Case Study: Boehm Pressed Steel reshorses automotive die production with Hexagon FormingSuite Professional

Simulation software enables Boehm Pressed Steel to reshore complex automotive process yielding 4x run rate with less labor and scrap

Boehm Pressed Steel, a die shop and stamper, faced significant challenges with an offshore manufacturing process for automotive brackets that had a 40-65% rework rate due to part defects. The company was tasked by an automotive OEM with reshoring and completely redesigning the tooling to meet original part specifications within a tight 18-week deadline. To overcome this, they turned to Hexagon's FormingSuite Professional and COSTOPTIMIZER software solutions.

Hexagon's software provided a digital twin for simulation, allowing Boehm to rapidly test and validate their new 12-station progressive die design without costly physical prototyping. This solution from Hexagon enabled them to complete the project in just 12 weeks. The results were substantial: a 4x increase in production to 1,000 parts per hour, a 20% reduction in material usage, the elimination of all rework, and a significantly lower piece price, all while requiring only one operator instead of five.

Boehm Pressed Steel

Don Mikuluk

Designer & Tooling Engineer