Case Studies

Trenton Forging has a long history of taking on projects that others shy away from due to their complexity or equipment limitations. Even though our normal forging size limitation is 15-20 lbs we can reengineer the product to work with our equipment and still keep the same functionality for the customer.

In this case a robotics company looking for a load bearing forging for their new product approached us. It was an intriguing opportunity that Trenton wanted to follow but the part was simply too large for our drop hammers to forge or our induction heaters to accept. Instead of passing up the business opportunity, our engineering department separated the forging into two pieces. They now had the ability to forge them separately and robotically weld them together using a fixture designed here as well. This allowed Trenton Forging to produce the parts and not compromise safety or quality that is always expected of us.

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Trenton has jumped into industries that no forging manufacturer has ever tried to enter. One of the more apparent of those industries is precast concrete. Precast is used in structural walls for roadways, bridges and buildings. Before now, most precast concrete manufacturers used fabrications or weldments to hold reinforcements to their cast slabs. Trenton developed special stronger forgings to take their place, saving them money and future quality issues. This shows once again our ability to solve customer problems with innovative forgings.

The U.S. Army Corps of Engineers enlisted Trenton Forging to go beyond their own limits to help with a new project. While the size of the forgings required to rebuild a water retaining dam in Northeast Kansas are normally far too large for our equipment, it was a project we wanted to take on. Working on a project that important and safety critical almost seemed like our duty. We perform work that others can’t when safety and quality are of the utmost importance.

Forged Models 3 days or less

With an extensive stable of in-house machine tools, Trenton Forging continues with the “first to market” concept by producing production tooling in as little as one day to meet customer demands. A prime example of this concept in action is the development of a customer’s ATV ball joint housing.

Upon receiving a 3-dimensional model of the requested part from our customer, Trenton Forging engineers created a forging blueprint for inspection purposes and in-plant reference using software programs Solid Works, AutoCAD and Creo (Pro “E”). Our engineers developed the machine tool path required to manufacture the die and programmed the specifications into the 18,000-rpm CNC milling machine tools. Within just ten hours, the forging tooling was 100% complete. Trim and coin tooling was completed on complementary CNC equipment and sample forgings were ready to run the next day.

As well as running tooling jobs at a moment’s notice Trenton can provide plastic or renwood models of customer designs and concepts. This has become a high demand service that Trenton Forging offers. The plastic models are important customer tools for evaluating new ideas and potential cost savings. Customers can identify design flaws, make necessary modifications or enhancements and measure how the designs will affect their internal operations before committing to production.
Please allow us to work with you to get your product to market first or to enable you to evaluate your latest designs quickly and cost-effectively.