At The Federal Group USA, we partner with world-class original equipment manufacturers (OEMs) to resolve complex metal fabrication bottlenecks, reduce unit costs, improve structural integrity, and optimize lead times. Explore our verified engineering case studies below to see how our ISO 9001:2015 certified manufacturing ecosystem delivers measurable results.
Cold Heading
When a Tier-1 industrial equipment client faced severe material waste and elevated unit costs using traditional screw machining for custom steel fasteners, TFG USA redesigned the part for high-speed cold heading. Our engineers optimized the diamond-knurl pattern and secondary thread-rolling dies.
Metal Stamping
A global commercial cookware brand required a seamless aluminum baking shell featuring strict radius tolerances and uniform wall thickness. TFG USA's tooling specialists designed multi-stage progressive deep drawing dies, eliminating surface cracking and achieving a flawless cosmetic finish.
Multi-Process
Partnering with JanFan, a prominent industrial ventilation manufacturer, TFG USA consolidated a multi-component heavy-duty fan assembly. By integrating precision wire forming, investment cast mounting hubs, and custom cold-headed fasteners, we streamlined supplier management.
Gravity Casting
Lang Specialty Trailers needed to replace failure-prone sheet metal corner covers with rugged structural aluminum end caps. TFG USA implemented gravity permanent mold casting, creating a high-density, corrosion-resistant component capable of enduring high vibration and environmental stress.
Metal Forging
To eliminate field weld failures in severe structural joints, TFG USA engineered a hot-forged steel crimp replacement. By refining continuous grain flow and eliminating internal porosity, the forged crimp joint delivered unprecedented tensile and fatigue strength under dynamic load cycles.
Cold Forming
A municipal snow and ice control equipment manufacturer experienced shear failures with standard grade studs. TFG USA engineered custom cold-formed alloy steel studs with specialized induction heat treatment, eliminating stress concentration points and extending service life in harsh winter conditions.
CNC Machining
A fluid management systems client required complex grey iron pump housings with ultra-tight concentricity and bearing bore tolerances within ±0.0001 inches. TFG USA combined sand casting with high-precision 5-axis CNC finish machining and CMM 100% inspection protocols.
Quality Control
Persistent thread-stripping in overhead industrial fan mounts posed severe liability risks for an OEM. TFG USA performed root-cause metallurgical analysis and redesigned the thread pitch profile using roll-threading technology, boosting stripping resistance and assembly safety factor.
Our global engineering network and ISO 9001:2015 certified quality processes are ready to analyze your technical prints, optimize your design for manufacturability (DFMA), and lower unit costs.
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