Beyond the Basics – How Smart Tooling Reduces Cost and Complexity

Modern manufacturing demands more from every process—more efficiency, more precision, and more innovation. At Wauseon Machine, we help customers move beyond traditional forming by applying advanced tooling techniques that consolidate steps, reduce variation, and improve repeatability.

Innovative Tooling Techniques in Action

• Multiple Beads in One Hit: Instead of resetting tooling multiple times, we can form two or more beads in a single stroke using sliding inserts and spring-return mechanisms.
• Beadlocking Components: Want to attach a hose fitting or bracket without welding? Beadlocking lets you mechanically affix components directly to a tube, improving reliability and reducing post-process cleanup.
• One Setup, Multiple Forms: Some projects require beads in swaged sections or multi-stage forming. Our custom tooling allows multiple forms to be created in one clamp-and-hit cycle, eliminating setup changes and saving hours.

Designing for Materials Different materials behave differently during forming. For example:

• Stainless may require dwell time to retain its shape
• Aluminum and copper work-harden and must be treated accordingly
• Annealed tubing needs extra lubrication to avoid galling

By tailoring tooling and process parameters to the specific material, we help our customers avoid cracking, collapsing, or excessive wear.

What Makes Wauseon Different? We don’t stop at "what's standard." Our in-house design and engineering teams collaborate with you to push the boundaries of what's possible with traditional forming. Whether it's reducing labor, cutting cycle time, or integrating automation, we're here to innovate with you.

Smart tooling transforms forming from a basic process into a competitive advantage. Let us help you reduce complexity, improve quality, and deliver more value to your customers. That’s the power of partnership.