The April 2025 issue of Production Machining highlights the technological and generational evolution of Air-Way Manufacturing, the largest independent hydraulic fitting manufacturer in the United States. Below is a summary of the main points, with a focus on the company’s technological transition and the role of Buffoli machines in this transformation.

Company Background
Founded in 1950, Air-Way Manufacturing operates four U.S. plants: two in Olivet, Michigan, one in Hamilton, Indiana, and one in Edgerton, Ohio. The company is family-owned and managed, with John Hamm approaching retirement and his sons, RJ and Kyle, preparing to carry on the legacy. Innovation has always been at the heart of Air-Way Manufacturing’s approach, and over the years, the company has embraced advanced technologies to enhance its manufacturing capabilities and meet the evolving demands of the market.

The turning point with Buffoli
One of the most significant changes in recent years has been the gradual replacement of cam-driven automatic lathes with more flexible and efficient CNC machines.
In February 2023, Air-Way Manufacturing  installed its first Buffoli CNC transfer machine at the Hamilton plant—an advanced horizontal model with a trunnion axis, bar-fed. The machine was engineered for high-volume output (with an average cycle time of 6.5 seconds per part), while maintaining the versatility to efficiently run smaller batches—an essential aspect of Air-Way Manufacturing’s business strategy. It currently runs 50 different part numbers with minimum batch sizes of 5,000 pieces, thanks to features such as:

• Tool presetting with a Zoller Smile 420 unit
• Automated parts collection into multiple baskets
• Custom spindles and quick-change tooling designed in-house (including FANUC wire EDM capabilities)
• Use of standard tools and Genesee hollow mills for varying diameters

To adapt the machine to Air-Way Manufacturing’s specific needs, Buffoli:

• Customized the standard machine footprint to reduce space requirements
• Developed a tailor-made parts collection system to optimize productivity without adding strain on operators
• Provided on-site support for several months, working closely with Plant Manager Alex Garrett

Second Buffoli Machine (2025)
In 2025, Air-Way Manufacturing is scheduled to install a second Buffoli machine to complement the existing one. Among the notable innovations:

• A longer recess head to accommodate fittings with large dimensional jumps
• A dedicated oil mist extraction system, integrated directly into the machine

John Hamm emphasizes how rotating long bars often results in vibration, inaccuracy, and extended setup times. The Buffoli solution, by machining from slugs rather than long bars, overcomes these issues—ensuring more stable, accurate, and predictable performance.

Strategic Vision
The adoption of CNC technology is not just about efficiency; it’s a strategic move to support generational transition and foster a modern, appealing work environment for younger talent. Digitizing production processes reduces reliance on highly specialized cam lathe operators and makes the shop floor more accessible to the next generation—facilitating a smoother transition and securing long-term competitiveness.

Read the full article in the April 2025 issue of Production Machining or download the pdf.