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Expanding Capabilities in Metal Fabrication

by profusionusa
written by profusionusa
bystronic xpert

Profusion Expands Capabilities with Cutting-Edge Additions: NEW Bystronic, 1st in the USA, ByCut Star 4020 20 KILOWATT Fiber Laser and Bystronic Xpert Pro 14 ft, 220 TON Press Brake

Profusion, a leader in the state of Florida for metal fabrication, is proud to announce a significant expansion of its capabilities with the addition of two state-of-the-art machines: the Bystronic ByCut Star 4020 (6’ X 12’ sheet/plate size) 20 Kilowatt Fiber Laser (Made in the USA) and the Bystronic Xpert Pro 14 ft, 220 Ton 6 Axis Press Brake. These cutting-edge machines mark a new era in precision cutting and metal forming, positioning Profusion as a frontrunner in the industry. The ByCut Star 4020 Fiber Laser and the Xpert Pro 14 ft Press Brake represent the embodiment of Profusion’s unwavering commitment to providing optimized solutions in metal fabrication. As professional metal specialists, our dedication to precision, quality, and innovation is evident in every project we undertake. Both machines work seamlessly from part quoting, cutting, and forming, all based on the same software between these two innovative machines, all powered by integral software and SolidWorks’ 3D CAD. We aim to provide value to our customers through efficient technology that allows our team to deliver the best parts for the first time.

 

At Profusion, we offer a wide range of services to cater to your specific needs, including:

Precision Laser Cutting: With the ByCut Star 4020, we bring you unparalleled precision in laser cutting, ensuring your designs come to life with impeccable accuracy.

Abrasive Waterjet Cutting: Our expertise in abrasive waterjet cutting enables us to handle even the most challenging materials with ease and precision. With our USA made, Omax machine, 7 Axis cutting capabilities with a table size of 6‘ X 12’ allows large format cutting of almost any material, including : All metals, wood, rubber, plastics and stone.

Custom Metal Fabrication: We specialize in custom metal fabrication, turning your ideas into reality, whether it’s architectural elements, structural components, or specialized machinery.

Custom Railings, Gates, & Staircases: Elevate the aesthetics of your space with our custom railings, gates, and staircases, meticulously crafted to meet your unique vision.

Certified Welding & Machining: Our certified welding and machining services guarantee the structural integrity of your projects, ensuring they stand the test of time.

Engraving & Marking: Personalize your metal creations with our engraving and marking capabilities, adding a distinctive touch to your work. Along with part marking and adding detail to control panels and various products.

With the addition of the ByCut Star 4020 Fiber Laser and the Xpert Pro 14 ft Press Brake, Profusion is your partner with limitless possibilities for metal projects. Whether you require intricate designs, large-scale production, or custom, one-of-a-kind creations, we have the technology, expertise, and craftsmanship to bring your projects to fruition.

 

ByCut Star 4020 Bystronic 20 Kilowatt Fiber Laser: Precision Beyond Measure with speed bring value and fast service making us your first choice for fast turn around and excellent cut quality.

fiber laser

The ByCut Star 4020 Fiber Laser is the crown jewel of our new acquisitions. Boasting a 20-kilowatt fiber laser, this machine offers precision cutting capabilities that are second to none. Whether you require intricate cutting and detail in thin materials or need to slice through thick, robust metals, the ByCut Star 4020 delivers with unparalleled accuracy, designed and built for large-scale, high-volume projects.

 

Key Features:

 

  1. Unmatched Precision: The cutting system ensures even the most intricate designs are executed flawlessly, meeting the highest industry standards for precision.
  2. Cutting-Edge Technology: With a 20-kilowatt fiber laser, this machine effortlessly tackles a wide range of materials, including:
  • Steel
  • Aluminum
  • Stainless steel
  • Brass
  • Copper
  • Titanium

The ByCut Star 4020 provides even better quality with an optimized cutting process, ensuring precise and reliable cuts in these materials.

  1. Speed and Efficiency: The ByCut Star 4020 completes jobs faster and more efficiently, reducing production lead times and costs.
  2. Versatility: Its wide range of capabilities makes it suitable for various industries, from aerospace to automotive, catering to diverse customer needs.

 

Bystronic Xpert Pro 14 ft, 220 Ton 6 Axis Press Brake: Craftsmanship Meets Technology

 

The Xpert Pro 14 ft Press Brake adds a new dimension to Profusion’s metal bending capabilities. With a 14-foot bed length and 220-tons forming power, this machine is designed to handle even the most demanding metal bending projects.

 

Key Features:

 

  • Precise Bending: The 6-axis design ensures that complex bends and shapes are achieved with unparalleled accuracy.
  • Large Capacity: With a 14-foot bed, it accommodates large workpieces, making it ideal for oversized projects.
  • Enhanced Efficiency: Quick setup and high-speed operation reduce production time while maintaining exceptional quality.
  • Diverse Applications: From architectural elements and precision sheet metal forming to heavy machinery components, this press brake handles a wide array of metal bending tasks.

 

These new additions to Profusion’s equipment lineup demonstrate our commitment to delivering top-quality products and services to our valued customers. With the ByCut Star 4020 Fiber Laser and the 14 ft. Xpert Pro Press Brake, we empower our clients with enhanced capabilities and greater flexibility in their metal fabrication projects.

Profusion continues to invest in cutting-edge technology and skilled craftsmanship, making us the preferred choice for precision laser cutting & fabrication needs. Our dedication to quality, efficiency, and innovation is what sets us apart in the industry.

As we embrace the future of metal fabrication with our laser cutting and bending capabilities, we invite you to experience the unparalleled precision, value, and versatility that Profusion can offer. Join us in our journey to redefine possibilities in metal fabrication. Contact us today to explore how these innovative machines can transform your ideas into reality, delivering exceptional quality and precision every step of the way. We are a leading metal fabrication company dedicated to delivering high-quality solutions for various industries. With a commitment to innovation, precision, and customer satisfaction, Profusion has established itself as a trusted partner in the world of metal fabrication.

For inquiries, quotes, or to learn more about our expanded capabilities, please visit our Contact Us page.

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Sheet Metal Fabrication

by profusionusa
written by profusionusa
sheet-metal-fabrication-projects

Benefits of Sheet Metal Fabrication

There are different technologies for sheet metal fabrication. However, none are faster, efficient, and more precise than laser cutting.

Laser cutting works by melting the metal using a high-powered laser beam. The technology solved the inadequacies of manual cutting and is used in industries such as aerospace, automotive, and electronics.

Laser cutting comes with unique advantages that make it a good fit for sheet metal fabrication.

Precision

Laser cutting technology is highly precise, up to 25 microns, which is narrower than a strand of hair. It also has an accuracy of about 10 micrometers with repeatability of about 5 micrometers.

Other cutting technologies produce a lot of heat that can damage the metal being cut. However, laser cutting machines only heat a small area of the metal undergoing fabrication. Therefore, there is minimal risk of damage to the material.

Besides, the laser cutting machines have a jet system that feeds compressed air, which expels the evaporated residue. This expelling of residue further enhances the cutting accuracy and quality.

Ultimately, laser cutting provides accurate, smooth, and clean cuts.

Versatility

Laser cutting performs all your metal fabrication needs:

  • The laser beam can cut a wide range of flat, profiled, and tubed materials, including stainless steel, mild steel, aluminum, and even wood and plastics.
  • With laser cutting, you can achieve any design specification, from delicate and small designs to large and complex creations.
  • Laser cutting can also be used for a wide range of fabrication services, including marking, engraving, and drilling. The controlled heat output and intensity allow the different applications of laser cutting.

Speed

Laser beams cut through metal fast. Typically, laser technology will cut through 1mm thick mild steel at the speed of 18m/min. If you are working with 3mm thick steel, you can expect speeds of up to 4.5m/min.

However, you have to optimize the speed and power of the laser nozzle, depending on what you are doing. For instance, while engraving, you can use the maximum speed and set the power level depending on the darkness level your project needs. On the other hand, when cutting, the maximum speed might be too fast to cut all the way through depending on the thickness of the metal.

You can reduce cutting times by using multiple lasers simultaneously or multi-head lasers.

Efficiency

Laser cutters use a beam, meaning they do not make direct contact with the material. Therefore, they do not wear down; neither does work stop for retooling or replacement of components. Laser cutters can work for long hours, which improves efficiency.

Additionally, these machines work through automation. All you have to do is enter codes on a computer, and the machine will start working with precision and produce work with little or no defects. So, you can improve efficiency by leaving the machine to work overnight when there is no one around.

Consistency

Automation also eliminates human error. Therefore, you get accurate and consistent results. Duplicating a design multiple times is a breeze with laser cutting.

Consistency and accuracy only require the right software and quality laser cutting machines and parts.

Cost-effectiveness

In the long run, laser cutting is cheaper than other sheet metal fabrication methods. For starters, it does not require multiple human operators, meaning it saves you labor costs.

Then, there is the improved speed and efficiency. Remember, time is money. Plus, the improved speed and efficiency do not necessarily translate to more energy consumption. Combined with energy-efficient technology, laser cutters use small amounts of energy.

Additionally, laser cutters require little maintenance.

 

Versatility, precision and accuracy, speed, efficiency, and consistent results at a relatively low cost – what more could you want from sheet metal fabrication technology? Contact us at ProfusionUSA now for more information on laser cutting.

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Metal Products as a result of Custom Fabrication

by profusionusa
written by profusionusa
metal-products

Essentials to Know About Custom Metal Fabrication

Fabricated metal products are becoming popular by the day due to their diverse applications. Even so, few people know how the metal fabrication process works. Custom metal fabrication involves replicating any generic metal product in functionality and look. The process is used to create architectural materials, structural metals, cutlery, and hand tools. Here are some essentials that you need to know about custom metal fabrication:

Custom Metal Fabrication is a Centuries-Old Technology

Human beings have created and used metal products for centuries. Therefore, custom metal fabrication is one of the earliest technologies used by human beings. Iron, gold, tin, silver, mercury, copper, and lead were the primary metals used in ancient societies. Metalworking technologies such as forming, cutting, and joining were common. Blacksmiths were among the most prominent and revered members of society.

Leonardo da Vinci sketched a rolling mill in 1485, and this sketch was later used to create a press for rolling gold sheets into coins. During the Industrial Revolution, metal fabrication became even more popular due to the development of different metallic products.

You Can Create Everything Imaginable

metal-product

As the name implies, this process creates everything you can think of, be it stairway railings, vehicle components, or construction equipment. The main raw materials used in metal fabrication are formed and expanded metal, plate metal, tube stock, welding rod/wire, and sectional metal.

These raw materials are meant for specific applications, and therefore, you can create everything imaginable. Here’s how the raw materials get utilized for different applications:

  • For engineering and construction projects, metal fabricators mainly use sectional metals, including bars and rods, the Z shape, the I-beam, and structural sections.
  • Expanded metal sheets are ideal for fabricating screen doors, outdoor furniture, and safety guards on machines to prevent contact with hot surfaces.

The Process Involves More than Cutting and Welding

Many people think that custom metal fabrication is all about cutting and welding. However, metal fabrication shops use various processes and techniques to ensure that the final product meets the desired standards. These include forging, punching, brazing, and spinning. A specialty shop can also implement advanced procedures such as chipping, casting, powder metallurgy, and powder coating.

The Metal Fabrication Process is Complex

Looking at custom metal fabricators doing their job, you might think that it’s easy. However, a lot goes into the process. For starters, sketches must be drawn and engineered for a particular idea in mind before being presented to the metal fabrication company.

A team of experts will study the sketches to determine whether the idea is feasible and the type of materials needed. It’s only after a consensus regarding design, cost, and execution are reached that the fabrication work can start. The custom metal fabrication process is generally broken down into three major steps, which are:

  • Project design
  • Fabrication of different individual components
  • Assembling the individual pieces into the final product

The metal fabrication process is complex, highlighting why you should rely on experts whenever you have a project. The main advantage of choosing a one-stop metal fabrication shop is that experts will do everything under one roof. The centralization of all the processes involved guarantees the quality of the final product. It also ensures that the final product is delivered within the stipulated timeframe.

Final Words

The quality of your metal fabrication project depends on the shop you choose. At Profusion, we know all about custom metal fabrication, and our experts have the experience to bring all your ideas to life. We leverage our expertise to create quality products for our customers. Contact us today to learn more about our services.

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Differences in Precision Cutting Methods

by profusionusa
written by profusionusa
Differences in Precision Cutting Methods

The Pros and Cons of Precision Cutting Techniques

Metal fabrication involves the use of a wide variety of options for precision cutting of metal materials. The most common cutting options are water jet and laser cutting. Here is an in-depth look at the applications and the pros and cons of these two metal cutting options.

Water Jet Cutting 

Water jet cutting involves the use of pressurized water with an abrasive such as garnet to cut material. With this method, a high-pressure pump is used to drive water through hoses causing a forceful water jet, hence the name water jet cutting. This metal cutting method is common because it can cut any material, including combination materials. Water jet cutting also handles a range of thickness that is greater than many cutting methods’ capabilities. ProfusionUSA uses this process for flat surfaces.

One main advantage of water jet cutting over laser cutting is edge finish. Laser cutting produces heat, which results in a heat-affected zone. This distorted zone requires a secondary finish. With water jet cutting, there is no heat-affected zone. The process does not damage any parts. Waterjet provides a smooth edge finish. This means there is no need for a secondary finishing process. 

One of the downsides of this metal cutting technique is that it is time-consuming. Water jet cutting is also noisy and results in a big mess. A significant amount of waste is produced because of the mixture of water and an abrasive. This method will require a more laborious and costly cleanup and disposal process than laser cutting.

Laser Cutting

laser-cutting

Laser cutting involves the use of a gas laser for energy. For example, a CO2 laser can be used. In this case, the CO2 is transmitted via a beam. This beam is guided by mirrors which direct it at the material. ProfusionUSA uses laser cutting with various materials, including glass, plastic, wood, and metals. However, this method is difficult to apply to a material combination, especially if the materials have different melting points.

Laser cutting does not require strict safety measures like water jet cutting. With the water jet cutting method, you will require ear protection because the process is very noisy. You will also need protection against the pressured water jet. Specific safety glasses, covers, and gears are used for protection.

The main precaution you need to take during laser cutting is to have proper ventilation. This will protect you from toxic dust and smoke. Laser cutting is less noisy, and after the process is complete, the machine does not need to be thoroughly cleaned since the cutting waste is dust, which can be easily vacuumed. However, the major downside with laser cutting is thermal stress that can impact heat-affected zones. The best way to prevent thermal stress cracking is by adjusting the speed of the cutting machine.

Laser cutting is highly renowned for its precision. This method is faster than water jet cutting. Laser cutting is also far cleaner than the water jet technique, which is quite costly in disposing of waste material. Laser cutting also supports a tolerance of within 0.002”. Laser cutting is best suited for tubes, squares, bars, and flat sheets.

In Conclusion

Water jet and laser cutting methods are one of the most common techniques in the metal fabrication industry. When choosing a metal cutting technique, a lot needs to be considered. You first need to consider the type of material you are cutting. Some methods do not work well with a combination of materials. 

Other things you need to pay attention to include safety precautions, speed, and clean up services. Cutting techniques also vary in terms of the range of thickness, cut quality, and productivity. If you want quality cutting services by a seasoned and reputable firm, ProfusionUSA will not let you down. Reach out to us today and experience quality metal fabrication services. 

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Maintenance of metal laser cutting equipment

by profusionusa
written by profusionusa
maintaining-metal-laser-cutting-equipment

How to Get the Most Out of Your Laser Cutting Equipment

Metal laser cutting involves advanced equipment that requires regular maintenance to ensure high performance. After all, laser cutting is all about precision, so keeping your machines in peak condition is crucial to getting the results you or your clients expect. Without the right maintenance plan, the quality of your cutting can suffer. You’ll quickly be dealing with trouble getting precise cuts, the lower overall quality in your products, and faster breakdown of what can be very expensive equipment. On the other hand, the right preventative maintenance plan will keep your laser cutting equipment working without issue for years. It’s one of the best ways to get peace of mind knowing you’re always ready to go with precise laser cutting that looks amazing. Here’s some information on what you can do to keep your equipment in great shape for years.

Stay Ahead of Equipment Temperatures

Monitoring the performance of your chiller is key to long-term laser cutting performance. Owners and operators should constantly be aware of what’s going on inside the temperature gauge. If you see swings in temperature, then it’s likely time for chiller maintenance to avoid any larger problem from happening that will be more expensive to fix.
Thankfully, advances in control technology mean that fabricators can better regulate temperatures. Still, operators need to regularly check water levels to stay on top of conductivity in your equipment.

Focus on the Optics

Optics can be some of the most sensitive laser cutting components. They are incredibly important to beam quality and cutting quality, so getting the maintenance right here counts a great deal. Getting your optics back to OEM specifications should be a priority whenever you do any type of maintenance on your equipment. That ensures they cut the way they are designed to and provide you a consistent baseline to work with. Professional laser cutting maintenance teams use expensive equipment like beam profilers or analyzers to get your optics back in perfect alignment.

Clean Your Equipment Regularly

It sounds simple, but so many businesses neglect to clean laser cutting equipment regularly. Regular cleaning protects your investment long-term and will keep your machines working for longer. One of the biggest causes of laser cutting maintenance issues is the accumulation of dust and debris. It gets caught inside components and drags down performance. Even a small amount can nudge things enough to affect how your cutting comes out.
Failing to clean your equipment can also lead to a thermite hazard. Leaving dust and scrap in your work areas for too long is a hazard that’s easy to avoid. Don’t take any chances. Make cleaning part of your regular work routine.

Profusion Metal Fabrication is a national leader in laser cutting and other advanced metal fabrication technologies. We have decades of experience working with all types of metals and know what it takes to get the best results out of laser cutting equipment. Following these steps will ensure your laser cutting comes out quickly and looks fantastic. This dedication to detail will get you ahead of the game and keep your equipment working well for years.

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Safely Working with Custom Metal Fabrication

by profusionusa
written by profusionusa
custom-metal-fabrication-and-safety

Custom Metal Fabrication Safety Precautions and Tips

 

Metal fabrication is an integral part of many different industries with custom metal fabrication serving an even more niche role yet still widely important. It is a process that involves the use of raw materials to create structures and components. However, your metal fabrication workshop can be a dangerous job because it can sometimes require your employees to engage in high-risk activities.

 

Custom Metal Fabrication Dangers

Some of these dangerous activities may lead to:

  1. Cuts

Cuts are some of the most common injuries in the metal fabrication industry. Arm injuries can occur during any of the processes found in metal fabrication processes.

For instance, the edges of sheet metal are often razor-sharp. A hand tool can also be a source of injury in metal fabrication processes. Excessive tool handling or repetition and poor equipment maintenance can also lead to hand injuries.

  1. Burns and Lacerations

Many metal fabrication burns are caused by hot substances or fire touching the skin. Metal fabrication exposes your workers to intense heat, making burn injuries common. These welding injuries are also known as arc eye or flash burns. The welding arc emits extremely concentrated rays.

One of the common and well-known metal fabrication related injuries is the flash burn. A flash burn can be caused by exposure to a welder’s arc or even a desk lamp. Your welder can also come into contact with toxic chemicals while performing his work.

 

Safety Precautions and Tips

 

Here are a handful of metal fabrication safety tips from the experts to reduce the potential for injury or disease.

  1. Wear Heavy-duty Gloves

Heavy-duty gloves have a three-layer design focused on increased burn protection, heat resistance, and comfort. The ideal gloves provide a balance of durability, dexterity, abrasion resistance, and comfort. Heavy-duty gloves can only protect you while they’re on your hands.

General-purpose welding gloves are made of resistant split cowhide, which provides exceptional durability and abrasion protection. These gloves should be used by any person involved in either light-duty or heavy-duty welding works.

  1. Wear a Respirator or Dust Mask

Dust masks will protect your mouth and nose from droplets and dust. It is well suited for maintenance welding operations, torch cutting, and brazing.

On the other hand, a respirator includes a facepiece or mask, and a filter/cartridge. A respirator can be worn for comfort against non-toxic nuisance dust. The use of any respirator, including a dust mask, is mandatory in any metal fabrication workshop. However, if you wear a mask long enough, it can damage the lungs.

  1. Sufficient Training

It is your responsibility to train your employees to work safely. Metal fabrication safety courses such as welding safety rules and tips are specific to each metal fabrication company. The training provides a high-level overview of the most common types of metal fabrication injuries. Other safety programs cover the Personal Protection Equipment (PPE) requirements and environmental safety.

Your employees need to be trained to follow safe fabrication procedures. These welding safety courses will help keep your employees safe. Your employees should also know how to read and follow the safety labels and safety precautions.

  1. Use a Fire Extinguisher

Fire prevention and safety are a must when using metal fabrication equipment. First, you have to train your staff in the use of fire extinguishers. It would be best if you also kept a suitable Class ABC fire extinguisher nearby while welding. Type A fire extinguishers are used for combustible solids such as wood. For magnesium fires, it is best to use a Class D fire extinguisher.

The fire extinguisher(s) must be located so that it is easily accessible for use. It must also be tested annually. You should also have the extinguisher replaced or repaired if you find any damage.

Be Safe

Metal fabrication safety is obligatory, not an option. Follow all the instructions and metal safety tips to avoid any hazards. ProfusionUSA exercises the utmost safe practices with all their projects to guarantee a successful job as well as a safe one.

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