DEDICATED TO QUALITY
Experience & Machinery
At our new state-of-the-art 157,000-square-foot manufacturing facility 15 miles outside of Milwaukee, Wisconsin, we provide cost-effective solutions to some of the most complex issues facing the transportation industry. Each one of our engineered components is designed to enhance the control of movement, improve the user experience and add value to your vehicle.
Tell us what you need, and together we’ll make it work.
Experience & Machinery
We're Ready for Anything
At our new state-of-the-art 157,000-square-foot manufacturing facility 15 miles outside of Milwaukee, Wisconsin, we provide cost-effective solutions to some of the most complex issues facing the transportation industry. Each one of our engineered components is designed to enhance the control of movement, improve the user experience and add value to your vehicle.
Tell us what you need, and together we’ll make it work.
Creative Design Solutions
ER Wagner is your collaborative partner – helping you design the best products possible. Our design engineers are available to help you quickly create custom products of any size to fit your needs, with emphasis on creative design solutions, design optimization through FEA, enhancing product value and design for manufacturing.
Customer Input
Through our collaborative design process we'll develop the right solution for your project by establishing:- Design Guidelines
- Performance Criteria
- Packaging / Environment Constraints
- Cost Targets
- DVP&R
Design Process
With constant customer feedback, our engineering staff with decades of experience works to develop:- Swing Studies
- CAD
- CAE
- Cost Estimates
Deliverables
As your production partner, we’ll supply a comprehensive supplier plan & proposal, including:- Finalized CAD
- Cost Effective & Robust Design
- Validation Plan
- Launch Support
- Production Support
Advanced Engineering Capabilities
At ER Wagner, we don’t just make parts, we engineer solutions that improve and add value to our customers’ products. With ER Wagner Parts on 65%-75% of all autos on U.S. roads, we have extensive experience designing products and even complete systems based on your exact needs through:
- Innovative Design Solutions
- Design Optimization through FEA Software
- Design for Manufacturing
- Production Intent Prototypes Including 3D Printing Capability
- SolidWorks 3D Design Software
- SolidWorks Enterprise PDM System
- Program Launch Management
- APQP Process
- Integrated Launch Team
- Design Validation
- VAVE (Value Engineering)
- Tool Design
- Cross Functional Team
- SolidWorks Simulation
Quality Management & Testing
ER Wagner is committed to quality at every step of the manufacturing process. That’s why we have developed extensive design engineering, testing, measurement, quality management and certification practices to ensure you get a superior, long-lasting product that provides optimum performance at the best value.
Quality Management
- CMM Programming & Inspection
- Six Sigma Black Belt & Green Belt
- Certified Quality Engineers
- Certified Quality Auditors
- Poka-Yoke
- Error Proofing
- PPAP
Testing & Inspection
- Rockwell Hardness Testing
- Tinius Olsen Compression/Tensile Testing (60,000 lb capacity)
- Cleanliness Testing
- Eddy Current Inspection
- Vision Inspection
- Gauge Design & Build
Measurement & Certifications
- Brown & Sharpe CMM w/ PC-DMIS
- Optical Comparator
- Surface Roughness Testing
- Torque Testing
- Custom Gauging
- Calipers, Micrometers, Plug Gages
- IATF 16949:2016
- ISO 14001:2015
Engineered Hinges
Two-leaf, three-leaf, four-bar, six-bar hinges and more are right in our wheelhouse. Spring rotational assist, friction hinge control, detents and other custom features can be engineered into both simple and complex hinge mechanisms.
660 tons
Roll Feed Press Lines from 80 to
168"
Press Bed Sizes from 21.6" to
.312mm
Material Thickness .015" to
48"
Coil Widths up to
- Four Slide Forming
- Bihler Forming
- CNC Swiss Lathe
- Double-disc grinding
- Vibratory Deburring
- Fully & Semi Automated Assembly
- Hand Assembly
- Robotic MIG Welding
- TIG Welding
- Resistance Welding
- Orbit Forming
- Riveting
- Sheer Tube Cutting
- CNC Tube Cutting
- Wrapped Tubular Components
- Tube End Finishing
AMERICAN-MADE, GLOBALLY AVAILABLE
Working with OEMs in over 16 countries in Europe, Asia, North America and South America
600-Metric-Ton Punch Press
ER Wagner’s new Nidec Minster punch press is now available for production, greatly increasing ER Wagner’s metal stamping capabilities. The new 600-metric-ton press is the latest technology in metal stamping, giving us the ability to stamp bigger parts made of thicker metal – including high-strength metals – with complex geometries and tighter tolerances. Other benefits include improved part quality through programmable forming speed, and lower part costs due to increased production rates, value added tapping, insertion and welding.Servo Press Features
- Bed Size: 60"-168"
- Speed Range: 1-90 SPM
- Direct Drive Servo Slide
- Stock Width: 14"-48"
- Stroke: 12"-16"
- Shut Height 35"
- Rapid Acceleration and Deceleration
- Infinitely Adjustable stroke and speed
- Full Energy at Any Speed
- Pendulum Motion and Full Rotation
Machine and Wrapped Tubes
When you need precision tubes think ER Wagner. Machined & wrapped tubes can be made in almost any configuration – square, round, octagon, punched, notched, welded, you name it we can do it. As an added bonus – wrapped tubing is often more cost effective than traditional drawn-over-mandrel tube manufacturing.
Shear & Machine Cut Tubes
Tube cutting capabilities range from high-speed scrap-less to precision machined cut-offs. Machine cut tubes include ID/OD chamfering and turning on both ends and also facing with surface finishes less than Rz 10. End facing can include custom end profiles.
Capabilities
- Parallelism 0.1mm
- Perpendicularity 0.15mm
- Flatness 0.1mm
- Length tolerance +/- .05mm
- Length range 10mm – 610mm
- OD range 6mm – 82.5mm
Precision Wrapped Bushings
Roundness and strength are the keys to performance when it comes bushings used in NVH body mounts tubes for axles suspensions and engine cradles as well motor and solenoid housings. Virtually gap-less seams that can be butted, welded or interlocking to rigidity. Our bushings can be flanged, edge treated and chamfered.
Capabilities
- 0.1mm roundness tolerance
- Up to 152mm long
- 102mm max OD
- Up to 4mm wall thickness