Introduction: A Smarter Way to Build Metal Stairs
When demand soars, efficiency isn’t just nice to have—it’s essential. That’s the challenge StairSupplies faced as orders for their sleek, modern Viewrail metal stair systems surged. This Indiana manufacturer is known for high-end stair parts and minimalist floating stairs. They needed a better way to drill fast, accurate holes in metal. Traditional methods were too slow and labor-intensive to keep up.
That’s when they turned to Flowdrill technology—a friction drilling technology that doesn’t just punch holes, it redefines how they’re made. This change boosted speed, improved quality, and made assembly easier. This change didn’t just keep them afloat during rising demand—it helped them surge ahead.
In this blog, we’ll look at how the Stair industry uses Flowdrill machine. This helps them boost production, lower costs, and stay ahead in metal stair manufacturing.
1. The Pressure to Perform: StairSupplies’ Production Challenge
StairSupplies isn’t your average stair part maker. With over 230 employees spread across six production facilities in Indiana, they’re a major player in the custom stair game. Viewrail’s floating stairs are popular with architects, builders, and homeowners. They are known for their clean lines and open space design.
But with popularity comes pressure. As orders for their metal stair components soared, so did the need for faster, more precise production methods. Traditional drilling techniques couldn’t keep up. Each hole took time, required skilled hands, and left little room for error. That slowed things down, especially for complex steel stair stringers made from thick 7-gauge steel.
The production floor became a bottleneck. Meeting tight customer deadlines stretched teams thin. This raised labor costs and risked inconsistent quality. StairSupplies needed a better way to drill metal. They wanted a solution that could handle high volume but still maintain precision and performance.
2. A Friction-Based Breakthrough: Discovering Flowdrill
In 2018, StairSupplies made a pivotal move. They added Flowdrill technology to their production lines. This change will transform how they make metal stairs.
Unlike conventional drill bits that cut and remove material, Flowdrill uses friction drilling. The process involves a solid carbide tool spinning at high speeds to generate heat. That heat softens the metal just enough to push it aside, not chip it away. The result? A clean, raised collar blends seamlessly with the material. It’s perfect for creating strong, durable holes without needing extra hardware, such as weld nuts or rivets.
This approach was tailor-made for StairSupplies. It let them drill directly into thick steel tubing, aluminum, and stainless steel with incredible speed and accuracy. It cut down the number of parts and steps for assembly. This gave the production team a big boost in efficiency.
What started as a solution to a growing problem soon became a cornerstone of their manufacturing process.
3. The Benefits in Action: Flowdrill technology Impact on Production
Time is money.
Flowdrill technology reduced drilling time by over 50%. This speed helps StairSupplies fulfill more orders without needing extra shifts or machines. The team could skip traditional drill presses. This way, they move quickly through production and meet tight deadlines with ease.
Precision Perfected
Each friction-drilled hole came out clean and consistent, with no burrs or warping. The built-in collar made threading stronger and more secure. This is essential for structural parts like stair stringers and treads.
Material Mastery
Whether it was steel, aluminum, or stainless steel, Flowdrill handled it all. This flexibility helped the team simplify their workflows. They needed fewer specialized machines or setups.
Plug-and-Play Simplicity
Our Flowdrill machine was also easy to operate. New operators picked it up quickly, thanks to its intuitive design and consistent performance. That meant less time on training and more time on production.
Bolts Without Borders
Flowdrill technology made it easy by creating threaded holes right in the metal. This means no more weld nuts, rivets, or backing plates are needed. This not only simplified assembly but also reduced shipping complexity, since parts could be bolted together on-site without welding.
Lean and Clean
Fewer fasteners meant the company saved on materials and inventory costs. They also needed fewer machines, which helped open up factory floor space and lower maintenance overhead.
Each benefit led to faster, smarter, and more scalable production. This was just what StairSupplies needed to meet demand.
4. Viewrail’s Competitive Edge: Scaling with Confidence
The efficiency gains from Flowdrill technology have positioned StairSupplies to double production capacity—without doubling costs. By eliminating unnecessary fasteners, reducing training time, and cutting down on rework, the company created a lean, responsive manufacturing model that thrives under pressure.
This change is more than just numbers. It’s about staying competitive in a market focused on high design and high performance. With Flowdrill technology, Stair manufacturer has the agility to respond to demand, the flexibility to evolve, and the confidence to grow.
5. Collaboration for Success: The Stair manufacturer + DOBEMY flowdrill CNC Machine
Every great manufacturing upgrade relies on a strong partnership.
From the start, Dobemy didn’t just provide a machine tool—we provided tailored solutions and hands-on support. our team partnered with our customers to customize equipment setups. We also recommended best practices and solved any production issues that arose.
That kind of collaboration paid off. With training, technical support, and easy expert access. More than just a vendor, Dobemy will become a strategic ally, helping StairSupplies optimize performance.
6. At a Glance: Flowdrill technology’s Value to the Stair industry
Sometimes the big picture is best understood at a glance. Here’s a summary of how Flowdrill technology has elevated StairSupplies’ operations, from the production floor to the bottom line:
| Feature | Benefit for Stair Manufacturere |
|---|---|
| Friction drilling process | Faster hole creation with no pre-machining or cleanup |
| Strong threaded holes | Secure bolt connections—no nuts, welds, or backing plates needed |
| Material versatility | Works on steel, aluminum, stainless steel, and more |
| Reduced cycle time | Over 50% faster than traditional drilling |
| Cleaner, more precise holes | Higher quality finish, less rework |
| Easy operator training | Quick learning curve, even for new staff |
| Lower hardware costs | Thousands of fasteners replaced with direct-threaded holes |
| Smaller machine footprint | Fewer tools required, saving space and maintenance costs |
This simple switch in drilling technology helped the Stair industry unlock faster production, cleaner assembly, and more confident growth.
Conclusion: Engineering Efficiency for the Future
In the fast-moving world of custom stair manufacturing, precision, speed, and scalability aren’t just goals—they’re requirements. StairSupplies rose to meet those demands by embracing Flowdrill friction drilling, transforming their production process, and unlocking a smarter way to build.
By cutting drilling time in half, eliminating extra fasteners, and creating stronger, cleaner connections, Stair industry will operate with greater efficiency and confidence.
This isn’t just a story about holes—it’s a story about innovation, partnership, and the power of choosing the right tools at the right time. As demand continues to rise, one thing is clear: stair manufacturers is ready for the climb.
Looking to learn more about how Flowdrill technology can upgrade your manufacturing line? Explore our case studies or dive into the Flowdrill product overview to see what friction drilling can do for you.
