Bespoke Metalwork Fabrication.
Manufacturing Bespoke Metalwork in Nottinghamshire, Great Britain.
Manufacturing bespoke metalwork has been a key part of our business for over thirty years and even though we have now diversified into the manufacture of our own products, bespoke metal work is still a very important part of our business.
Bespoke Cabinets
We are regularly tasked with the manufacture of bespoke metal cabinets. Whether they are shotgun cabinets, controlled drugs cabinets or completely unique items, we are ready for the challenge. Using the latest CAD, laser cutting and CNC panel bending technology, our bespoke cabinets are accurate first time we are able to turn them around in a shorter than ever timeframe. Every bespoke cabinet is treated the same and follows the same process through production. From design through to assembly their production progress is tracked and monitored to our ISO9001:2015 standards. Whether you need 1, or 1000, we are ready for the challange.
Manufacturing Bespoke Metal Work
Thirty years of manufacturing bespoke metalwork is quite a long time and we’d like to think we know quite a bit about it by now.
Metalworking is what we do best and has supported and helped develop our range of stock products. It has also enabled us to provide bespoke metalworking solutions for some well known household names over the years. We believe that the continued use of our services by these well known names speaks for the quality and service provided by us at HEC Showman.
We are all too aware of the importance of speed and quality in the bespoke metalwork. Most commonly metalwork items need to be turned around quickly without a compromise in quality. We have many years of experience of this and utilise the latest machinery to ensure we can meet demand.
The Process of Manufacturing Bespoke Metalwork and Cabinets:
- Step One is to find out what the customer requires. We discuss all aspects of the work including specification and work through any drawings etc. available.
- Step Two we prepare an engineering drawing of the bespoke work. This drawing will be used to manufacture product(s) once it has been approved by the client. To obtain client approval, we send a copy of the drawing and then talk it through with them to ensure they are happy with every aspect. We make any changes necessary.
- Step three will see us preparing the drawings for the profiles required for the laser cutting process. This is now a simple process using the sheet metal function of Solidworks. Here we export the components to the software of our panel bender
- Step Four sees the Salvagnini software calculate the bends and adjusts the flat profiles to the correct sizes for cutting. It both creates the automation process for bending and the flat part profiles for laser cutting. These profiles are then laser cut from flat sheet steel.
- Step Five will be bending the parts that have been laser cut. We do this using a machine called a “press brake” and our new Salvagnini P2 panel bender. The press brake machine has a top tool in the shape of a V and a bottom tool with a matching female V. When the steel to be bent is placed between the two tools with the bend line in the correct position the two tools are brought together, and a bend is formed. The Salvagnini is a highly automated device that quickly re-tools to form complex bend sequences quickly, accurately and repeatably.
- Step Six has the various bent parts of the product assembled and tack welded. Tack welds are small welds that hold the parts together temporarily, so we can check the cabinet fits properly and is the correct size. When we are happy with everything the product is welded. We use a method of welding called TIG (tungsten inert gas) which offers a neat weld bead and requires minimal weld dressing.
- Step Seven will require us to remove the surplus weld using a sander to achieve a smooth finish prior to powder coating. All edges are filled and de-burred.
- Step Eight; we’re almost finished now. We send the products over the yard to our powder coating shop to be finished (if required). This involves special applicator guns, when the fine particles of powder are applied with up to 100,000 volts of positive static charge then sprayed on the surface being powder coated. Coated parts are earthed so the charged particles adhere until fused to a solid coat after passing through the curing oven. The powder and the metal part being coated have opposing electrical charges, the powder sticks to the surface of the part. This static charge pulls the powder to all the awkward spaces difficult to reach using wet paint techniques. Parts pass in front of the operator on an overhead conveyor line where the powder is applied as described above. Parts when coated with powder continue along the conveyor where they pass through a tunnel oven and bake for approx. 12 to 20 minutes at 180 degrees. While in the oven, the powder is fused to a smooth coating with a consistent, heavy-duty and high-quality finish, without runs or drips. The parts continue round the conveyor, leaving the tunnel oven where they are allowed to cool and are then removed, checked and packed ready for dispatch.
- Step Ten is where we assemble and pack the product ready for shipping or customer collection.