Thunderbird Metals/Metal Impact, LLC
Website: https://thunderbird-metals.com
Metal Impact, LLC is now doing business under the name Thunderbird Metals. This rebranding initiative reflects the strength and vitality achieved through the parent company, Thunderbird LLC. Thunderbird Metals, LLC is a leading U.S.-based aluminum and steel impact extrusion contract manufacturer. With multiple locations totaling more than 400,000 square feet, state-of-the-art presses, and automated processes, they have the capacity and scale to support OEMs across a broad range of markets and applications. Thunderbird’s experienced teams quickly produce near-net shapes, custom-engineered to customers’ specifications, allowing tight-tolerance finished parts to be completed faster. As an example, part walls made from alloy 6061 can be precision manufactured to within .02 inch even when the walls are less than 0.205 inches thick.
The manufacturing advantages include reductions in per-part costs, stronger components, reductions in material waste, and accelerated timelines.
Plant certifications include:
- ISO 9001:2015 certificate for Elk Grove, IL, facility
- ISO 9001:2015 certificate for New Albany, MS, facility
- IATF 16949:2016 certificate for Elk Grove, IL, facility
- IATF 16949:2016 certificate for New Albany, MS, facility
Aluminum Impacts-simple and complex near net shapes
Simple and complex shapes are generally asymmetrical in shape, have tolerances ranging from +/-0.005 range, and require no special surface finish outside the normal range of the process. These products often require minimal tooling costs and may require other forms of secondary processing following the impact extrusion process. Examples of these types of products are air conditioning cans, power equipment, handles, and oxygen concentrators. Metal Impact’s capability to use automated press lines to produce high volumes at high production rates increases efficiencies.
Aluminum Impacts-Difficult to manufacture products
Thunderbird Metals, LLC views the aluminum impact, difficult to manufacture product category, as its niche market. Product requirements in this category require much closer tolerances for size, concentricity, straightness, surface finish, and strength. These products usually require specialized processes utilizing multiple steps in the extrusion to consistently maintain the product requirements. Tolerances for size can be as close as +/- 0.001″ straightness requirements of 0.0005″ over a 1″ length, and surface finishes of 8 microns. Oftentimes, the capabilities of a manufacturer to meet product requirements is based largely on owning specialized equipment, using the right lubrication, or the industry experience and technical capabilities of the staff.