EOM | D&S Manufacturing

Heavy Plate Fabrication

Over 50 Years of Metal Fabrication

Black River Falls, Wisconsin · 150,000 sq ft · Steel 5/8" thick and larger

D&S Manufacturing is an ISO 9001:2015 certified manufacturer of medium to large scale components, assemblies, and complete weldments — and a cornerstone of the Employee Owned Manufacturing portfolio. Founded in 1965 when James Dougherty purchased a local welding and repair shop, D&S has grown into a premier provider of custom metal fabrication for industrial OEMs across agriculture, construction, railroad, military, and specialty markets.

Everything happens under one roof: cutting, forming, machining, welding, finishing, and turnkey assembly. That single-source model removes handoffs between vendors, compresses lead times, and puts one quality system behind the entire part — from raw plate to a painted, assembled unit shipped direct to your customer.

In 2021 D&S became 100% employee owned. Today 135 employee owners run three shifts across 150,000 square feet, with an average of more than 13 years of service on the floor.

Fabrication equipment set up for a production run at D&S Manufacturing in Black River Falls, Wisconsin

1965 Fabricating Since

Machined steel weldment on a pallet at D&S Manufacturing

1965 Founded

100% Employee Owned

135 Employee Owners

150,000 Sq Ft of Plant

3 Production Shifts

13+ yrs Average Tenure

WHAT WE DO

Capabilities Under One Roof

Six in-house disciplines take a job from raw plate to finished, painted, assembled product — without leaving the building.

Cutting

High-definition plasma, fiber laser, and oxy-fuel cutting of aluminum, carbon steel, and stainless steel from 16 gauge through 6″ thick.

Two Messer MG Titan II machines sharing one rail
Four ALFA oxy-fuel torches and one HyPerformance HPR260 plasma per machine
12′ × 80′ self-cleaning downdraft cutting table
BySprint Pro 4020 6,000W fiber laser — plate up to 3/4″
Cincinnati CL-850 5,000W laser — dual 80″ × 160″ pallets

Large CNC press brake set up to form a steel plate part at D&S Manufacturing

Forming & Rolling

Press-brake forming to 485 tons and plate rolling to 10′ wide, with formed lengths up to 16′ on a single hit.

AccurPress 485-ton, 6-axis, 14′ bed
Pacific Hydraulic 400-ton, 16′ bed, automatic back-gauge
Strippit/LVD 350-ton, 10′ bed
Roundo PS255 plate bending roll — 10′ × 0.50″
Carell 308 HV4 angle roll for structural profiles

CNC Machining

Bridge milling, vertical and horizontal machining centers, and CNC turning — machining finished weldments as large as 20,000 lbs.

Okuma MCR-A5CII bridge mill — 200″ × 100″ table, 70″ work height
35 HP spindle with 5-side machining and coolant through spindle
Toyoda FH1250SX, FA800, FH630SX, FH450S and Okuma MB-500H horizontals
Seven HAAS vertical centers (VF6, VF5, VF2) with 4th-axis positioners
HAAS ST-40T live tooling and DMG MORI CTX 800 turning

Welding

Manual and robotic welding in mild steel, stainless steel, and aluminum, with a full-time AWS Certified Welding Inspector on staff.

GMAW, GMAW-P (pulse), FCAW, GTAW/TIG, soldering and brazing
Two ABB IRB 2600 six-axis robots welding in coordination on one part
Part touch sensing and seam tracking for repeatable penetration
ABB 5000K Sky Hook — 11,000 lb capacity, pre-heat and temperature sensing
Weld positioners to 20,000 lbs; non-destructive testing on all welds

Finishing

Shot blasting, powder coat, and liquid spray paint with inline wash and iron phosphatizing — parts leave ready to install.

Batch booth — 14′ × 14′ × 25′ wet paint, 14′ × 14′ × 20′ powder coat
Powder bake oven, 180°–450°F; wet paint bake to 200°F
Powered conveyor line — 144′ track, 1,100 hooks at 300 lbs each
Six-stage power spray wash with iron phosphatizing
Pangborn ES-2050 belt blaster plus Bronco spinner and tumble blasters

Employee-owner assembling a fabricated component at the bench at D&S Manufacturing

Assembly

Turnkey mechanical, hydraulic, and electrical assembly — complete units shipped direct to your final customer.

Mechanical assembly of castings, forgings, and machined components
Hydraulic assembly — cylinders, pumps, motors, and valves
Electrical assembly — wiring, motors, drives, and controls
Complex weldments built from 200+ individual parts
Turnkey programs with direct-to-customer shipment

ON THE FLOOR