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WI: (262) 446-4431 IL: (773) 346-7000

 
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Chicago Custom Aluminum Extrusions, anodizing, fabrication
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Aluminum Extrusions

Mid-States Aluminum

Location: Fond du Lac, WI
Employees: 150

Mid-States Aluminum is your ultimate one-stop solution for value-added aluminum extrusions.  Within our 250,000 square foot facility we are able to provide single-source extrusion, fabrication, anodizing and assembly.   That means fewer steps for you to manage, greater cost controls through reduced inventories, quality improvement through our extensive product knowledge and overall lead-time reduction through our lean manufacturing principles. We are able to deliver a product that is ready to enter your primary production stream.

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MANUFACTURING CAPABILITIES

  • Extrude Aluminum
    • Extrusion Presses:
      • 880 ton — 4.5″ (113mm) diameter
      • 1800 ton — 7.0″ (178mm) diameter
      • 2200 ton — 8.0″ (203mm) diameter
    • Alloys:
      • 6063 / 6463A / 6005A / 6061
    • Extrudable Weight:
      • 0.040 lbs/ft up to 5.0 lbs/ft
    • Tempers:
      • F / T1 /T4 / T5 / T6 / T61
    • Profiles Extruded:
      • Solids / Semi-Hollows / Hollows
  • Fabrication
    • Precision cutting, miter-cutting, V-notching
    • Punching (150 ton presses with 126″ beds)
    • CNC machining centers (long-bed, high-speed, vertical, horizontal, tapping centers)
    • Drilling/Tapping/Countersink/Counterbore
    • Milling
    • Deburring
    • Bending/Forming
    • Automated robotic cell handling and machining applications
    • Hardware insertion (clinch studs & nuts, heli-coils, riveting)
    • Prototype production
    • Wire EDM machine
  • Tooling
    • In-house tool & die services
  • Anodizing
    • We’re able to anodize any size component up to 150 inches, from the smallest cut-length piece to long, linear extrusions. Our two-step process incorporates sulfuric anodizing with inorganic and electrolytic color methods to provide the traditional range of attractive, durable colors. All colors currently offered by Mid-States Aluminum are light and weather-fast, and will outperform any organic coating in the market.
      * Colors shown here are not exact. Mid-States Aluminum works with their customers to establish acceptable color ranges for each project.
  • Part Specifications
    • Maximum width of 30″
    • Maximum height of 48″
    • Maximum length of 150″

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ASSEMBLY

  • Riveting or screwing components to an extrusion (stoppers, end caps, plates, brackets)
  • Assembling two mating parts together (snap-fit, telescoping or interlocking extrusions)
  • Riveting, staking and fastening several extrusions together
  • Addition of seals and gaskets
  • Plastic component assembly

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QUALITY CONTROL

Mid-States Aluminum Corp. is ISO 9001:2000 certified. The quality management principles defined in the ISO standards are used in the daily operations of our company to remind us of the need for customer focus, while involving every one of us in improving our company’s performance.

We regularly follow APQP (Advanced Product Quality Planning), PPAP (Production Part Approval Process) and similar processes for new product introduction, validation and documentation. As part of our normal process we create control plans and control charts that are used to guide design and production.

In addition to our own quality standards, we work hard to incorporate all customer-driven standards into our process. We believe that customer satisfaction must be a collaborative effort.

  • First article inspection certificate of compliance
  • PPAP (Production Part Approval Process)
  • SPC (Statistical Process Control)
  • Adherence to Customer Quality Specifications
  • FMEA (Failure Mode Effects Analysis)
  • APQP (Advanced Product Quality Planning)
  • Chemical & Physical certifications

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ENGINEERING SUPPORT

Mid-States Aluminum employs value engineering — increasing efficiency, saving time and money.

Our engineering team is skilled in Lean Manufacturing principles. They apply these principles in their daily jobs to everything from customer quotations, to continuous improvement efforts, to daily 5-S activities and cost reduction projects.

At the initial request for quote, we are already looking for innovative and creative ways of minimizing waste and maximizing throughput. Our engineering team is responsible for the entire manufacturing process — for every part that runs through our facility — so they are constantly looking for ways to improve efficiencies of the entire value stream.

WE CAN HELP LEAD YOUR PROJECTS FROM START TO FINISH

It is very common for our Process Engineers to be intimately involved all the way from the design and development stage, through the pre-production/prototype phase, to part qualification and into full production. For this reason, some customers want us to help manage their projects for them.

Our goal is to simplify the overall process, enabling you to focus on your core strengths. We map out the entire value stream all the way to your assembly line, identifying improvement opportunities in the overall process. By looking at the entire process, both companies can understand what the other is doing, potential duplication can be eliminated and we’re able to identify operations that might be more cost-effectively performed at Mid-States Aluminum or at your facility.

Often, our extrusions are part of a larger assembly containing hundreds of other components. Projects that require several different extrusion profiles — in several different lengths, configurations and finishes, with a variety of production tooling required — can be very difficult to manage. We have adapted our organizational structure to be able to quickly and effectively respond to a wide range of customer demands, consistent with our lean manufacturing principles.

For projects that would be ordered in smaller quantities with hundreds of variations, the purchasing and order entry functions can create a process bottleneck. To simplify this, we work to coordinate our information systems with yours in a way that minimizes excessive manual data entry, while facilitating clear communication and maintaining accuracy and system integrity.

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MARKETS SERVED

  • Transportation – Automobiles, trailers & semis, light vehicle trucks & SUV’s, truck & buses, rail cars and recreation vehicles
  • Building & Construction – Windows, doors, railings & support systems, hearing & ventilation, equipment used in building & construction markets & manufactured housing
  • Machinery & Equipment – agricultural & mining machinery, process industries equipment, service equipment & supplies, ladders & scaffolds, professional & scientific equipment, office copiers and instrumentation devices
  • Electronics – heat sinks, housings, lighting applications, power transmission & communications
  • Medical Equipment – healthcare devices, hospital beds, diagnostic equipment, x-ray & lab equipment
  • Office Furniture – desks & tables, files, interior wall systems & displays.

 

Aluminum Extrusions Sample Parts Gallery

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Gorham Inc. works with small, medium & large manufacturing & distribution companies that primarily reside Wisconsin & Illinois. The major metro markets that we visit daily are located in Milwaukee, Madison, Wausau, Sheboygan, Waukesha, Oshkosh, Kenosha, Racine, Chicago, Rockford, Aurora, Moline, Joliet, Elk Grove Village, Addison & Peoria. The primary manufacturing processes that we represent are: Aluminum extrusions, castings, injection molding, metal stampings, powdered metal, precision machining and specialty cold heading. The hardware products we represent are bearings, knobs and seals. Please visit our Request for Quote page for a no obligation quote.