SMITHFIELD, R.I. - TelAve -- A louver manufacturer returned to AIM-Joraco® for a specialized forming solution capable of producing precision blowouts in metal cups of six different sizes.
The unique shape of the cups presented an engineering challenge. Finished parts could not be removed from the tray using the same motion in which they were loaded, creating a risk of collision between the forming tool and the automatic slide tray. To address this issue, our engineers developed an expanding blowout tool that engages the press plate and forms each cup according to the machine's controlled shut height. A standardized shank diameter and adapter simplify tool changes.

Using a Toggle-Aire® 2530 press, the team integrated custom expandable tooling, an automated pneumatic slide tray, and sensor-based safety controls. Precise shut height adjustment ensures consistent blowout dimensions while improving repeatability, operator safety, and production efficiency.

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To streamline part removal, engineers developed a pneumatic slide tray with a stainless-steel trap door. Once forming is complete, the trap door opens over a collection chute, allowing the finished part to drop automatically into the collection area. This process eliminates manual part removal and prevents the cups from contacting the tray's sliding components.

Protective guarding and integrated sensors further enhance operator safety by helping prevent tool collisions. A versatile tray nest and five interchangeable adapter plates accommodate six-part sizes, ensuring precise alignment between each workpiece and its corresponding forming tool while improving flexibility, reliability, and ease of maintenance.
To simplify tooling changes, engineers developed a split-collar shank adapter and standardized the shank diameter across all six tools, allowing them to be removed and installed more easily. An optional automatic cycling mode also enables the press to operate at timed intervals, reducing the need for continuous manual cycling.

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The completed system delivers precise, repeatable blowout forming across six sizes. Adaptable tooling, automated part handling, integrated safety controls, and automatic part ejection reduce manual handling, help prevent tool collisions, and improve overall production efficiency.

About AIM Joraco
Joraco Press Company has been an innovator in the pneumatic press industry since 1947. The trademarked TOGGLE-AIRE® Series has been the core product of Joraco Press for over 60 years, having been installed in thousands of manufacturing facilities all over the world. The past 20 years have seen Joraco Press expand its benchtop pneumatic press products to cover more applications and more force ranges than ever before. Joraco Press Company is a division of Automated Industrial Machine, Inc located in Smithfield, RI. – All products are made in the USA Visit http://www.joraco.com for your press needs!