Throughout our manufacturing process, we prioritise customer inputs, considering them as integral to our operations. Once the design is accepted, we procure the necessary raw materials and initiate the physical manufacturing process. This process involves several stages, each facilitated by specialised machinery and producing specific outputs.
To ensure exceptional quality, we exercise rigorous Quality Assurance at crucial checkpoints during the Manufacturing, Integration, and Testing phases. These checkpoints are carefully documented to maintain transparency and accountability. Our Testing procedures are predetermined and documented during the Design phase, and they are executed and recorded accordingly during the Testing phase.
We work collaboratively to visualise a concept for every need. Drawings are stored in a client-confidential system protected via daily backups. For accuracy and efficiency final drawings are automatically sent to our machines.
PUNCHING MACHINE: AMADA VIPROS
22 ton press capacity
2500 x 1250 mm maximum sheet size (with one reposition)
3 mm Maximum Material Thickness (Mild Steel)
2 mm Maximum Material Thickness (Stainless Steel)
3228 IPM Positioning Speed
±0.5 Punching Accuracy
PUNCHING MACHINE: AMADA
30 ton press capacity
2500 x 1500 mm maximum sheet size (no reposition)
3000 x 1500 mm maximum sheet size (with one reposition)
3 mm Maximum Material Thickness (Mild Steel)
3 mm Maximum Material Thickness (Stainless Steel)
500 HPM on 1″ centre – world’s highest hit rate!
Higher positioning speed improves productivity
Brush table design provides scratch-free processing, eliminating secondary finishing
Laser Cutting
Laser cutting machines can accurately produce complex exterior contours and take direct input from a CAD drawing to produce flat form parts of great complexity in Mild Steel, Stainless Steel and Aluminium.
Punching
New technology and flexible tooling allow short runs and complex part configurations to be produced in the most economical way possible.
Pressing, Rolling & Notching
Our innovative fastener insertion machines enable us to use a wide range of self-clinching fasteners, optimising labour, enhancing quality, and increasing productivity. This technology ensures greater reliability in Stud and Bush design, while diverse tooling provides flexibility. Additionally, our department includes Corner Notcher and Rolling machines, expanding our capabilities to accommodate a variety of applications.
Bending
To change the shape of metal the material is stressed beyond the yield strength but below the ultimate tensile strength. Our substantial tooling and a 220 ton press strength allows us to bend almost every possible combination requested.
Forming
Our range of machines are CSM of which one is a CNC and the other is NC.
220-ton capacity
4000 mm max bend length
3760 mm between frames
470 mm open height
300 mm stroke
CNC Controlled
100-ton capacity
3000 mm max bend length
2700 mm between frames
200 mm open height
100 mm stroke
CNC Controlled
88-ton capacity
2500 mm max bend length
2200 mm between frames
500 mm open height
200 mm stroke
CNC Controlled
Maximum 38mm diameter
Available tools: 25.4mm diameter/50.8R, 63.5R, 88.9R including rolling and 32mm diameter/150R
Maximum 89mm diameter
Available tools: 50.8mm diameter/150R, 32mm square/112R, 50mm square/152R, 50x75mm rectangular/152
Milling
Milling cutters of many shapes and sizes are held and can move in three perpendicular directions to cut flat surfaces, grooves, dovetails, T-slots and even concave and convex forms with combined maximum working dimensions: X-1020mm, Y-550mm and Z-540mm.
Turning
The process whereby a centre lathe is used to produce “solids of revolution”. It can be done manually, in a traditional form of lathe or by using an automated lathe referred to as having computer numerical control, better known as CNC, with combined maximum working dimensions: 280mm diameter and 550mm long.
Stud and Bush Inserting
Fasteners for sheet metal provide deep-tapped female threads or self-clinching studs for use with thin sheet metals. Once installed, they’re permanently attached to the mating material, allowing the nut or bolt to be removed without the risk of the fastener becoming dislodged. Easily installed using equipment such as Haeger Presses, our factory has two Haeger 618 Modular Autofeed Systems with 6 tons of ram force and a 457 mm throat depth and a Haeger 824 Plus with 8 tons of ram force and a 610 mm throat depth for larger jobs.
Fanuc Welding Robot
• With Lincoln Electric Power Source
(Power Wave F355i)
• High motion speeds with great performance and productivity
• Integrated Servo Torch with wrist-mounted wire feeder
• Mild or Stainless Steel applications
• Dual Table Setup for increased productivity
Spot Welding
Resistance welding is one of the oldest electric welding processes. The weld is made by a combination of heat, pressure and time. The pressure exerted by the tongs and electrode tips, through which the current flows, holds the parts to be welded in intimate contact before, during, and after the welding current time cycle.
Grinding
Our grinding rooms are in excess of 100m2 and have over 10 workstations, they are split equally to avoid contamination between Mild and Stainless Steel. Various grit discs are used, from 36-180 depending on the product and desired finish, in this highly skilled manual process.
Powdercoating
Proper preparation is crucial for successful coating and our efficient five-stage cleaning process ensures this is done economically. Parts are then sprayed with electrostatically charged paint in a wide range of stock colours, or RAL colours, and oven cured to create a continuous film. With fully automated plants, we maintain high flexibility in meeting market demands.
Pickling & Passivation
Stainless steels rely on a vital passive film for their corrosion resistance. This is often damaged by welding and the affected areas require repair by a pickling & passivation dip system.
Electro-Chemical Cleaning
This process cleans by means of an instantaneous electrolyte reaction with the chemical agent, resulting in excellent quality cleaning and passivation of welds on Stainless Steel items which have been MIG or TIG welded.
Marking
The Marking System allows any logo or graphics to be instantaneously and permanently etched onto Stainless Steel with a maximum height of 70mm and any length.
Electroplating
One of the latest advancements in the factory is an automated Electroplating Plant that deposits an adherent surface layer of a metal having a desired property such as abrasion, wear resistance, corrosion protection, lubricity, or improvement of aesthetics, onto a substrate lacking that property. An example we use is the coating of an electrically conductive object with a layer of zinc.
The product finishes are as follows:
• Yellow Passivated
• Blue Passivated
• Yellow Passivated with Superseal
• Blue Passivated with Superseal
• Plating with no Passivation – preparation for Powder Coating
From Li-ion Storage, InRow Cooling and HACS to Fire Detection & Suppression, Access Control and CCTV our specialist equipment and software to ensure top-notch integration services.
Once fully set up on-site, final integrations and testing are completed as per the design specifications.
