How Astro Shapes Uses Kenwood DMR Two-Way Radios to Run a High-Output Aluminum Extrusion Facility
By Ion, Inc - www.twowayradio.com - Bruce F. , Two Way Radio Expert
Published: March 30, 2026
How Astro Shapes Keeps a High-Output Aluminum Extrusion Facility Running with Kenwood DMR Two-Way Radios
Industry: Aluminum Extrusion Manufacturing: Struthers, Ohio
Solution: Kenwood NX-1300DUBK DMR Two-Way Radios with Voiceporter Speaker Microphones and Multi-Unit Chargers
Kenwood NX-1300DUK5 Two-Way Radio - 5W, 256C, Analog/DMR, LCD, UHF(400-470MHz) - K01
Voiceporter VPA-CHR6KEN1 Multi-Unit Charger - 6-Pocket - Fits NX-1200, NX-1300, KNB-45L
Voiceporter VPS850-K01 Speaker Microphone - LOUD, Heavy Duty, Kevlar, IP68, USA Brand - Kenwood K01
At a Glance
Customer:
Astro Shapes LLC, a full-service aluminum extrusion manufacturer headquartered in Struthers, Ohio.
Challenge:
Coordinating real-time communication across a busy production floor, finishing lines, fabrication areas, and receiving dock without dropped calls, dead zones, or analog interference.
Solution:
44 Kenwood NX-1300DUBK 5 -watt UHF Digital Mobile Radio (DMR) units paired with 44 Voiceporter VPS600WL-K01 IP67-rated speaker microphones and 6 six-pocket multi-unit charging stations.
Result:
Seamless, floor-wide digital voice communication that supports faster coordination between extrusion, finishing, thermal barrier, fabrication, packaging, and operations management teams.
About Astro Shapes
Astro Shapes LLC is a leading aluminum extrusion partner serving customers across multiple industries from its facility at 65 Main Street in Struthers, Ohio. Holding ISO certification and offering an end-to-end suite of value-added services, Astro Shapes handles everything from computerized extrusion pressing and liquid paint finishing to thermal barrier assembly, precision fabrication, and customized packaging.
The company's reputation is built on two pillars: extrusion excellence and on-time delivery performance. Achieving both demands tight, real-time coordination among skilled personnel spread across a large, noisy manufacturing environment. When seconds count on a press run or a finishing line changeover, crystal-clear communication is not optional.
The Communication Challenge in Aluminum Extrusion
Aluminum extrusion facilities present some of the most demanding communication environments in manufacturing. High-decibel press operations, paint booth ventilation, quench tanks, die ovens, and busy packaging lines create constant background noise. Traditional analog radios struggle in these settings: audio quality degrades, signals bleed across channels, and handheld units worn in industrial environments routinely face moisture, dust, and physical impact.
For Astro Shapes, the stakes are especially high. The company's Total Quality Assurance Program and commitment to guaranteed delivery capacity require that supervisors, press operators, quality technicians, and logistics staff stay in constant contact. A missed call during a die change or a misunderstood instruction on the finishing line can mean scrap material, delays, or safety incidents.
The facility needed a communication upgrade that would deliver:
Digital audio clarity across every square foot of the production floor
Durable hardware capable of surviving daily industrial wear
Weatherproof accessories for use near quench systems and wash stations
Scalable charging infrastructure that keeps a large fleet of radios ready for every shift
The Solution: Kenwood NX-1300DUBK DMR Radio System
Primary Radio: Kenwood NX-1300DUBK
Astro Shapes deployed 44 units of the Kenwood NX-1300DUBK, a professional-grade 5-watt UHF digital two-way radio covering the 450-520 MHz frequency band. Operating in Digital Mobile Radio (DMR) mode, the NX-1300DUBK delivers a significant upgrade over legacy analog systems in three critical dimensions: audio intelligibility, spectrum efficiency, and battery life.
DMR digital technology converts voice into a compressed digital signal before transmission, which means background noise from presses, saws, and conveyors does not modulate onto the audio channel the way it does with analog FM. Workers on a loud extrusion press floor hear their colleagues with the same clarity as if they were standing in a quiet office. The radio supports 16 channels, providing enough channel separation to assign dedicated talk groups to each department: extrusion, finishing, thermal barrier, fabrication, packaging, and operations management.
Accessories: Voiceporter VPS600WL-K01 Speaker Microphone
Every radio in the Astro Shapes fleet is paired with a Voiceporter VPS600WL-K01 speaker microphone. This IP67-rated accessory is fully sealed against dust ingress and immersion in water up to one meter, making it ideal for use near the facility’s quench tanks, wash stations, and outdoor receiving areas. The Kevlar-reinforced cable resists the abrasion and flexing that quickly destroys standard coiled cords in industrial environments.
The extra-long cord allows the speaker mic to be clipped to a shoulder or chest strap while the radio stays secured in a hip holster, keeping both hands free for operating equipment. The 3.5mm audio jack provides a standard connection that works reliably even after repeated exposure to metallic dust and grime.
Charging Infrastructure: Voiceporter
Voiceporter VPA-CHR6KEN1 Multi-Unit Charger - 6-Pocket - Fits NX-1200, NX-1300, KNB-45L
Multi-Unit Chargers
Six Voiceporter VPA-CHR6KEN1 six-pocket multi-unit chargers are staged throughout the facility to ensure no radio ever goes into service with a depleted battery. Each charger accommodates up to six NX-1300 or KNB-45L battery units simultaneously, meaning a single charging station can restore an entire shift’s worth of radios overnight. Centralizing charging in break rooms and near supervisor stations also creates a natural accountability point, ensuring radios are returned at end-of-shift and ready for the incoming crew.
How Two-Way Radios Support Astro Shapes’ Operations
Extrusion Press Coordination
The heart of Astro Shapes’ operation is its fleet of computerized extrusion presses capable of producing intricate aluminum profiles for diverse markets. Press operators, die technicians, and shift supervisors use the Kenwood DMR radios to coordinate die changes, billet loading schedules, and run completions in real time. The digital audio quality allows clear communication over the noise of hydraulic presses without shouting or repeating instructions.
Finishing Line Quality Control
Astro Shapes’ liquid paint finishing operation demands strict quality control at every step from pre-treatment through top coat. Quality inspectors and finishing line leads use the radios to flag color deviations, mask changes, or equipment stoppages the moment they are detected, keeping rework to a minimum and throughput high.
Thermal Barrier and Fabrication
Thermal barrier assembly and precision fabrication require close coordination between engineers and production staff. The ability to reach a design engineer or fabrication lead instantly via radio compresses the feedback loop on custom orders and helps Astro Shapes deliver the design-to-delivery partnership it promises every customer.
Receiving and Shipping
The receiving dock at 65 Main Street handles inbound aluminum billet deliveries and outbound finished profile shipments simultaneously. Dock supervisors use radios to coordinate forklift movements, communicate with warehouse staff, and confirm outbound order readiness with operations management, all while keeping their hands free for physical tasks.
Safety and Emergency Response
In any manufacturing environment, the ability to communicate instantly during a safety incident is critical. The Kenwood NX-1300DUBK’s digital platform supports emergency call features that allow any worker to immediately alert supervisors. The IP67-rated speaker microphones ensure the accessories remain functional even if a radio is exposed to water during an emergency response.
Results and Business Impact
Since deploying the Kenwood NX-1300DUBK radio system, Astro Shapes has strengthened the real-time communication backbone that underpins its Total Quality Assurance Program and on-time delivery guarantee. Key outcomes include:
Improved coordination across six distinct service departments without the channel interference and audio degradation associated with legacy analog radios
Reduced verbal miscommunication on high-noise press and finishing lines, supporting lower scrap rates and faster changeovers
Hands-free operation enabled by IP67-rated speaker microphones, keeping workers safer and more productive
Simplified fleet management with centralized six-pocket charging stations that ensure every radio enters service at full capacity
Scalable infrastructure that can accommodate headcount growth and facility expansion without significant reinvestment
Why Astro Shapes Chose Ion, Inc. – TwoWayRadio.com
Astro Shapes sourced its radio system through Ion, Inc. operating as TwoWayRadio.com, a Stillwater, Minnesota-based communications equipment specialist. TwoWayRadio.com provided a complete, pre-configured solution that matched the specific demands of an aluminum extrusion environment: UHF frequencies for penetration through metal structures, DMR digital protocol for noise-immune audio, and IP-rated accessories for wet and dusty conditions.
The order was fulfilled on NET30 terms under Sales Order 300014387, covering 44 radios, 44 speaker microphones, 6 multi-unit chargers, and ground shipping, representing a complete, deployment-ready communication system delivered to the Astro Shapes receiving dock in a single transaction.
Conclusion
Astro Shapes LLC operates in one of manufacturing’s most demanding communication environments. Loud, fast-paced, and safety-critical, an aluminum extrusion facility requires instant, reliable, and intelligible voice communication from the press floor to the shipping dock. By standardizing on the Kenwood NX-1300DUBK DMR radio system with Voiceporter IP67 accessories and multi-unit charging infrastructure, Astro Shapes has equipped its workforce with professional-grade tools that match the quality standards the company upholds in every aluminum profile it produces.
For manufacturers evaluating two-way radio solutions for heavy industrial environments, the Astro Shapes deployment demonstrates the tangible operational value of upgrading from analog to digital DMR, investing in ruggedized accessories rated for industrial conditions, and building a charging infrastructure that keeps an entire fleet mission-ready around the clock.
About TwoWayRadio.com
Ion, Inc. – TwoWayRadio.com | 6770 Stillwater Blvd N, Ste 205, Stillwater, MN 55082 | sales@twowayradio.com | 866-589-6929
About Astro Shapes LLC
Astro Shapes LLC | 65 Main Street, Struthers, Ohio 44471 | (330) 755-1414 | www.astroshapes.com