How ARROW® Fixtures Doubled Nozzle Production Capacity

Challenge

In December 2024, All World was contacted by a manufacturer to assist with a nozzle machining project involving multiple castings and finished part numbers. The production strategy incorporated automation—the company was planning to use a 5-axis machining center with a 12-station pallet changer and robotic loading system, and they needed a fixture solution that could reliably support high-volume, automated runs.

The nozzles themselves posed a significant challenge: thin-walled, with close tolerances, and very little space to clamp without risking distortion. Initially, the team assumed that completing the work in a single clamp might not be possible, and they expected to have to machine the part in two separate holds.

The challenge was to develop a fixture that not only held the fragile parts securely for complete machining but also integrated seamlessly into the automated system to maximize throughput.

Overall Results:

• Production capacity doubled: 24 nozzles per cycle, while the common solution would have been 12
• Unattended operation: Machine runs for half a shift or more without operator intervention
• Minimal part distortion: Deflection under 0.0005" during machining
• Reduced downtime: Faster loading/unloading reduces labor costs.
• Consistent quality: FEA-driven fixture design protects fragile, thin-walled nozzles

Solution

All World engineers approached the problem methodically:

Prototype and Concept Development
Using FEA (finite element analysis) software, an All World engineer modeled how the nozzle would bend under clamping forces. The analysis revealed optimal clamping points and showed that the part’s internal pins acted like ribs, providing strength to allow clamping from one side while machining on the other.

Innovative Fixture Design
Each fixture holds two nozzles using a fixed Vee with a scissor-jack style clamp, enabling both parts to be clamped simultaneously with compensation for part variation. The design allows gentle but secure holding, minimizing distortion (less than half a thousandth of an inch) even under machining forces that are hundreds of pounds.

Iterative Testing
Prototyping proved essential. Initial tests showed the parts could move if clamped too lightly. Adjustments, including improving the clamp mechanism, ensured that even with minimal clamping force, the parts remained stable during heavy cutting operations.

Automation-Ready Capacity
Twelve identical fixtures were fabricated specifically to align with the manufacturer’s automation plan. Operators manually load all 12 onto the machine pallets, after which a robotic arm picks each fixture and positions it into the machine envelope. With two parts per fixture, the system can machine 24 nozzles per cycle. Finished parts are returned to the carousel, and the machine can run unattended for a half-shift or more, exactly the “lights out” production the manufacturer was targeting.

Outcome

The custom ARROW® Fixtures doubled production capacity by allowing up to 24 parts to be machined between operator interaction. By combining precision clamping, FEA-driven design, and compatibility with automated handling, All World delivered a solution that fit seamlessly into the customer’s existing automation strategy. Operators now load the machine once, walk away, and return only to unload finished parts and reload, drastically reducing downtime and improving throughput.

Engineering Insight

“All World Engineering focused on designing a fixture that could hold extremely delicate parts securely, even in a tight machine envelope. By prototyping and using FEA analysis, we were able to machine the part completely in a single operation and make it work with the customer’s automation strategy. That was the key to doubling production,” said Steve Hagedorn, All World Sales Engineer and Engineering Manager at the time of the project.

ARROW Fixtures by All World

This project highlights the advantages of ARROW Fixtures, designed and manufactured by All World:
• Fixtures incorporate easily accessible and replaceable fasteners and parts. With all internal porting, they require less maintenance, resulting in higher productivity and lower lifetime costs.
• Sized to the needs of the application, from lightweight precision parts to heavy-duty castings that require crane loading.
• Custom-made to hold virtually any material type, including aluminum and magnesium die castings, sand castings, forgings, and bar stock.
• Easily integrated into robotic cells or manually loaded on standalone machines.
• Option to design and build custom gauges, enabling operators to quickly spot errors, stop production, and correct issues before they impact throughput.