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The E.K. Machine animated website shows the capabilities of E.K. Machine and the process that the products are made all in a interactive presentation.To view this interactive area, please download the latest version of Macromedia Flash Player.  Production Machining
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FabricationE.K. Machine has full-service in-house capabilities to provide a fabricated, machined and finished weldment to your specifications. We laser cut raw stock from sheet or plate. Parts are formed, welded, machined (if required), and powder coated or plated to provide you with a dock to stock bolt-on subassembly to your product. Our Fabrication department includes:
Laser CuttingE.K. Machine has laser cutting capabilities up to ¾ in. steel, ½ in. stainless steel, and 3/8 in. aluminum. We can also punch standard cut-outs, raised louvers and extruded holes to accommodate self-tapping screws. Our Laser Department includes:
FormingE.K. Machine has close tolerance brake presses to form up to ½ in. x 6 ft. length., 3/8 in. x 9 ft. length. and ¼ in. x 14 ft. length. With proper tooling we can form 1/2 rounds, offsets and larger vent louvers to your specifications. Our Forming Department includes:
Roll FormingRoll Forming A new Roundo .25" mild steel rated (4) roll full CNC controlled roll. E. K. Machine has the latest in CNC sheet metal rolling capability with 12 foot capacity; Roll is capable of rolling 7 gauge mild steel 144" long into a 14" inside diameter. CNC control allows quick set-up with accurate, repeatable rolling. No pre-bend required in most instances. CNC control allows easy programming of shapes such as box, triangle and ellipses with 9" corner radius. Materials that can be rolled include:
Welding DepartmentE.K. Machine recently completed a new state-of-the-art welding facility. The department works in conjunction with our fabrication, machining and powder coating departments to give our OEM customer a completed ready to install assembly. All welders are qualified to AWS D1.1 standards. Our Welding Department includes:
Robotic Welding CellsWhen the volume justifies fixture tooling, E.K. Machine offers Robotic Welding when the welds are repetitive and quality and speed are crucial. The complexity of the fixture can vary to hold a simple tacked weldment for finish welding to securing all components in a close tolerance relationship. Our Robotic Welding department includes:
Manual Weld StationsWire Feed and TIG Manual Stations are manned by Qualified AWS D1.1 welders to ensure your products continuously meets your specifications. Our Manual Welding department includes:
Resistance WeldingResistance welding refers to several methods that generate heat to produce a weld by the resistance of the welding current through the workpiece. This process can spot weld lighter gauge materials to one another and weld an array of fasteners, nuts, studs, etc. to a substrate. Resistant Welders include:
Powder CoatingPowder coating is a dry finishing process using finely ground particles of pigment and resin that are electrostatically charged and sprayed onto electrically grounded metal parts. The charged powder particles adhere to the parts and are held there until melted and fused into a smooth surface coating in a curing oven. Before coating, the parts are cleaned and pretreated through a 7 Stage Pretreatment Process in-line with the coating and curing operations. The powder may be a thermoplastic or thermoset polymer that creates a hard finish which is tougher than conventional paint. Our Powder Coating Department includes:
7 Stage Pretreatment ProcessProper pretreatment of the parts to be coated is critical to support good powder adhesion. One of the most critical areas is laser scale (oxidation produced from laser cutting metal) E. K. Machine uses a phosphate free acidic solution in stage one that removes this oxide and allows the powder to adhere directly to the base metal ensuring paint durability. E. K. Machine closely monitors each pretreatment stage with an automatically computerized titration monitoring system that ensures consistent titration levels. Our 7 Stage Pretreatment Process includes:
Powder Coating ProcessThere are two main classifications for powder coatings: thermoplastic and thermoset. A thermoplastic powder coating melts and flows when heat is applied but continues to have the same chemical composition once it cools to a solid coating. Thermoset powder coatings also melt when exposed to heat. However, after they flow to form a continuous film, they chemically crosslink on additional heating. The final coating has a different chemical structure than the applied powder. Powder coatings can be formulated to withstand higher temperatures, elevated salt spray, UV fade and chemical resistance. Our Powder Coating Process offers:
Inventory ControlOn contract, E.K. Machine will establish minimum and maximum inventory stock levels to assure your parts are always in stock and can be shipped to your weekly production requirements. For those less frequent part requirements, we will run up to three month usage and ship over that three month period. This allows our customers to take advantage of higher quantity pricing.
Material ControlE.K. Machine contracts with domestic raw stock suppliers for plate, sheet, bar, tube, castings and forgings. We inventory the more commonly used materials and those required through contracts with our customers. Certification is available for all raw materials used in production. Materials Processed:
Tooling / Fixture ControlSince most parts only require programming of our CNC controlled equipment, tooling or fixturing is not necessary. Tooling and Fixtures are sometimes needed in more complex or close tolerance work. The tools and fixtures are designed, built and qualified at our facility. They are stored, maintained and qualified to meet your requirements for each production run. Tooling can be purchased up front or amortized in the part cost through the first year's production. Quite often, pattern mold tooling is required by the casting and forging supplier. This can be invoiced thru E.K. Machine or directly to the customer. Typical processes requiring tools or fixtures:
Quality AssuranceE.K. Machine Co. Inc.'s Quality Policy: "E.K. Machine is dedicated to providing our customers with products that meet or exceed their expectations and to continually improving the quality management system." The entire E.K. Machine team will adhere to the spirit and intent of this quality policy, as well as the requirements of the Quality Manual and its supporting quality system documentation. Please contact your salesman for a copy of the Quality Manual. Dimensional InspectionE.K. Machine strives on maintaining quality throughout the manufacturing process. Active participation with manufacturing personnel and in-process inspection and final inspection under the guidelines of ISO9001-2000 is vitally important to certify that the parts meet your specifications. The plant has three main temperature controlled QA labs with several machine operator QA stations throughout our manufacturing facility. Dimensional Equipment includes:
Characteristic InspectionE.K. Machine has the capability to also test for characteristics other than dimensional. Our quality personnel are versed in all aspects of product qualification to meet your rigorous requirements. If we can't inspect or source inspect to your specifications, we simply won't take the business. Additional Characteristic Testing:
E.K. Power ProductsEK Power Products is quickly becoming a reliable aftermarket equipment source for generator enclosures, trailers and UL 142 sub base fuel tanks. At EK Power, we put the customer's needs first. EK Power can offer you and your customer a great quality product while keeping your costs low. We specialize in the speed of which we do business. Many quotes will be done as you wait or within hours. Lead times will range from 6-10 weeks or sooner if possible. We are conveniently located in Fall River, WI, just 30 minutes from Madison and 2 hours from the Milwaukee airport. EK Power Products has assembled a team of engineers, quality personnel, and salesmen with over 25 years experience in the gen/set marketplace. We also feature standard enclosure packages to ease the ordering process. With our new addition coming in 2008, EK Power Products will be positioned to become the leader in the generator enclosure market. Custom designs are available for any unique situations that you may have. At EK Power, we measure our success by our customers' success. For a quote please contact: Power Product Sales EK Power Products Phone: 262-492-4600 Fax: 920-484-3709 Email us for a quote! Factory Information: EK Machine & Fabrication 671 S. Main Street Fall River, WI 53932 Phone: 920-484-3700 Fax: 920-484-3709
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