Category Archives: Manufacturing

Tella Tool’s Prototype Capabilities

At Tella Tool & Manufacturing Company we are an industry leader in the metal stamping & assembly, fabrication and CNC machining business.  Currently we occupy 150,000 sq. ft. in 4 plants and 2 states, with over 125 employees providing metal forming and machining services to numerous industries.  We also offer full prototype capabilities, with quick turnaround service.  One industry that has taken advantage of this is the medical device manufacturing industry.

Prototypes are an essential component in the development of metal stampings, and fabricated and machined components.  They can save time and costs by detecting issues during the design phase, instead of after a full production run is completed.  At Tella Tool we have the resources and equipment to offer complete engineering support to develop prototypes of our customer’s concepts and designs.

Our prototype capabilities include the following equipment:

  • 3 Axis Laser
  • Vertical & Horizontal CNC machining
  • Press Brakes
  • Turret Presses
  • Mig, TIG and Spot Welding
  • Shear
  • Secondary punch presses

Our experienced, diverse and innovative Engineering team lends support, assistance and guidance through the entire product development process.  Our Engineers work hand-in-hand with our customers’ engineers to collaborate and ensure maximum efficiency and effectiveness through the design and prove out phases of a program.

Along with our prototype capabilities, we also offer program management resources which are dedicated to transforming the customer’s vision and expectations into an executable plan.  Our capabilities and experience allow us to streamline the delivery process, control costs and improve project results.  We will align our project management strategies directly with our customer’s business goals and objectives to make sure we meet their needs and expectations.

For more information regarding our prototype capabilities, as well as our other services and capabilities, visit our website or contact us here.  For the latest company news and updates, be sure to follow us on Twitter and LinkedIn.

The Growing Medical Manufacturing Industry

The medical manufacturing industry is rapidly becoming one of the fastest growing industries in the world.  As the population continues to age, many resources are being put towards developing new medical devices that can be used to treat these patients.

Medical Manufacturing

From 2015 to 2020, the growth of the technical medical device market is expected to grow at compound annual growth rate (CAGR) of 5.5%. This translates to an equivalent of $428,970,000 USD. Several factors are contributing to this growth, such as technological advances, chronic disease, an aging population that is growing, and a rise in disability adjusted life years (DALYs).

Overall, there are 10 types of medical devices that are distinguished by type and/or region.

These include:

  • In vitro diagnostics (IVD)
  • Diagnostic imaging devices
  • Cardiology devices
  • Orthopedic devices
  • Endoscopy devices
  • Ophthalmology devices
  • Orthopedic devices
  • Diabetes care devices
  • Anesthesia/respiratory care devices
  • Kidney/dialysis devices

The largest share of the global market comes from North America, followed by Europe and Asia-Pacific. Due to easy access of advanced medical devices and established channels of distribution, the U.S. is currently the top market. However, with a rapidly growing region, Asia-Pacific is being driven by a large population and increasing health care needs in their healthcare infrastructure which is constantly improving.

At Tella Tool, engineering support is offered to aide in design for manufacturability for new projects and ideas. We offer high/low volume precision metal stampings, assemblies, fabricating, and CNC machining solutions. Our precise and quality work is well suited for most industries, including the rapidly growing medical manufacturing industry.

Tella Tool is committed to helping customers find the perfect solution for their needs, whether for the medical manufacturing market or any other industry. At Tella Tool we believe in supporting our customers fully – providing innovative engineering support, reliable product quality, and responsive customer service to our entire growing customer base. Contact us here for more information.


Imagine a manufacturing unit work floor. The machines are huge and archaic. And they turn workers into just another cog in the system facilitating rote jobs. In fact their presence is a nod to the company’s policy of retaining human employees. The truth is the computer is enough to get everything done!

Now turn the clock forward to 2016 and take a look at the global economy. Offshoring is no longer as lucrative as it used to be. Enterprises are returning to the US soil in record numbers and they need talent to get their factories operational. And lean production paradigms like Six Sigma are creating factories that are equipped with cutting edge technological advancements to minimize wastage. Machining is no longer a push button operation. Each unit comes with its own level of challenges requiring skilled craftsman with backgrounds in mathematics, metrology, metallurgy, and machining to ensure defect free final products. If the Best Workplaces in Manufacturing and Production survey is to be believed, punch and leave employees now make up just 26% of the workforce. 34% of the labor is now skilled and qualified. And the need of such white collar specialists will only grow with time.

Let’s Take a Look at STEM:

The skill gap in US is no secret. There are more available jobs in the manufacturing sector than there are potential candidates. And this is why many industries have to contend with employees who are not a good fit for the positions they are accepted into.

The country needs more young minds in the fields of Science, Technology, Engineering and Mathematics collectively known as STEM. Currently only 5% of US laborers are engaged in jobs that require STEM knowledge. And 40% of students who plan to graduate in STEM disciplines end up choosing something else.

The problem lies in the image of STEM fields and manufacturing. They are both viewed as difficult, uninteresting and unrewarding. This perception has to be revised. Students need to be shown that a STEM background can allow them to earn roughly two times more than their peers in other disciplines and that manufacturing is now a futuristic space with potential for real growth and perks down the line.

Tella Tool Supports STEM & Manufacturing:

As market leaders in precision metal stampings, assemblies, fabricating and CNC machining, Tella Tool is proud to wholeheartedly support STEM endeavors and practices such as Manufacturing Week. To know more about our values and our services, contact us here.

Manufacturing Day

This month the United States celebrated Manufacturing Day. Manufacturers across the country opened their doors to local students, curious adults and even politicians to showcase that manufacturing in the country is alive and well.

When many people think about manufacturing, they think of their grandfathers in old dimly light and dangerous factories, but that’s not the case anymore; manufacturing today is a high-tech endeavor. In order to get the tight tolerances many customers need, factories are well equipped with CAD/CAM technologies. These computer programs allow workers to not only meet deadlines and specifications, but also allows them to do it safely.

Manufacturing is also thought as a low wage, low skill job and that assumption is very far from the truth! Manufacturing workers earn over $75,000 annually including pay and benefits. And with such a great salary, one would think there aren’t enough jobs for all the applicants. Unfortunately that isn’t the case either. Since manufacturing has become more high-tech, workers need to be a little more skilled than they were even a few decades ago. For that reason, there has been a skills gap and there are jobs that are going unfilled due to that. The good news though is that many companies are more than happy to offer on the job training for those who wish to get into the manufacturing sector.

October is Manufacturing month in Canada and we think our neighbors to the north are onto something. Manufacturing deserves more than one day, it deserves the whole month because it is so important to the economy and offers such a great career that many people may not think about. To get a good look at what a modern manufacturing company looks like, check out our video here. And if you think this is a career path for you, contact us today!

Manufacturing capabilities

Fotosearch_k11353134TELLA TOOL & MFG. CO., is located in Lombard, and it is one of the companies that is continuously growing and progressing. Its total dedication to quality and personal interest in servicing the needs of the customers has earned a reputation of being one of the highest quality sources of precision metal products in the country.

Tella Tool is a leading custom job shop, which is equipped with the state-of the-art capabilities that include tooling. Tella Tool manufactures precision metal work for a wide variety of industries, including Aerospace, Telecommunications, Computer, and Automotive.

The following are the services offered by Tella Tool & Mfg.:

  • TOOL & DIE – They are involved in the designing and building of all the tooling and fixtures, from simple short-run dies to elaborate class AA progressive dies.
  • COMPLETE STAMPING LINE – They offer punch presses from 10 to 1000 tons.
  • MACHINING DEPT. – They are involved in CNC Machining Centers and CNC Turning Centers for both short-run and long-run orders.
  • SHEET METAL FABRICATIONS – They offer shearing, punching, (including 8 N.C. presses and one 2600 watt laser machine) drilling, forming, welding (conventional and robotics), grinding/polishing, and assembly depts.
  • MODEL SHOP – Prototypes are always welcome.

The Lombard facilities incorporate over 110,000 square feet with more than $25,000,000 in state of the art precision equipment to meet or exceed the needs of the customer and to deliver quality products which are expected by the customer. In addition, Tella has a 50,000 square foot facility in Brownsville. This facility, encompassing metal stampings utilizing presses up to 600 tons and maintains service for South and Southwest customers. This facility operates with Engineering and Management support from TELLA TOOL & MFG. CO., Lombard, IL.

Metal Stamping and Forming on the Rebound

Abstract metal backgroundBusiness conditions for metalforming companies have been on the rise for the last several months and the outlook was reasonably bright. This was according to statistics gathered by the Precision Metalforming Association (PMA), along with its economist Dr. Ken Mayland. The last several issues of the monthly PMA Business Conditions Report identified a 5 to 6-month upward swing based on key measurable — most notably, expectations for general economic activity during the 3 months. This trend line climbed upward without pause since November 2010.

Studying the various market segments, Dr. Mayland expected the sales of automobiles and light trucks to continue to run-up. Dr. Mayland’s thoughts were backed by several industry analysts, including those from IHS Automotive. IHS analysts projected U.S. light-vehicle sales to rebound to 13.1 million units in 2011, from 11.6 million in 2010. Moving forward, IHS predicted a steady uptick in light-vehicle sales through 2017—14.9 million units in 2012, 16 million in 2013, and 17 million units in 2015.

Among the reasons for optimism at IHS are the mending of consumer confidence and trends in the consumer price index (CPI) for new and used cars. The CPI data, according to IHS, hinted that new is cheaper than used. IHS also noted favorable demographic trends that bolstered the long-term outlook for light-vehicle sales in the United States.

All of these facts were considered to be relatively clear skies for suppliers to the automotive market. Survivors amongst the metalforming companies enjoyed a 2-year trend of bringing back the laid-off workers, quantified by the PMA Business Conditions Report. The report indicated a nearly 2-year downward trend in the percentage of companies with a portion of their workforce on short time or layoff. While one year ago, 42 percent reported employees on short time or layoff; today, only 12 percent face that predicament.

History of the Progressive Die

The development of modern metalworking and die casting is relatively modern when compared to the human development of tools. Before the rise of metalworkers the majority of the tools made by humans were made of bone, wood, and rock. Once humans discovered the connection between fire and rock, metals became an important part of life.

From there, the field of metallurgy experimented with dies and eventually a two die system for coins was created. The first record of guides to “ensure punch-die alignment” in a machine is in the 15th century, a German hinge maker used it in his process. It wasn’t until 1796 when a French inventor issued an official patent for “Dies for Punching and Drawing Sheet Metal,” and the progressive die was born.

The first half of the 20th century saw companies beginning to produce their own single press die systems, mostly to create electric-motor components. Demand for production rose from the industrial revolution and later World War II. Speed became a primary goal but worker safety also became an important issue, producing challenges for the development of the die business.

Ed Stouten started a die design business in 1953 called Capitol Engineering Company in Grand Rapid, MI and focused on the safety and production challenges facing die casting. It was Stouten who came up with the alien concept of “leaving scrap material between parts to carry them in a strip through a single multi-station die,” soon he found a shop owner who successfully tested the system and word spread quickly about this new development in metalwork.

The rest is history, but it is important to keep in mind the importance of innovation and new techniques in die casting. Have you heard of any new developments in the industry, tell us by commenting below! Visit our website to see how our trusted capabilities work!

U.S. Reshoring and Innovation Hubs


It seems that only yesterday the United States biggest problem was lack of exported materials, excess of imported goods, and an influx of outsourced jobs. But today, with pressure from rising manufacturing costs in China, the U.S. manufacturing industry is coming home. This trend is in part due to a program proposed by the White House that centers around the concept of Manufacturing Innovation Institutes.

Also called “innovation hub,” these are public-private centers made up of industry leaders, universities, and the federal government and paid by an initial government 5-year investment matched by corporate or educational partners. It’s goal? Not only to spur the manufacturing industry within U.S. borders but also increase the rate of production for innovative solutions. The Obama administration modeled the program after Germany’s Fraunhofer Society but while the German program already has 67 institutions, the U.S. is starting with 45.

The first institute opened in 2012 in Youngstown, Ohio with a focus in additive manufacturing and 3D printing and there are more to come. While it is a relatively young program, it has a large amount of stakeholders and those in the manufacturing industry are already commending it. Vicki Holt, the CEO of Proto Labs, a “quick-turn” manufacturer of plastic and metal prototype parts, expressed support for the program, “The future of our industry lies in the integration of hardware and advanced software to maximize the efficiency, quality and affordability of manufacturing processes…Leveraging the innovation of the American software community is the key to making American manufacturing competitive once again.

While its not certain whether these programs or other factors like higher costs in China, the North American Energy Boom, or just general confidence are to blame for the rise in manufacturing, they seem to have a positive impact on various industries. The Institute for Supply Management released a monthly business report showing the increase of 15 out of 18 manufacturing industries in the month of June. Not only that, but an index based on five different industry indicators showed that American manufacturing has been steadily increasing for 13 continuous months and these programs are likely to keep that trend moving. What do you think is driving this increase in U.S. manufacturing? Share or let us know your thoughts!