Manufacturing Services Overview
Chart Denver provides manufacturing services to companies who want to out-source some or all of their manufacturing processes, and to companies that have capacity issues with their current manufacturing resources.

We offer flexible manufacturing capabilities that can accommodate almost any volume or product-mix challenge.

We specialize in forming, fabrication, machining, machined components, welding and assembly for a wide range of raw materials and structural configurations, including electro-mechanical devices.

By utilizing the latest metal working technology and highly disciplined process controls we deliver reliable quality, on-time, every time at optimized costs.

Our unprecedented knowledge and experience in metal fabrication, machining, welding and assembly will provide breakthrough productivity savings for you that can only be realized by working with a world-class supplier that is highly specialized in this field.


Manufacturing Services Topic Guide

Learn more about our services by clicking on the following subjects:
Build to Print Services
Modern Manufacturing Equipment and Systems
Productivity and Flexibility
Speed to Market with DFM Support
Cost Reduction Collaboration
Manufacturing Services vs Job Shop Services

Manufacturing Services, Capabilities and Core Competency

Large CNC Milling and Machining

• Four late-model large vertical machine centers
• X=275”, Y=98”, Z= 31.5”
• Vacuum-table clamping provides rapid setups for machining complex, high-precision features on large sheet and plate surfaces that would be virtually unattainable using conventional clamping techniques.

CNC Machining

• 25 various mills, lathes and machine centers
• Modern equipment with the latest speeds, feeds, auto-feeds and tool changers
• Milling capacity - X=40”, Y= 20”, Z=25”
• Turning capacity - swing = 21”, Dia = 14.5, X=11.4”, Z=25.6”

Plasma Cutting

• Dual torch, 800-amp power source with high definition option
• 11' x 25' capacity with integrated water bath for slag containment and submersion cutting
• Precision cutting of aluminum and steel sheet and plate up to 3" thick

Plasma Welding

• State of the art plasma welding equipment with integrated automatic fixtures
• 100% penetration, single-pass seam welds
• Ideally suited for mission critical high volume production of aluminum weldments, components and assemblies

MIG, TIG, and Sub-Arc Welding, Aluminum, Stainless and Copper

• Specializing in aluminum welding, stainless steel welding, Inconel welding, and copper welding – sheet, plate, tube, pipe, wire-rope and bi-metal joints
• Certified code welding to US and European standards.
• Over 25 various machines with integrated auto and semi-automatic positioners and assorted fixturing devices
• For ASME welding certifications, see Quality Systems

Brazing, Laser Welding and Hydrogen Furnace Brazing

• Specializing in silver brazing, copper brazing, brass brazing, Inconel and other high-end metal fusion technology
• 16 Years' experience producing high precision assemblies, consuming more than 100,000 lbs. of copper per year
• Proprietary environmental weld chambers with refrigerated heat-sink fixturing for high volume production and Six Sigma quality

Fabrication, Forming, Rolling, Punching and Cutting

• Modern NC shears, press brakes, rolls, saws, and punching equipment
• Roll forming specialists, close tolerance cylinders, aluminum and stainless

Turnkey Assemblies and Sub-Assembly Services

• One-stop manufacturing services including final inspection, test and packaging
• Sub-assembly modules that are packaged in reuseable Kan Ban containers
• Optimized throughput cycles for products that require complex welding, machining and assembly sequences

Cleaning, Degreasing and Aluminum Acid Etching

• Unique proprietary 6-tank cleaning system for large components and assemblies
• Class 1,000 clean room for cleaning, inspecting and packaging critical components

Tanks, Pressure Vessels and Cylinders

• More than 40 years' experience producing pressure vessels and cylinder components
• Certified to ASME, TUV and PED standards
• X-ray, UT, die-pen and helium mass-spectrometer leak testing
• Large surface milling machines enable us to install complex, high precision features in large cylindrical components

Cryogenic Dewar and Cryogenic Equipment Manufacturing, Vacuum Insulated Construction

• More than 40 years' experience producing products, sub-assemblies and components for cryogenic applications, to include vacuum jacketed piping and vacuum jacketed valves
• Experienced with application of super insulation, pearlite, fiberglass and hydrogen getter materials
• Proven process and systems for vacuum pumping, vacuum leak detection and achieving high vacuum results
• Pristine aluminum seam welds using the latest plasma welding technology
• Can provide any level of service from components, to code stamped vessels to finished product

Government / Military Equipment and Parts – (Click here for complete details)

Quality Systems and Certifications – (Click here for complete details)

 

Build To Print Manufacturing Services
Your design and print packages will be completely checked and transformed into process documentation that integrates with our production and quality control processes. This information can then be translated into CNC machine language using CAD interface software. If design issues and/or opportunities are uncovered during this process you will receive detailed feedback and recommendations for your consideration.

Modern Manufacturing Equipment and Systems
Our 16-year relationship with GE Medical has taught us the importance of embracing new methodologies like Six Sigma and investing in state-of-the-art metal working equipment so we can fulfill our obligation to continually deliver more value for less money to our OEM customers. While many companies have only begun Six Sigma implementation, our resident Six Sigma Blackbelts, Greenbelts and Champions have 5 years' experience delivering substantial results from successful Six Sigma projects. This competency, along with our modern machinery, robust manufacturing support systems, highly disciplined QA and process control systems, and many years of machining, welding and fabrication experience will provide you with competitive advantages that cannot be matched.

Productivity and Flexibility
Our OEM customers benefit from our state-of-the-art manufacturing operation because it supports maximum flexibility for the lowest cost. Our highly disciplined manufacturing processes are designed to eliminate non-value costs using Six Sigma based controls while providing the flexibility needed to respond immediately to demand flow signals from customers with fluctuating capacity requirements and a low-volume-high-mix product portfolio.

Speed to Market with DFM Support
We assist our OEM customers in achieving speed-to-market with a robust concurrent or simultaneous engineering process. DFM (design for manufacturability) is an essential ingredient of this process. As OEM equipment companies outsource more of their metalworking and fabrication work it becomes extremely important that they align themselves with progressive suppliers who proactively backfill the knowledge gap that develops when they no longer perform this type of work. We are relentless in our pursuit to be best-in-class for our industry and our customers rely heavily on our metal working DFM experience when developing new products or improving existing designs.

Cost Reduction Collaboration
As an OEM service provider we will succeed long-term if we help our customers continually reduce cost. We have a long history of achieving at least 5% annual cost savings through productivity workout sessions with our customers. Many of our cost-down contributions come from productivity improvements that involve up-stream and down-stream processes. We have no boundaries when it comes to helping our customer win the “more-for-less” contest.

Manufacturing Services vs. Job Shop Services
As a manufacturing service company our capability goes far beyond a typical job shop profile. In our pursuit to be a best-in-class manufacturing service supplier, we have had to distance ourselves from old-school job-shop practices. Economic run quantities, batch manufacturing, capacity driven lead times, and material/process queues, are antiquated practices that cripple a company and its OEM customers. Today, OEMs and their suppliers must be masters at mix-model line design, demand flow scheduling, lean manufacturing, Six Sigma quality, variable capacity, on-time delivery, 1-for-1 lot sizes, and flexible workforces to be in the game. These modern practices have been mastered by Chart Denver and are now the essence of our culture.

JOB-SHOP SERVICES		MANUFACTURING SERVICES
• Economic Run Quantities		• Mixed Model Line Design	• Zero Defects
• Batch Manufacturing		• Demand Flow Scheduling	• On-Time / Every Time
• Material and Process Queues		• Lean Manufacturing	• EOQ lot size = 1
• Capacity Driven Lead-times		• Six Sigma	• Flexible Workforce 2000
		• Variable Capacity