Estes Power Point Presentation

Why Estes

• Product breadth– Our strong mix of engineering support and state-of-the-art

technology allows us to develop products that a traditional fabrication shop cannot.

• Product cost– We can value engineer your projects to identify a more cost-

effective design and employ more efficient processes which decrease production time.

• Product quality– We have the flexibility to run short pre-production runs as well as

full production runs.– Our project managers stay with each project from start to finish –

increasing the level of quality control.– We have a dedicated prototype shop which allows you to work

with our engineers to repeatedly tweak your product design, which speeds your time to market.

– Our state-of-the-art equipment produces a higher quality product that is more aesthetically pleasing.

• Customer service– Our level of customer service is unparalleled in the industry.– Our quote turnaround time is days – not weeks.– We have full-time engineers on staff, available to assist you with

product design and specifications.

Employing the latest technology to meet your outsourcing demands in sheet metal fabrication.

04/10/23 2©2009 Estes. All rights reserved.

Industries Served

• Aerospace

• Appliances

• Containers

• Enclosures

• Food equipment

• HVAC

• Medical equipment

• Office furniture

• Renewable energy04/10/23 3©2009 Estes. All rights reserved.

The Company We Keep

We value long-term partnerships.


Our Fabrication Services

• Rapid prototyping (dedicated prototyping shop)

• Pre-production runs• Full production• Coordination of subcontract work

– Powder coating or painting– Screen printing– Plating, etc.

• Assembly and packaging• Inventory management

assistance– Kanban for JIT deliveries


Our Design Services

• Complete product development

• Turnkey design from a customer’s concept

• Value engineering

• Design for manufacturability

• Design for assembly


Our Equipment

• Salvagnini S4 CNC punching/shearing centers (2)• Salvagnini Panel Bender CNC forming centers (4)• Salvagnini L2 laser cutting center• Salvagnini MV material handling system• PRIMA™ Domino• Amada Astro robotic brake press• Genesis robotic welding cell


3D Laser Welding

• Realize a cost savings of up to 25% over traditional welding processes

• Improve your time to market

• Capture exclusive market share by obtaining patents for laser welded products

• Expand your product offerings to your customers - handle materials and thicknesses that traditional processes cannot

• Substitute more cost-effective material without sacrificing product quality

• Produce extremely consistent, reliable welds with minimal distortion, a small heat affected zone and high quality appearance

• Reduce the costs associated with scrap and waste


3D Laser Welding: The Estes Advantage• Estes can be your one-stop shop for 3D

laser welding, rapid prototyping, and traditional fabrication services.

• Estes’ dedicated engineers prefer to work with your engineers or product development team early in the process so that we can design the product around 3D laser welding standards and capabilities.

• Estes’ 3D laser welding services help reduce your overhead and labor costs by outsourcing your production needs to us.

• Estes’ laser welding shop can be used as a model shop for your short runs


3D laser welded part

Traditional TIG welded part

3D Laser Welding


3D laser welded part

Traditional welded part

Rapid Prototyping: The Estes Advantage• Guarantee the quickest, highest quality

prototype available, helping your company gain market share and premium revenue by getting your product to market faster than the competition.

• Stop interrupting revenue-generating production on your machines to meet your product development goals – utilize our dedicated prototype shop as your model shop.

• Be proactive by analyzing ways to help you reduce product costs without sacrificing quality through our value engineering services.

• Increase efficiency of prototype production using our highly automated equipment.

• Save your company the time and costs associated with working with multiple vendors – our capabilities include rapid prototyping, 3D laser welding, and traditional fabrication services.


Rapid Prototyping


What Customers SayNew design yields 20% cost reduction for food service equipment clientClient Need: One of the country's largest original equipment manufacturers of food service

equipment commissioned Estes to design a new rotisserie that was engineered around Estes' superior laser welding capabilities.

Estes Solution: Estes worked with the client to redesign a rotisserie that was engineered around Estes' superior laser welding capabilities.

The Results: By utilizing a team with more than 20 years of design and engineering experience, Estes produced a commercial-grade rotisserie design that yields a 20 percent cost reduction for the entire assembly.

Estes develops a better product at a lower cost for new clientClient Need: A client recently revealed to Estes that with their old fabricator, they were

managing the production process themselves – taking three weeks to shuttle parts from one subcontractor to another, wasting precious time that could have been spent on revenue-generating business operations. Raw materials alone cost more than $24 per product produced. Continuing to manage production in this manner would prohibit the client's growth.

Estes Solution: The client visited the Estes prototype shop and watched as their design was brought to life by the automated cell. The result was a new prototype for the client that was cheaper ($24 finished product cost) to produce and provided the same quality as the traditional product. The client was blown away by the time saved with the new design – from a production time of three weeks to a production time of three days – and, the final product looked better than the previous design.

The Results: The client now produces a better product at a lower cost, and all without having to lift a finger during the production process. Now, with less time spent managing the production process, the client is able to grow his business while Estes produces quality products for his customers.

“Estes is the closest to having your own fabrication shop as you’re going to get.”- Dick Valentine, Former Venture Manager, ITW


What Customers Say

Estes Design and Manufacturing

470 S. Mitthoeffer Rd.

Indianapolis, IN 46229

317-899-2203 phone

317-898-2034 fax

[email protected]

Estes Express Prototyping

[email protected]


Questions & Answers

Prospect Logo HereProspect Logo Here


Appendix


• Equipment slides

Salvagnini S4 CNC punching/shearing centers (2)


• Specifications:– Capacity - 30 tons– Sheet size - up to 60” x 120”

• Benefits include:– Consistently high quality– Automatic load and unload– Flexible capacity– Runs unattended – Results in shorter lead times

Salvagnini Panel Bender CNC forming centers (5)


• Specifications:– 14 gage carbon steel– 18 gage carbon steel

• Benefits include:– Automated precision bending– Bend line accuracy to within

+/- .004”– Automatic Length Adjust

tooling – eliminates secondary forming operations and reduces set up time

Salvagnini L2 laser cutting center


• Specifications:– Capacity – 3300 Watts– Sheet size - 60” x 120”

• Benefits include:− High-speed cutting of any 2-

dimensional shape – without tooling

− Flexible capacity – runs unattended

− Shorter lead times

Salvagnini MV material handling system


• 175 storage bays

• Enables unattended production for four major work centers = surge capacity

• In-process inventory management to enhance JIT or Kan Ban solutions

PRIMA™ Domino


• Specifications:– Capacity – 3300 Watts– Sheet size - 60” x 120”

• Benefits include:− Max combined linear axes

speed: 150m/min; Max combined acceleration: 2G

− A real 5-axis machine for 2D and 3D processing

− Flying optics: the work-piece remains fixed throughout the work process

− Unitized structure: all elements are embedded in a single, easily transported block

− Extremely reduced footprint

Amada Astro robotic brake press


• Specifications:– Capacity: 10 feet x 138 tons

• Benefits include:− Automated precision bending− Six-axis material handling

robot− Five-axis bending robot− Runs continually, unattended

Genesis robotic welding cell


• Specifications:− Process: GMAW-STT− Capacity: 118” x 36” x 10.5”

• Benefits include:− Automated precision welding− A dual-table ferris wheel

positioner for continuous welding

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