Beyond Laser Cutting: What Happens to a Component After It's Cut?
The fabrication process often begins before manufacturing, with design and planning. However, laser cutting is often the first stage of the manufacturing process. Laser cutting uses laser beams to cut, melt or vaporise metal materials.
At ELC Group, we start with a flat sheet of metal and fabricate it into a high-quality product.
From Flat Sheet to Formed Component
During forming (the process of reshaping metal into a desired shape through mechanical deformation), tolerances are critical. Even a fraction of a millimetre can compromise the product's structural integrity, cause assembly issues, increase the rejection rate, and lead to delays and rework. CNC machines have revolutionised forming by offering greater versatility and user-friendly interfaces.
How does a press brake work?
A press brake uses controlled force to press sheet metal between a punch and die, creating the required bend. Modern CNC press brakes provide precise control over bending angles and repeatability. Tooling is very important in this process. It minimises spring-back, prevents material distortion, and improves real-time accuracy.
Bringing Components Together
Welding is the gold standard for joining sheet metal. It is versatile and includes several techniques to get the desired finish. These include
TIG (Tungsten Inert Gas): Welding for thin sheets and precise fabrication.
MIG (Metal Inert Gas): This is perfect for thicker materials.
Spot Welding: Ideal for overlapping joints.
We use several welding processes, including TIG, MIG, and spot welding. At ELC Group, our welding capabilities include manual welding, fibre laser welding, and robotic welding, so that we can choose the best approach for each project's requirements.
Manual welding: Best for custom jobs and intricate shapes.
Fibre laser welding: Creates an aesthetically flawless finish.
Robot welding: Optimal for high-volume production.
Protecting and Finishing the Component
Protecting and surface finishing is the second-to-last, and one of the most crucial, stages of the metal fabrication process. This step protects and enhances the performance and longevity of a custom-engineered product. Poor execution can lead to premature deterioration.
The right techniques vary depending on factors such as material type, environmental exposure, performance requirements, and the desired finished appearance.
Surface treatments
Powder coating
Powder coating is the process of electrostatically charging surfaces. Ingredients such as curatives, pigments, levelling agents, flow modifiers, and other components are blended to create a powder. Electrostatic spray deposition (ESD) sprays the powder onto the surface using a spray gun. The product then enters a curing oven, where the chemical reacts and forms long molecular chains, resulting in a high cross-link density. This provides a durable, aesthetically pleasing finish.
Galvanising
Galvanising is the process of coating metal with a protective zinc layer to prevent rust. Hot-dip galvanising, in which steel parts are submerged in molten zinc, is the most common method. This increases the metal's longevity by shielding it from corrosion in harsh environments.
Electroplating
The electroplating process deposits materials using an electric current. The object is connected to the negative terminal of the power supply. The plating metal connects to the positive terminal and supplies new metal atoms. The metal material is immersed in a chemical solution called an electrolyte solution. When the power is turned on, metal ions in the solution travel and bond to the negatively charged metal, creating a metallurgical layer.
Anodising
Anodising is an electrochemical technique that adds a thin oxide layer, from 1.8 to 30 µm thick, to the metal materials. This process thickens the natural oxide coating on the material's surface. This increases wear and corrosion resistance and provides a more appealing finish.
From Individual Parts to an Assembly
ELC Group provides end-to-end manufacturing. We are a single provider that manages metal fabrication from initial concept through to final assembly. If you are designing a complex bespoke project, managing multiple suppliers can be time-consuming and frustrating. Partnering with a team that handles the entire process removes bottlenecks.
Benefits of end-to-end manufacturing?
Streamlined processes: multiple suppliers mean multiple lead times. Working with ELC Group means that deadlines are more realistic. Time-sensitive projects can be completed faster without reducing quality.
Standardised quality control: Handover is often where quality slips. With a comprehensive supplier like ELC Group, we supervise the product from start to finish. This level of quality control reduces rework and costly mistakes.
Flexibility and customisation: Partnering with an end-to-end manufacturing company means we offer flexible metal fabrication solutions to suit your needs. We can provide real-time changes and streamline adjustments with unified standards.
Reduced cost: By consolidating everything under one roof, you are reducing overall costs. You eliminate supply chain overheads, minimise transport fees, optimise design for manufacturability, and reduce lead time.
More Than Laser Cutting
Laser cutting may be where the manufacturing process begins, but it is only one part of the journey from flat sheet to finished product.
At ELC Group, we can support your project through the full manufacturing process, from design and laser cutting to forming, welding, finishing and final assembly. By managing multiple stages under one roof, we can help streamline the process, maintain consistency and reduce the need to coordinate with multiple suppliers.
Whether you are developing a new product, need a bespoke component or require an end-to-end manufacturing solution, our team can work with you to find the right approach for your project.
Have a project in mind? Contact ELC Group to discuss your manufacturing requirements on +353(0)51 358144.
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