Case Studies


This is Racine’s coastline November 2019 which Racine is not known for. However, as for E. C. Styberg Engineering, We are now on a third generation of management and 5th generation of employees to design/produce products made from Steel and Stainless-Steel materials. Why think of Styberg? We have been in business for over 93 years. Seeing and producing many different designs and creations through our punch presses, CNC lathes & vertical machining, Surface grinding, Welding, Spotwelding, Wire EDM, Laser cutting, Laser Welding, 3D printing and more. Our history has shown that every 5 to 10 years we add a process and/or a new product line to increase our capabilities, and 2020 is no different. With a brand-new Wire EDM we can make our own special tooling, fixtures and gauges, prototypes for a wide range of new customers.

Just imagine as a Purchasing Agent, you need something new or in a hurry, why not try Styberg. We can do all processes in-house. No chasing around. We try and make it easy on the Purchasing group. Production volumes can range from 1000 to 500,000 annually.

As for qualifications, Styberg is certified to the ISO-9000, IATF-16949, and NADCAP. Our product lines range from High-Performance automobiles, Marine, Heavy duty transmissions, Mining, Aerospace components, etc.

Our goal is to continue in business for another 93 years, so give us a try. This will help us keep Mr. Styberg’s traditions alive in celebration of his October birthday.

What Styberg Engineering Can Do for You

Styberg recently received a telephone call asking if we knew how to connect an engine to an automatic transmission. We said yes, and through several additional conversations, Styberg was able to determine what the customer really needed. After several design modifications, our new customer agreed to proceed. Within months we supplied sample mockups, and now after two years, Styberg is in full production. You may be thinking this was a simple, one-piece component. Ultimately, this became a full assembly with a hub, formed flexplate, timing ring, and ring gear, all welded together and balanced. What Styberg did:

1. Listened to the customer.

2. Designed each component as we saw what was needed to work.

3. Reviewed design opportunities after our customer had questions.

4. Redesigned all areas that were potential issues (clearances, strengths, etc.).

5. Put the whole assembly together to make sure all of the pieces fit correctly.

6. Made prototypes at each stage of the process.

7. Toleranced the drawing for the customer.

8. Agreed to a final assembly design.

9. Made production tooling in-house.

10. Made first run samples.

11. Now producing production parts.

This was all done as a service to our customer and could be your organization’s next project that needs completion!

Change of Materials and Processes

Styberg was approached by one of its customers inquiring how they can make a family of parts less expensive. We visited the customer and reviewed what they were doing with several components in that specific line of products. After some investigation into the materials and processing, Styberg suggested using a high-carbon, hard-rolled material in place of a heat-treated material. Styberg then developed a process to spot-weld components of different carbon ranges with compounding thickness differences to meet and exceed all customer requirements. Styberg has now supplied more than 5,000,000 pieces without a rejection. This satisfying solution emphasizes our commitment to quality and service. We were informed that, after the first year, the customer saved $1,000,000.

Complex Design & Strength Improvement

Styberg has a wide range of process equipment, resulting in design processes that can form, blank, machine or weld difficult shapes with fewer production operations. A heavy-duty mounting bracket with a three-piece welded design needed greater strength in critical areas. Redesigning to a one-piece construction from coil steel resulted in fewer manufacturing operations and increased the strength of a single-piece component.

Mechanical Components

An existing tank wheel needed lighter weight but a higher tensile strength. The life of the wheel depended on the mechanical design and mechanical strength. Tapping on engineering expertise and tooling knowledge of ferrous and some non-ferrous materials, a design was developed using a formed material in different patterns allowing for the use of thinner materials (reducing weight by 10 pounds) and increasing the tensile strength by 100%.

Weight Reduction

Styberg redesigned a cast-splined part to reduce weight and production costs while maintaining all the spline dimensions. The part was produced from coil stock and, utilizing the “Grob” process, we reduced the weight from a 32-lb splined casting to a processed piece weighing 12 lbs while retaining all the spline dimensions, resulting in a lighter product with lower production costs.

Wire EDM

With the COVID situation a small business can either sit back and wait it out, or push forward. Styberg Engineering has decided to forge ahead. We have had to adjust our hours to match sales, but we continue to look for advancements in Machinery that will help Styberg and all employees. Our latest purchase is a state-of-art Wire EDM machine. It is large enough to do most everything we have. It allows Styberg to make prototype in half the time, and all of our own tooling in-house again faster. We are finding new ways to use this machine to help Styberg’ s bottom line.