From 2 Million Cycles to the Next Generation
Quick Summary: Back in 2018, Chapter 2 built a custom power bar press that’s still running strong today—logging more than two million cycles and proving the reliability of our design and build process. What started as a one-off solution turned into a long-term success, and now that same customer has come back for a next-generation machine with even more automation and efficiency. It’s a great example of how our team’s hands-on approach, from concept through build, delivers real value and lasting performance in the toughest production environments.
In 2018, the Chapter 2 team designed and built a custom power bar press machine for a customer—a complex, large-scale project that demanded tight collaboration, creative problem-solving, and robust engineering. Today, that same machine has logged more than 2 million cycles, continuing to run reliably on the customer’s floor and serving as a real-world proof point of our build quality and long-term support.
A 2018 Project That’s Still Delivering
The original power bar press was conceived as a one-off solution to a specific production challenge. It required us to combine precision machining, custom fabrication, and smart controls into a single, integrated system tailored to the customer’s workflow. From the first concept discussions to final run-off, our engineers and technicians worked closely with the customer.
Surpassing 2 million cycles without major interruption is not just a milestone—it is a direct reflection of how we approach custom equipment: design it to run, day in and day out, in real production environments.
When we build a custom machine, reliability is engineered in from the start. Our in-house capabilities allow us to control critical details that often make the difference between an average machine and a long-lived asset. Our customer was thrilled to finally have a solution, after several failed attempts with other machine builders.
From Proven Performance to Next-Gen Automation
The real success story is what happened next. After years of dependable operation, the same customer came back—this time asking us to design an additional machine, with increased automation and enhanced productivity. That kind of repeat engagement is one of the best indicators that a custom solution has delivered real value in their daily operations.
The new machine concept builds on what worked in 2018 while incorporating today’s automation and integration expectations. Our goal is to evolve the original success into a more capable, more automated system that further reduces manual intervention, increases throughput, and strengthens the customer’s competitive position.
Celebrating the Team Behind the Machine
Behind every long-running machine are the people who designed, built, assembled, wired, programmed, and supported it. This power bar press represents the efforts of our engineers, machinists, fabricators, assemblers, and technicians—each contributing specialized expertise to create a durable, high-performing system.
As we embark on the next-generation version of this project, we’re also taking time to recognize the team members who made the first machine such a success and who continue to push our custom machine solutions forward.
Custom Machine Building at Chapter 2
The power bar press is one example of how we approach custom machine building: start with the application, then engineer the most effective combination of mechanical design, automation, and manufacturability. As an “inside outsource” partner, Chapter 2 supports customers who need off-catalog solutions—machines that don’t exist in a brochure but are critical to their operations.
Our custom machine and automation capabilities include:
- Custom machine design and build services, from clean-sheet concepts to retrofits.
- Custom robot cells, HMI systems, and end-of-arm tooling.
- Custom inspection and testing systems, vision-based and sensor-driven.
- Equipment customization and retrofitting to modernize existing assets.
- Full-service engineering support.
By combining these with in-house CNC machining, welding, assembly, painting, and quality assurance, we deliver turnkey solutions that move from idea to implementation under a single, accountable partner.
Ready to Explore Your Own Custom Solution?
If you have an application that doesn’t fit neatly into a catalog machine, or you’re looking to automate a challenging process, Chapter 2 can help you define, design, and build the right solution. From standalone machines like the power bar press to fully integrated automation cells, our team is ready to collaborate from initial concept through installation and support.
Contact us today to review your industrial automation and custom machine building needs!