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Engineering Capabilities
Model Shop and Short Run Departments
Weber Knapp’s Model Shop and Short Run Departments offer
many potential advantages for customers. The Model Shop serves as an extension
of Product Design Engineering, with fast turn-around of
functional prototypes. Additionally, the area supports low
volume production requirements and acts as a hedge against
interrupted supply of purchased components. In addition to
typical manual equipment such as lathes, mills, drill
presses and the like, the Model Shop also includes
computer-controlled machines. The Short Run Department is
really an extension of the Model Shop and includes CNC
turning centers, CNC laser cutters, and hydraulic brake
presses. As well as supporting prototype builds, the Short
Run Department offers an avenue to bridge the lead-time gap
between initial product launch and availability of
production tooling. It also provides the means by which a
customer can introduce a product to the market without
significant tooling investment. Weber Knapp’s unique methods
using laminated dies produce products that are nearly
identical to those manufactured on fully tooled progressive
dies, offering a seamless transition between low and high
volume production.
CNC Turning Capabilities
 Weber Knapp’s manufacturing
capabilities include one CNC turret lathe and two Swiss
style CNC turning centers. The heavy duty, 12-tool, turret
style lathe is capable of turning bar stock up to 2 ¾” in
diameter. Two Swiss style turning centers employ live cross
tools and synchronized primary and secondary spindles for
turning bar stock up to ¾” in diameter. The equipment is
completely programmable to operate unattended in off-hours.
 Robotic Welders
Although low to medium volume
production jobs still require manual welding, Weber Knapp
addresses higher volume production needs with two, 7-axis,
MIG robotic welders. The 48” long dual table allows separate
programs to be run on each side. The equipment is capable of
coordinated motion and weave welding and produces strong,
consistently welded joints.
CNC Laser Cutters
CNC laser cutters are used to support product
development, prototype manufacture, and production jobs for
which the cost of full progressive die tooling is not
supported by projected volume. Two CO2 laser cutters, 4000
 Watt and 1800 Watt, are fully programmable and capable of
producing highly complex shapes. These pieces are most often
used as blanks to feed secondary forming presses or CNC
brake presses, although the lasers are also used to produce
flat components such as link arms. The equipment accepts
sheet sizes up to 5’ x 10’ and can cut carbon steel up to
1.0”thick (0.50” for stainless steel, 0.375” for aluminum),
as well as nylon and Delrin sheets up to 0.125" thick. It
also cuts and scribes wood. Rotary axis capability is
available for tube-cutting and scribing.
 CNC Router
A CNC router, guided by GE FANUC 180i controls, gives
Weber Knapp the ability to cut and profile a variety of
materials, such as laminates, phenolic composites, wood,
plastics, and aluminum of varying thickness. Dual spindles
are run by a 30 hp motor with speeds up to 30,000 rpm,
producing a high quality edge without the need for finish
machining. The maximum work piece size is 5’ x 10’, with a
feed rate of 3,150 inches per minute. The router includes an
aggregate- ready tool changer for up to 8 tools with a
maximum diameter of 6.5”.
Progressive Die
Stamping
Weber Knapp’s manufacturing
operations include ten primary and eleven secondary
hydraulic presses. Coil-fed automatic primary presses range
from 50 to 300 tons. Secondary presses range from 35 to 110
tons. Our quick change clamping process
 significantly
reduces set-up time and increases productivity. Weber
Knapp’s unique tool methods include design of a master die
with interchangeable components, providing maximum
flexibility, reduced handling during changeover and,
ultimately, lower overall costs.
Production flexibility and cost minimization is further
enhanced by our in-house steel coil slitting operation.
Steel coil stock is purchased in only a few commonly
available widths and then slit to size in-house for specific
jobs. This allows rapid inventory turn-over and maximum
customer responsiveness.
Product
Engineering
Engineering is the heart of Weber
Knapp Company. Our Product Design Engineers effectively
collaborate on designs with customers, functioning as an
extension of the customer’s engineering department. However,
we are equally adept at independently devising solutions
based upon customers’ application requirements. Weber Knapp
supports numerous design platforms, including SolidWorks and
Pro-Engineer 3D modeling and FEA packages. Our technical
skill base is broad. However, our specialty lies in devising
robust, high cycle life, mechanical
 subsystems to accomplish
specific motions and sweep patterns. These may include
features to mechanically counterbalance a specific load or
maintain a specific open position. Once assigned, a Product
Engineer takes ownership of a project, retaining
responsibility from concept development through prototype,
test, and production launch. This philosophy provides
continuity and assures smooth and efficient transitions
between project stages.
Testing
 Weber Knapp operates our own test facility, which
is equipped for both static and dynamic product validation.
Our cycle testing lab is constantly updated to conform to
new testing methods and new product requirements.
Prototypes are tested and certified to meet customer
specifications and/or standard industry specifications. All
Weber Knapp Company products are unconditionally warranted
to meet the performance standards of the customer.
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