Forging New Relationships Through Smart Weld Solutions

Aggressive Tooling is proud to support Dennen Steel with the design and integration of a heavy-duty jack weld fixture for their Jost Sand Shoe assemblies. This project combines both manual assembly and robotic welding, creating a flexible, future-ready tooling solution that accommodates multiple part variants. At the core of the system are two custom-built subplate tooling assemblies that allow for quick, toolless changeovers to account for part height differences. The design includes pneumatic clamping, hand slides for side gussets, and sensors to verify part presence. The system is integrated directly into an existing robotic weld cell, with plates mounted on both sides to support increased throughput. Weld spatter protection, flow-controlled cylinder motion, and guarded sensors ensure both safety and performance. Additionally, Aggressive updated the PLC/HMI programming to include part-specific recipes by number, streamlining operation and reducing the chance for error. With Dennen planning future expansion, we also designed the system with adaptability in mind—accommodating larger base plates, new hole locations, and variant-specific requirements without needing a full redesign. This project reflects our commitment to creating smart, robust manufacturing solutions tailored to each customer's evolving needs.