Defense-Grade Welded Assembly: Front Grill Guard System Built to Spec
Overview: A Defense-Grade Welded Assembly Built to Spec
When a defense supplier needed a complex front grill guard system produced quickly, Leonhardt Manufacturing delivered. The project involved a large scale, multi process assembly requiring tight tolerances, structural integrity, and a high quality finish — completed just five days after print release.
By combining value added Engineering for Manufacturing, superior customer service, and fully integrated in house capabilities, Leonhardt produced a structurally sound, visually consistent, and dimensionally precise welded assembly under an aggressive timeline.
The Challenge
- Rapid turnaround — less than one week from print release.
- Precision fabrication across multiple disciplines: tube, sheet, weld, and finish.
- Dimensional control on a 96″ × 27.5″ × 19.25″ structure weighing 185 lbs.
- Polished, defense grade finish suitable for integration into a larger vehicle system.
Additionally, the design called for engineering collaboration to refine the part for manufacturability and ensure consistent fitment during final assembly.
Our Approach
Customer Collaboration and Team Coordination
Leonhardt’s culture of responsiveness and teamwork was key to the project’s success. Our team maintained open,
frequent communication with the customer from the first CAD review through shipment, keeping quality high and the
schedule on track.
Engineering for Manufacturing (Design Refinement)
Early CAD reviews identified opportunities to improve manufacturability—adjusting bend radii and tab locations.
These refinements simplified fabrication and reduced rework.
Product Improvement & Advanced Quality Planning (AQP)
Early quality planning ensured accuracy at every phase. Critical-to-quality checkpoints verified tube-to-sheet alignment and key dimensions with full traceability, minimizing variation and confirming each assembly met
specifications.
Integrated In-House Manufacturing
Precision Tube Bending & Fabrication
Using advanced CNC tube bending equipment, Leonhardt formed the main tubular frame components with exceptional
precision. Tight radius control ensured every bend aligned with CAD specifications and weld fixtures.
Laser Cutting for Sheet Components
Sheet components were laser cut in house, enabling immediate adjustments to mounting plates and brackets when
needed. Keeping these processes under one roof gave Leonhardt complete control over schedule and quality.
Certified Welding & Cosmetic Finishing
Certified welders assembled the structure with precision, integrating all tube and sheet components seamlessly.
After welding, each assembly was inspected, then polished to achieve a uniform, high-end cosmetic finish.
The Result
Quality, Schedule, and Integration Outcomes
- Completed in 5 days, including full engineering review and production.
- All fabrication performed in house for consistent quality and schedule control.
- Maintained dimensional accuracy across the large scale 96” × 27.5” × 19.25” assembly.
- Achieved seamless alignment between engineering, production, and finishing teams for a production ready component.
Why It Matters: Reliability for Critical Applications
This project demonstrates Leonhardt’s ability to combine speed and precision without compromising engineering discipline.
Our Engineering for Manufacturing approach bridges the gap between concept and production, allowing customers to meet demanding schedules while improving manufacturability, consistency, and long term part performance.
From CAD review to polished assembly, Leonhardt’s integrated capabilities make complex parts possible and tight deadlines achievable.
Key Takeaways
- Customer Focus: Clear communication and responsive service accelerate timelines and eliminate errors.
- Integrated Engineering and Fabrication: Early design collaboration reduces costly changes later in production.
- Quality Planning: AQP checkpoints ensure consistent, dimensionally accurate results.
- In House Control: Tube bending, welding, and finishing all under one roof streamline production.
- Team Coordination: Sales, Customer Service, Engineering, Manufacturing, and Finishing teams worked together to achieve a five day delivery.
Work With a Proven Defense Manufacturing Partner
At Leonhardt Manufacturing, every project is an opportunity to prove what responsiveness, craftsmanship, and engineering discipline can achieve under pressure. From initial CAD review to finished assembly, our team delivers precision, consistency, and confidence — even when timelines are tight and tolerances are tighter.
If you’re ready to partner with a responsive, precision-focused manufacturer who treats your project like it’s their own, let’s start the conversation.
FAQ
What makes a welded assembly “defense-grade”?
Code-compliant welding procedures, certified welders, documented AQP/CTQ checkpoints, and cosmetic finishing that meets specified appearance requirements for visible components.
Can Leonhardt support both structural and cosmetic requirements?
Yes—our teams handle structural integrity (WPS/PQR/WPQ) and visual finishing (grinding, blending, polishing) under one roof to meet dual performance and appearance specs.
How does Engineering for Manufacturing reduce risk?
Early design refinement (bend radii, tab/slot placement, fixture strategy) lowers rework, stabilizes throughput, and improves dimensional repeatability during production.
Do you manage documentation for audits?
We maintain traceable inspection records, CTQ checkpoints, and process documentation suitable for supplier audits and PPAP/AQP reviews.