Many of today’s leading companies have well-established origins. However, there are others that share the story of a humble beginning and defying all odds to succeed. No company embodies this better than MERRILL, a strong U.S. business with nearly 700,000-square-feet of facility and expertise to design and manufacture intricate prototypes through high-volume production.
MERRILL’s journey began in 1968 when its founders— Gary and Mary Kay Yackel—opened a small machining shop in a 3,000-square-foot facility. Here, they began machining parts with limited resources - a small lathe, a grinder, and a Bridgeport mill, dedicating themselves to building products that meet customer requirements. This passion, combined with their aspiration to stand out in the marketplace, led them to embrace new technologies, add more capabilities, and enhance service excellence at every turn.
The first example of MERRILL’s appetite for innovation was when it expanded its machining capabilities with specialized fabrications, engineering and design capabilities. Since then, technological upswings and process improvements have been routine for the team. MERRILL has continued to expand its high-end large 5-axis capabilities and has remained at the forefront of innovation for the last five decades, staying relevant and competitive at all times. It’s no wonder it has gained a sterling reputation in CNC machining, specializing in designing, fabricating, and integrating every operation imaginable.
“Technological advancement is one of the key aspects that remain constant at MERRILL facilities,” says Jeff Yackel, owner and VP of MERRILL. “We always wanted to separate ourselves from our competition with technology and equipment size.”
The next-generation leadership team at MERRILL follows the same passion and builds on the same foundation of constant innovation. Under new leadership, MERRILL is an agile machining specialist that employs over 400 people in five state-of-the-art facilities equipped with the latest technologies and vertically integrated manufacturing capabilities. With inhouse expertise in designing and manufacturing intricate parts through high-volume production, it delivers the highest quality products.
MERRILL caters to a broad spectrum of industries, including aerospace, defense, robotics, shipbuilding, chemical, transportation, mining and energy, with its clients comprising top defense and aerospace manufacturing OEMs like Lockheed Martin, Raytheon Technologies, Northrop Grumman, Sikorsky Aircraft, General Dynamics, Boeing and Blue Origin. The team lives by the philosophy of “anything is possible,” as it can create all parts, irrespective of size, complexity, and application, according to client needs, by effectively managing the process from concept to delivery.
Built on the Bedrock of Constant Innovation
MERRILL’s story highlights the importance of timely investing in advanced technologies to align with industry trends. The leadership team, with extensive manufacturing experience and numerous collaborative customer relationships, is known for crafting innovation and investment plans that stand the test of time. Its investments focus on the four major pillars of its business: equipment, processes, systems, and people, giving MERRILL a natural edge as the go-to machining shop for defense and aerospace projects.
“We’ve invested over $30 million on equipment since the end of 2022, and most of that investment is in high-end, high-speed, 5-Axis CNC machines, which are the largest in the industry,” says Steve Ross, Director of Strategic Programs at MERRILL.
A strategic partnership with one particular equipment manufacturer has made these investments a reality, ensuring the best price, process optimization, training, and regular maintenance. MERRILL has established a solid relationship with FPT Industries S.P.A., an Italian Machine Tool Builder by equipping its facilities with multiple large FPT machines like the Raptocut, Castel, Dinomax, Ronan and Dinowide. This strategic investment has enhanced Merrill’s CNC machining capabilities with higher uptime and efficiency. In addition, Merrill is skilled at investing in equipment that meets defense industry standards and delivers on project requirements with tight tolerances and precision. For instance, MERRILL has procured FPT’s high performance Raptocut milling machine – a large bed machine that enables high volume machining of large radar arrays, while its facility houses other specialized FPT equipment, like the Dinowide, ideal for processing hulls and turrets of armored vehicles.
MERRILL’s equipment investments also focus on various space applications, particularly launch systems and rocket components. Its large 2,000 ton and 4,400 ton presses are used to form Inconel rocket components. Formed sections are welded using an electron-beam welding (EBW) machine purchased specifically for a particular client. The formed and welded components are roughed and final machined using high precision, high speed, 5-axis FPT machining centers. In one instance, the team helped a helicopter manufacturer that wanted to forge large titanium rotors, which was initially considered cost prohibitive.
