Where Wire Forming, Casting, and Cold Heading Converge
The Federal Group USA partnered with JanFan to manufacture a heavy-duty industrial fan for demanding commercial and industrial environments. While the fan’s original design was provided by the client, TFG was responsible for executing the manufacturing strategy required to consistently produce a durable, compliant, and visually distinctive product at scale.
Leveraging multiple specialized manufacturing processes under a single supply chain, TFG transformed the client’s design into a fully realized production program—ensuring repeatability, structural integrity, and long-term performance in harsh operating conditions.
Challenges
The primary challenge was integrating wire forming, metal fabrication, cold heading, die casting, finishing, assembly, and motor integration into a cohesive manufacturing program without sacrificing quality or consistency.
Other challenges included:
- Manufacturing a rugged fan assembly capable of withstanding vibration, impact, and continuous use in industrial environments.
- Modernizing legacy electric motor technology that relied on high copper content and low-capacity capacitors, resulting in lower efficiency, higher material costs, and reliability concerns.
- Ensuring the finished fan met all safety and compliance requirements, including UL listings for both the fan and power cord.
- Maintaining a consistent branded appearance across all production runs.
Our Analysis
TFG’s manufacturing team focused heavily on material selection, manufacturability, and long-term durability to ensure the fan would perform reliably throughout its service life.
During the analysis phase, TFG identified that many components of the 50-year old fan design had historically been produced using outdated manufacturing methods that were no longer efficient or well suited for modern production volumes. These legacy processes limited consistency, increased material usage, and made it difficult to maintain repeatable quality as demand scaled. Our team evaluated each component to determine where modern forming, stamping, fastening, and finishing processes could improve durability while streamlining production.
TFG also identified an opportunity to improve the fan’s electric motor, which was based on older technology developed when material and component costs were very different. Working with a specialty motor manufacturer, TFG helped update the motor design to improve efficiency, reduce unnecessary material usage, and enhance long-term reliability—while maintaining the performance characteristics required for industrial operation.
Our Solution
TFG implemented a comprehensive, multi-process manufacturing solution using the following core capabilities:
Wire Forming for the Blade Guard
As a full-service wire forming company, TFG produced a protective blade guard that delivered consistent spacing, structural strength, and user safety while meeting compliance requirements.
Metal Fabrication & Tube Bending for the Base
The fan’s base and frame were produced using metal fabrication, tube bending, and stamping processes to create a rigid structure designed to absorb vibration and resist deformation in industrial environments. Tubes were precision-pierced to accommodate custom fasteners and assembly hardware.
Cold Heading for Custom Fasteners
TFG manufactured custom fasteners via cold heading services to secure the blade assembly to the base and enable controlled directional adjustment. Custom rivets were also produced to attach the blades to the hub assembly. As a custom fastener manufacturer, TFG delivered high-strength fasteners with excellent thread integrity and repeatable performance.
Stamping of Fan Blades
The spring steel fan blades were produced using precision metal stamping processes. As a full-service metal stamping company, TFG achieved tight tolerances, consistent blade geometry, and balanced rotation across production volumes.
Die Casting of Hub / Impeller
The hub/impeller assembly was produced using TFG’s die casting services, allowing for precise geometry, structural strength, and reliable connection between the motor shaft and stamped steel blades.
Custom Powder Coating
The base and wire guard components were finished with a custom yellow powder coat in JanFan’s proprietary Pantone color, providing corrosion resistance, impact durability, and brand consistency. Fan blades were finished with a black powder coat for added protection and visual contrast.
Electric Motor Modernization
TFG partnered with a specialty motor manufacturer to update the fan’s electric motor, replacing legacy designs that relied on excessive copper and lower-capacity capacitors. By optimizing the winding configuration and increasing the capacitor microfarad rating, the updated motor improved efficiency, reduced heat buildup, and enhanced long-term reliability while maintaining UL compliance and required performance.
Final Assembly
TFG assembled the complete fan, integrating the modernized electric motor, structural components, blade assembly, hub, and protective guard into a fully functional unit.
Compliance & Certification
TFG coordinated and supplied UL-registered components for both the fan and power cord, enabling the client to obtain full regulatory compliance. Additionally, TFG produced and supplied a safety cable kit made from galvanized aircraft cable, ensuring secure installation in warehouse and industrial environments in the event of mounting failure.
The Outcome
The finished industrial fan delivered exceptional performance, durability, and consistency in real-world industrial environments.
The combination of stamped steel blades, die-cast hub components, and cold-headed custom fasteners resulted in a mechanically robust system capable of continuous operation with minimal maintenance. Precision wire forming and tube-bent structural components ensured dimensional accuracy and long-term stability, while custom powder coating provided lasting protection against corrosion and wear.
By consolidating wire forming, metal stamping, die casting, custom fastener manufacturing, finishing, motor modernization, and assembly into a single coordinated manufacturing program, TFG helped JanFan achieve reliable production, improved efficiency, reduced material cost, and a market-ready product that meets both performance and compliance requirements.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
