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Sheet Metal Fabrication

by profusionusa October 29, 2020

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.

October 29, 2020 0 comments

fabrication

Metal Products as a result of Custom Fabrication

by profusionusa October 27, 2020

written by profusionusa

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.

October 27, 2020 0 comments

fabrication

Differences in Precision Cutting Methods

by profusionusa October 23, 2020

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.

October 23, 2020 0 comments

fabrication

Maintenance of metal laser cutting equipment

by profusionusa October 15, 2020

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.

October 15, 2020 0 comments

fabrication

Safely Working with Custom Metal Fabrication

by profusionusa August 17, 2020

written by profusionusa

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:

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.

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.

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.

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.

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.

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.

August 17, 2020 0 comments

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Metal Fabrication and the LEAN Approach

by profusionusa August 17, 2020

written by profusionusa

Lean Metal Fabrication during Harsh Economic Times

Being able to manage large and small crises better is the purpose of lean metal fabrication manufacturing. Crises are always knocking on the door, and there are those big ones that you become a victim of, then there are the small ones that you can ignore.

However, many companies react by looking for areas to cut costs when faced with any kind of crisis. This isn’t the case with industrials, though. Manufacturers are starting to approach things a bit more agilely by turning to ‘lean’ roots to steady their operations and keep things moving forward with their metal fabrication. ProfusionUSA is one such company that hasn’t sacrificed quality and has continued to operate well in these current times.

Implementing lean strategies has helped countless manufacturers shorten lead times, increase cash flow, and lower PPM.

And in any case, the lean approach seeks to answer one question- where’s the bottleneck?

How the Lean Approach can Help in Metal Fabrication

Lean manufacturing in metal fabrication seeks to eliminate waste on all production phases. The idea is to make production more cost-effective while satisfying customers. As IndustryWeek advises, the worst thing you can do as a steel manufacturer during a crisis is to panic or react without a plan.

Instead, evaluate all current operational structures and their viability, especially in crises like this global pandemic. As you know, cutting costs in metal fabrication is almost impractical because the equipment used is usually too bulky to get rearranged in a way that can reduce machine and human movements.

Also, the cycle time of production will always be longer in metal manufacturing than in other businesses because of the product-sizes created. Not to mention that metallurgical constraints curtail the aggressive acceleration of cool-down and heat-up cycles.

This is where lean metal fabrication comes in. It helps metal fabricators realize significant reductions in production costs, cycle times, changeover times, and inventory. Lean manufacturing also helps to achieve substantial improvements in delivery, reliability, and quality.

And as you may know, this style of manufacturing is applicable in:

CRM
Hot Dip Galvanising
Al Zn Coating
Color Coating
Steel Corrugation
Flat Products
Tube Mills

The Seven Deadly Wastes Lean Manufacturing Eliminates in Metal Fabrication

Manufacturing efficiency experts Vorne Industries Inc. note that understanding the following wastes can help metal fabricators formulate a strategy for reducing inefficiencies in material handling, labor, and other resources:

Overproduction- Are you processing more than what the customer requires? Are there better ways to meet your customer requirements with your manufacturing processes?
Waiting- Is there a period where staff remain inactive while waiting for the next task in your production process? Is there a way to a more continuous production flow to give more value to your customers?
Transport- Are you unnecessarily moving finished goods, work-in-progress (WIP), and raw materials? What can you do to realize a linear flow of production?
Motion- How can you reorganize your workflow to reduce unnecessary staff movement? Can you rearrange your equipment to limit motion waste?
Over-processing – What are your manufacturing specifications as compared to your customer requirements? Are there any manufacturing simplifications you can adopt to process only what your customers need?
Defects- What is the most prevalent defect, and why does it keep occurring? Can you adopt a strategy to detect and curb future abnormalities?
Inventory- Is every raw material coming into your company truly needed? Is there a way to counter overproduction?

Go Lean with Better Planning

The lean approach boils down to getting rid of processes/ activities that don’t add to customer value. The end result is eliminating costly inefficiencies, improving productivity, and preventing unnecessary delays. The lean approach also helps with project inefficiency and streamlining of the purchasing process for customers.

August 17, 2020 0 comments

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Benefits of Waterjet Cutting on Fabrication

by profusionusa July 19, 2020

written by profusionusa

The Appeal of Waterjet Cutting for Fabrication

Waterjet cutting is a versatile tool that more businesses are using to make incredible products. With a high-pressure water stream, companies can cut through a wide variety of materials without heating them. Even though the process has been around for decades, recent developments in technology have given manufacturers more options than ever. That can be a huge money saver because you get to skip paying for all of the thermal distortions that occur in most machine parts. The cutting process places less stress on products being made and the machines that make them. When you need fast, detailed cutting, waterjet cutting can deliver the results you expect.

The Strength of Waterjet Cutting

Makers, and specifically manufacturing companies, are always looking for the most effective process that gives the best results. Many companies are turning to waterjet cutting because the strength of the water stream can cut through virtually any material without thermal stressing or producing any noxious gases. Manufacturers routinely use waterjet cutting on rubber, metals, glass, stone, and plastic. It works amazingly well on flat and uneven surfaces.

The Eco-Friendly Choice

We know manufacturers are more environmentally conscious than ever. It’s the new standard that partners, employees, and clients expect. This drive to protect the environment has led to creative new tools like waterjet tools that produce very little waste. The precision of waterjet tools allows manufacturers to use raw materials better because they cut in greater detail. There’s no thermal process or heating error to account for with waterjets as well.

Avoid Material Distortion

The system uses water to cut materials, so there’s little to no heat generated in the manufacturing process. That means your finished products match your initial product design very closely. You don’t have to make allowances for distortion that occurs through heating and cooling the material, sometimes multiple times. With waterjet cutting, you can create products that have unique shapes and require high levels of detail without concern. A lot of manufacturers are immediately impressed with how well water jetting gets the job done. There’s also no finishing process because cuts are so precise. That saves you time and money in the manufacturing process.

Modern manufacturers are turning to waterjet cutting for exact cuts that save on raw materials. There are fewer safety hazards, and your finished products look fantastic. Whether you’re looking for a standout product sample or need to implement a highly detailed production process, waterjet cutting offers the versatility and quality results you need. If it’s versatility and quality you’re after, allow Profusion to meet all your fabricating needs.

July 19, 2020 0 comments