Case Study: Custom Orbital Forming Solution for Low-Volume Agricultural Components

Client Challenge

A agricultural equipment manufacturer approached Experienced Concepts Inc. and eci SpinnOmatic in search of a reliable solution for improving the assembly process of rubber bumpers used in backhoe and tractor leveling shoes or sleeves. Their existing welding process was inefficient, inconsistent, and unsustainable for their low-volume production needs.

Because the project involved a possibility of 35 unique part variations, most orbital forming suppliers declined to take on the challenge. The client needed a partner who could deliver precision, repeatability, and flexibility—even at low production volumes.

Our Approach

At Experienced Concepts and eci SpinnOmatic we thrive on solving complex manufacturing challenges others turn away. Our team collaborated directly with the customer to evaluate the components, identify clamping challenges, and determine the optimal forming path.

We proposed a custom orbital forming system supported by:

• A specialized nest and part fixture capable of securely clamping each bumper configuration.

• A forming setup to accommodate the unique geometry and rubber-metal combination.

• Integration of a Y-axis servo table to handle positional variation and fine adjustment between part models.

• Able to accomodate the large number of parts and programs in one machine. each tailored for the specific geometry, material stack-up, and desired forming force.

This approach allowed us to adapt our orbital forming technology to a low-volume, high-mix environment, ensuring the customer’s needs were met without compromising on quality or repeatability.

The Result

The solution we developed not only met the immediate forming requirements but also:

• Eliminated the inconsistencies associated with welding rubber-to-metal interfaces

• Reduced setup and changeover time between part runs

• Enabled in-house assembly with minimal operator training

• Created a scalable process foundation for future part variations

At Experienced Concepts Inc. and eci Spinnomatic, we understand that low-volume production doesn’t mean over-engineering or unnecessary complexity. Our team focuses on listening to the customer’s real needs and designing systems that deliver precision, performance, and reliability all within a practical budget.

By combining custom fixturing, servo control, and orbital forming precision, we provided a cost-effective, flexible, and repeatable manufacturing solution for an application most competitors considered too small or too complex to take on.

Key Takeaways

• Industry: Agricultural / Construction Equipment

• Application: Rubber bumper forming for backhoe and tractor leveling sleeves

• Challenge: Low-volume, high-mix parts; difficult clamping geometry

• Solution: Custom fixture design with Y-servo orbital forming system

• Outcome: Increased repeatability, reduced welding reliance, and improved process efficiency

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Conclusion

This project demonstrates how Experienced Concepts Inc. and eci SpinnOmatic go beyond standard forming solutions. Whether it’s one part or one hundred, we engineer systems that fit the customer’s real-world production environment delivering precision, flexibility, and long-term reliability every time.