like plasma or flame cutting. However, proper ventilation, personal protective equipment (such as safety glasses and gloves), and training are essential to protect against fumes and laser exposure.

They are widely used in industries such as metal processing, automotive and shipping, furniture, chassis cabinets, kitchenware, advertising, education (for teaching aids), machinery manufacturing, fitness equipment, and elevator manufacturing.

Mechanical metal stamping is a manufacturing process that uses mechanical presses to form or cut sheet metal into specific shapes by applying compressive force through dies. The press, driven by a flywheel, descends onto the sheet metal placed between the tool and die, shaping it without heating the material.

The process involves feeding sheet metal (in coil or blank form) into a mechanical press. The press consists of a pad and plunger; the upper die attaches to the press slide, and the lower die to the bed. As the press cycles, it applies force to form, stretch, trim, punch, or perforate the metal between the dies, creating the desired part in one or multiple strokes.

Mechanical metal stamping offers high production speeds for mass production, high precision and consistency, cost-effectiveness for large volumes, reduced waste, and the ability to produce complex shapes efficiently. It also results in parts with good rigidity and strength due to work hardening during deformation.

Common materials include ferrous metals like carbon steel, stainless steel, and alloy steels, as well as non-ferrous metals such as aluminum, copper, brass, bronze, and even precious metals like gold and silver. Material choice depends on factors like strength, corrosion resistance, and application requirements.

Mechanical stamping presses are classified by frame type (open C-frame for smaller presses or closed H-frame for larger ones) and application (e.g., double-action deep drawing, multi-station automatic, rotary head, hot die forging, or cold extrusion presses). They range in force from 40 kN to 60,000 kN.

It is widely used in industries like automotive (brackets, horn parts), aerospace, electronics (appliance controls), medical equipment, lighting, and consumer goods (fasteners, clips). Stamped parts include brackets, hinges, tabs, and complex components for vehicles and machinery.

Progressive die stamping uses a series of dies in a single press to perform multiple operations (cutting, punching, bending) on a workpiece as it moves through stations, producing a finished part at the end. It's ideal for high-volume, complex parts with high productivity and precision.

Deep draw stamping forms hollow, cup-like components by stretching sheet metal into a die cavity multiple times, depending on the required depth. It's used for parts like cans or enclosures and can be performed on mechanical presses for efficient production.

Select based on the part's function, performance specs, cost, and stampability. Consider properties like tensile strength, ductility, and corrosion resistance. Ferrous metals suit high-strength needs, while non-ferrous like aluminum are chosen for lightweight and rust resistance.

The three main elements are the stamping machine (press), the stamping die (tooling), and the sheet material. The press provides the force, dies shape the part, and material properties affect the outcome. Proper alignment ensures quality and efficiency.

Sheet metal forming is a manufacturing process that involves deforming flat metal sheets into desired shapes without removing material, using techniques like bending, stretching, and deep drawing to create parts with high strength-to-weight ratios.

Common processes include bending (folding the sheet along a straight line), deep drawing (pulling the sheet into a die to form cup-like shapes), stretching (expanding the sheet over a form), stamping (using presses for cutting and shaping), and roll forming (continuously bending the sheet through rollers).

Materials commonly used include aluminum, stainless steel, mild steel, copper, zinc, and alloys like brass. The choice depends on factors such as strength, corrosion resistance, and formability, with aluminum often preferred for its lightweight properties.

Sheet metal forming focuses on shaping the metal through deformation (e.g., bending or drawing), while fabrication is broader and includes cutting, welding, and assembly. Forming is often a subset of fabrication, but stamping (a forming process) can provide tighter tolerances than general fabrication.

Cracking can occur due to high material hardness, excessive thickness, or too small a bending angle. For materials like aluminum, annealing (heat treatment) beforehand can improve formability and reduce the risk.

Springback is the elastic recovery of the metal after forming, causing the part to revert slightly to its original shape. It can be minimized by overbending the material, using materials with lower elasticity, or applying heat treatments to reduce internal stresses.

Defects include wrinkling (from compressive stresses), tearing (from excessive tension), and burrs (sharp edges from cutting). Avoidance methods involve proper die design, lubrication, controlling forming speeds, and post-process deburring through chemical or physical means.

Heat treatment reduces material hardness, improves plasticity, removes internal stresses, and enhances overall performance. Common types include annealing (heating and slow cooling), normalizing, quenching, and tempering, often applied before or after forming.

Advantages include cost-effectiveness for high-volume production, minimal material waste, ability to create complex shapes, and suitability for lightweight, high-strength parts. It's faster than machining for large quantities and offers design flexibility.

Industries include automotive (for body panels and frames), aerospace (for lightweight components), electronics (enclosures), construction (ductwork), and medical (brackets and housings), due to its versatility in producing durable, precise parts.

Sheet metal fabrication refers to the processes used to convert flat sheets of metal into three-dimensional objects. This transformation involves a series of techniques, including cutting, bending, and assembling, tailored to produce specific shapes and sizes needed for various applications. Common metals used in this process include aluminum, stainless steel, copper, and carbon steel.

Several key techniques define the sheet metal fabrication process: Cutting (including Laser Cutting, Water Jet Cutting, and Shearing), Bending (shaping metal into desired angles using equipment like press brakes), Stamping (pressing a die into the sheet metal to form shapes and patterns), and Welding (joining metal parts using techniques like MIG and TIG welding).

Common materials include Aluminum (lightweight, corrosion-resistant, ideal for automotive and aerospace), Stainless Steel (durable, resistant to corrosion and staining, used in food processing, medical equipment, and construction), Carbon Steel (strong, cost-effective, suitable for structural applications), and Copper (valued for electrical conductivity, used in electrical applications and plumbing).

Industries that benefit include Electronics (enclosures, heat sinks, brackets), Aerospace (parts like fuselages, wings, interior components), Construction (roofing, siding, ductwork, structural elements), and Automotive (components like body panels, brackets, chassis parts).

The benefits include Cost-Effectiveness (lower manufacturing costs for mass production), Precision and Accuracy (tight tolerances with advanced technologies like CNC machines), Versatility (accommodates various shapes, sizes, and materials), and Durability (strong, withstands harsh environmental conditions).

The process generally includes Design (creating blueprints using CAD software), Material Selection (choosing metal type and thickness), Cutting (cutting sheets to size), Forming (bending and shaping metal), Assembly (joining components using welding or fastening), and Finishing (applying surface treatments like painting or coating).

Factors include Material Type (e.g., aluminum may be more expensive than carbon steel), Design Complexity (intricate designs require more time and resources), Production Volume (larger runs reduce cost per unit), and Finishing Options (additional processes like coating can raise costs).

Quality control measures include Regular Inspections (checks at various production stages), Testing (physical tests like tensile strength to meet standards), and Certification (compliance with industry standards and regulations).

Advancements include Automation (robotics and automated systems improving efficiency), Advanced Materials (new alloys and composites enhancing performance), and 3D Printing (allowing rapid prototyping and complex geometries).

Sustainability practices include Recycling (reducing waste and environmental impact) and Energy Efficiency (adopting processes and technologies to minimize energy consumption).

Sheet metal roll forming is a continuous shaping operation in which sheet or coiled metal is plastically deformed along the linear axis by passing it through a series of rolls set in pairs (top and bottom). These rolls progressively form the metal until the desired cross-section is achieved.

Most metals available in coil, sheet, or strip form can be roll formed, including aluminum, steel (cold-rolled, hot-rolled, and galvanized), stainless steel, and copper. Some processes also handle pre-coated materials, plastics, or composites in specific applications.

Key advantages include high production efficiency, precise and consistent shaping, minimal material waste, the ability to create complex profiles, and cost-effectiveness for high-volume production. It also reduces labor needs and errors compared to manual processes.

A roll forming machine works by gradually bending and forming a metal strip as it passes through a series of rollers. Each roller set performs a specific bending or forming operation, progressively shaping the material into the desired profile.

Roll forming is a continuous bending process ideal for shaping long strips of material in high-volume production, while press braking is a discrete process that uses a punch and die for shorter or individual pieces. Roll forming is more efficient for long profiles.

Roll forming generally produces shapes with tolerances tighter than those from press braking. Specific tolerances depend on the material, design, and machine, but they can often be held to within tight limits—consult a design guide for details on your project.

Yes, roll forming machines can be adjusted to process various material thicknesses, typically ranging from as thin as 0.005 inches to as thick as 0.165 inches, depending on the machine's design and capabilities. However, there are limitations based on the equipment.

Roll forming is widely used in industries such as construction (for roofing panels and studs), automotive (for parts like frames), appliance manufacturing, aerospace, and building components production due to its efficiency and versatility.

While roll forming is most economical for higher volumes (often 30,000 to 50,000 linear feet to justify custom tooling), it can still provide value for lower volumes if existing tools are used, starting from around 5,000 linear feet. It's not limited to super-high volumes.

A wide range of products can be made, including steel studs, roofing panels, metal channels, window frames, automotive parts, roller shutters, and building profiles. It's suitable for both open and closed cross-sections like U-channels or tubes.

Tool and die manufacturing is a specialized branch of manufacturing that involves designing, creating, and maintaining precision tools, dies, molds, fixtures, and gauges used in mass production processes. These components enable machines to shape, cut, form, or assemble materials like metal, plastic, and ceramics into finished products. It is essential for industries requiring high-volume, repeatable production.

A tool and die maker is a skilled machinist who builds, repairs, and modifies tools, dies, and molds based on blueprints or CAD designs. Their responsibilities include operating machinery like lathes, mills, and grinders; interpreting technical drawings; ensuring precision through measurements; and troubleshooting issues to maintain production efficiency. They often collaborate with engineers to refine designs for manufacturability.

While the terms are sometimes used interchangeably, a toolmaker typically focuses on creating precision tools, jigs, and fixtures for general machining or assembly. A tool and die maker specializes in dies (used for stamping or forming) and molds (for injection or casting), often involving more complex processes like progressive die stamping. Tool and die making encompasses toolmaking but extends to high-pressure forming applications.

Most tool and die makers complete a high school diploma or equivalent, followed by a formal apprenticeship program lasting 4-5 years, which combines on-the-job training with classroom instruction in areas like blueprint reading, CNC programming, and metallurgy. Certifications from organizations like the National Institute for Metalworking Skills (NIMS) or community college programs in machining technology are common. Some pursue associate degrees in manufacturing engineering for advancement.

Common tools include calipers, micrometers, and gauges for measurement; hand tools like files and hammers; and machinery such as CNC mills, lathes, wire EDM (electrical discharge machining), grinders, and drill presses. Advanced software like CAD/CAM is used for design and simulation. These enable precise cutting, shaping, and finishing of tool components.

Key skills include proficiency in CAD/CAM software for design, strong mechanical aptitude, attention to detail for precision work, problem-solving for troubleshooting dies, and knowledge of materials science and manufacturing processes. Soft skills like teamwork, communication with production teams, and adherence to safety protocols are also crucial. Experience with quality control and lean manufacturing principles enhances effectiveness.

Tool and die manufacturing is vital in automotive (for stamping body parts), aerospace (for precision components), consumer electronics (for molding casings), medical devices (for surgical tools), and appliance manufacturing (for forming metal sheets). It supports any sector relying on high-volume production of parts from metal, plastic, or composites.

Technology has revolutionized the field through CAD/CAM for faster design iterations, CNC machines for automated precision machining, and additive manufacturing (3D printing) for rapid prototyping of tools. Simulation software reduces errors, while automation like robotics improves efficiency and safety. However, it has shifted roles from manual craftsmanship to programming and oversight, making the profession more accessible but requiring continuous upskilling.

Common materials include high-speed tool steel for durability and heat resistance, carbide for cutting edges that withstand wear, and alloys like tungsten or cobalt for specialized applications. For molds, aluminum or pre-hardened steel is often used. Material choice depends on factors like the production volume, operating temperatures, and the workpiece material being formed.

Safety measures include wearing personal protective equipment (PPE) like gloves, safety glasses, and ear protection; following lockout/tagout procedures for machinery; maintaining clean workspaces to prevent slips; and conducting regular equipment inspections. Training on hazard recognition, proper handling of sharp tools, and emergency protocols is essential to avoid injuries from heavy machinery, flying debris, or chemical exposures. Compliance with OSHA standards is standard practice.