Above: The Ursviken 2,000-ton press brake bump bends plate up to 4 in. thick and 28 in. wide
March, 2025- Weldall Manufacturing Inc. has built its revenue and its reputation on being a big-picture thinker. Plant Manager David Bahl Jr., the son of founder David Bahl Sr., agrees with the adage that “one should never underestimate small starts.” In 1973, Bahl Sr. borrowed $800, acquired a welding machine and rented a 500-sq.-ft . shop. Today, Weldall has three factories totaling more than 225,000 sq. ft . of manufacturing space and nearly 300 employees. The job shop thrives on tackling the metalworking industry’s most difficult jobs. It provides large-scale, turnkey solutions for a wide range of applications in industries that include automation, construction, mining, nuclear, rail, energy and power generation, and material handling.
Bahl Jr., who has been with the company for approximately 40 years, says Weldall’s story is a quintessential example of the American Dream. “Every day was a challenge,” he recalls. “But with good vendors and good employees we worked through it. A lot of the industries we serve are cyclical. We were either living high on the hog or down in the trough. We learned how to navigate that by becoming diversified in our capabilities, specifications, materials and certifications.”
Weldall has commissioned a new Ursviken Optima 700-ton press brake with a 21-ft. bed for more intricate bends from thinner material.
Ursviken’s Variable Die Tool is a CNCcontrolled tooling system that allows operators to make quick, precise adjustments to the die opening on the press brake.
Based near Milwaukee, the large weldment and fabrication manufacturer can engineer, blast, cut and machine turnkey solutions. Its specialty is medium to large weldments crafted by American Welding Society certified welders. The job shop is also known for its ability to perform large, complex forming for custom heavy-duty equipment fabrication projects.
CRAFTSMANSHIP
Weldall started with 100-ton mechanical press brakes. As its forming capabilities grew, so did its need for large tonnage bending capacity.
“You need skilled craftsmen to operate a large press brake for intricate fabrications,” says Maintenance Manager Justin Lyman. “Individuals that can perform the work and then teach others. We were looking for the same level of craftsmanship in a press brake OEM. We needed to replace our legacy equipment. We were struggling to get service and spare parts. We also noticed that technicians’ quality of service was dropping. They didn’t seem to have the same level of troubleshooting skill sets that we were used to.”
“We run high mix/low volume jobs,” added Bahl. “It’s onesy, twosy parts. So you need people who are good at math and reading print drawings. People who can combine that with the skills to build a part to specifications.”
In 2000, Weldall crossed paths with Ursviken Inc., which engineers, builds and delivers CNC press brakes, shears, hydraulic and straightening presses. “We bought an Ursviken 1,375-ton Pullmax press brake with a 30-ft . bed,” says Bahl. “Twenty-five years later that press is still running great. We operate it for two-plus shifts and we’ve experienced very little downtime. And that was handled quickly.”
Weldall uses the press brake to bump bend parts anywhere from 1 ft . to 30 ft . long from materials that range from high-strength and stainless steel to some aluminums in thicknesses from 12 gauge up to 2- in. thick. The machine supports jobs for power generation, rail, mining and construction equipment.
“In 2022, we happened upon a used 2,000- ton Ursviken press brake,” says Lyman. “We jumped on it to increase our forming capacity. We contracted with Ursviken to give the press brake a health check prior to the purchase. They also assisted us with the installation.”
The Ursviken 2,000-ton press brake bump bends plate up to 4 in. thick and 28 in. wide.
“We use the machine for heavy forming work for some of the same industries,” Lyman continues. “It runs one shift a day.”
SERVICE AND SUPPORT
Weldall’s experiences with the manufacturer’s press brake technology prompted the job shop to invest in a new Ursviken Optima 700-ton press brake with a 21-ft. bed. The machine is being built in Sweden at Ursviken’s main plant. Weldall will take delivery in July. “We had been contemplating replacing a legacy press brake for a couple of years,” Bahl says.
“We shopped around but didn’t have the same confidence in these OEMs that we had with Ursviken. This is where they really shine. Their service techs and spare parts availability stateside were two of the key reasons we chose them. It’s been a good run with them, and it is one we want to continue.”
The new press brake will have features Weldall finds especially attractive. The adjustable or variable die tool (VDT) is a CNC-controlled tooling system that allows for quick, precise adjustments to the die opening on the press brake.
“The adjustable die will save us time and enhance part quality,” says Bahl. “It also makes changing the bottom die safer for our operators. A laser-based system keeps personnel out of the bend zone.”
The Optima’s EcoPump will help Weldall reduce its energy use by up to 95 percent. Its tool magazine will hold Weldall’s tooling and punch tips, making it easier for operators to load tools. A smarter backgauge will allow the job shop to perform more intricate bends. The job shop plans to use the new press brake for thinner work 12 gauge up to 5/8-in. plate.
“A lot of off-the-shelf machines don’t fit us,” says Bahl. “Ursviken is engineering this press brake to fit our needs. The reason they got the order is because of the relationship we’ve built with them. Good service, evolving ideas and innovative upgrades. Our machines have to run to make money. That’s the bottom line. We have very demanding customers who expect parts when we promise them.”
Ursviken Inc., 847/214-8700, http://ursviken.com/
Weldall Manufacturing Inc., 262/544-1155, http://weldallmfg.com/
