You may have come across the term ‘laser cutting’ and thought to yourself: “what is laser cutting, and how does laser cutting work?” – perhaps that’s why you are here. Well, if you’re wondering what this fabrication process is, you’re in good hands. This is our definitive guide to laser cutting and all you need to know about it.
What is Laser Cutting?
Laser cutting is a non-contact fabrication process that uses a tiny, focused laser beam to burn through and cut materials like sheet metal, creating designs that are high-quality and dimensionally accurate. We are experts in laser cutting sheet metal at Salamander Fabrications.
As its name suggests, this manufacturing process uses a laser to cut designs in materials – this is a powerful laser beam that uses heat to burn, melt or evaporate materials to ‘cut’ them into shape. If you’re wondering “how does laser cutting work?”, we’ll explore the process below.
Using thermal heat to cut the material, the laser cutting process involves directing the laser beam through a nozzle to the material. When directed at the material surface, the laser head heats it until the target area of the material melts or evaporates. It’s this fusion of heat and pressure that allows the cutting action to occur.
Laser cutting is powerful enough to cut through various metals and non-metallic materials with varied thicknesses. Whereas other techniques require large machinery or equipment with immense power to be applied to the metal or material, laser cutting does the job without any contact. As a result, laser cutting is an efficient and durable sheet metal fabrication process. We hope this answered the question: what is laser cutting?
What Kind of Laser is Used
With our explanation of the laser cutter ticked off, let’s explain what type of laser is used. Four main types of lasers are used in laser cutting: CO2 lasers, neodymium lasers (Nd), neodymium yttrium-aluminium-garnet lasers(Nd: YAG) and fibre lasers.
Most laser-cutting companies and professionals use CO2 lasers when laser-cutting materials like metal; however, at Salamander Fabrications, we use fibre lasers for our laser cutting. We use a fibre laser because it is more efficient than other laser beams since it requires far fewer external gases and has less wastage. As well as this, fibre lasers allow for better and smoother cutting, quicker turnaround times and greater flexibility.
Fibre lasers are better than CO2 lasers for several reasons – but CO2 lasers are still widely used for the process of laser cutting. In the very first cases of laser cutting being used to cut sheet metals, CO2 lasers were used. In a gas combination that mostly contains carbon dioxide (CO2), helium, and nitrogen, the CO2 laser is generated. An electric discharge is used to electrically pump this kind of production laser.
Complex shapes and 3D shape designs are possible with laser cutting, but it must be done part by part. We can design custom shapes using our fibre laser beam and years of experience.
Laser Cutting vs. CNC Cutting
Laser cutting is one of the most effective metal-cutting methods out there, but it’s by no means the only one. CNC cutting and laser cutting are popular sheet metal fabrication procedures that are both high quality – however, they do have their fair share of differences and benefits.
CNC stands for Computerised Numerical Control. CNC cutting is a fabrication process whereby tools and machinery are operated by pre-programmed computer software. The process involves using a motion control system or computer to send a signal and CNC of the design to the cutting machine – where the technical design is then cut into a material. This process requires far more specialist tools and equipment than a laser cutter does.
Ultimately, the primary difference between laser cutting and CNC cutting is how each method goes about cutting a material – they each cut metal in their own way. Unlike traditional CNC cutting which relies on specialised tools to carve out the pattern, laser cutting uses a powerful laser beam to burn through and vaporise the metal material.
Laser cutting has higher speed and high-precision cuts
Compared to CNC cutting, laser cutting works twice as fast. A laser cut machine makes it simpler to construct thick pieces and cut material in one go. Manufacturing durable and accurate components does not necessitate a workpiece or physical force.
Another major benefit of laser cutting when compared to traditional metal cutting methods is that it allows for higher precision cuts and enables users to design curves and corners dimensionally accurately. While traditional CNC cutting uses tools with limited widths (an average radius of just less than 1mm, laser beams can have a radius as tiny as 0.1mm. As a result, laser cutting allows for more detailed cuts and intricate designs. It has no design limitations.
Some additional benefits of laser cutting include:
Can be cheaper thanks to no tool wear and less wastage
What Can Laser Cutters Actually Cut?
We’ve answered “how does laser cutting work”, but many people also wonder what laser cutters can actually cut. Well, laser cutters have wide material compatibility and are suitable for various types of materials. There is no other technology or tool that can fabricate and cut as many types of materials as a laser cutter can.
Our laser cutters are most often used to cut aluminium and mild or stainless steel at Salamander Fabrications since we specialise in producing products from sheet metal. Nevertheless, depending on the method you use or the industry you work in, laser cutting can be employed in a variety of fields for an extensive range of materials. Get in touch with us today to find out more about how our laser-cutting services can help.
Laser cutters can also be used to cut through most organic and thicker materials which include:
Metals
Wood, paper cardboard and cork
Some plastics
Acrylic
Teflon
Rubber
Cloth
Leather
Laser cutters can cut all types of metals, which is why they are a top solution for sheet metal fabricators like us at Salamander Fabrications. They can cut anything from mild steel and carbon steel to stainless steel and nonferrous metals. At Salamander Fabrications, we use copper and brass regularly in our work, in addition to steel and aluminium.
If you want a 3D model or some intricate models created, laser cutters can make the most complicated shapes on various materials without large-scale manufacturing machines.
Importance of safety when working with laser cutters
Although reflective metals like silver can be cut by a laser machine, they can be trickier to work with than other metals as they run the danger of reflecting laser beams, albeit this is a minor risk.
Other materials, including glass and ceramics, can be etched with a laser in conjunction with being cut. However, you must take extreme caution when utilising plastics as some plastics can melt, burn, catch fire or even release dangerous gases – as well as cause harm to equipment.
FAQs about Laser Cutting
Now you have a much better idea of what laser cutting involves and what it can do, let’s answer some of the most frequently asked questions regarding laser cutting.
Which laser is used in laser cutting?
There are a few different types of lasers used in laser cutting, such as CO2, Nd and Nd: Yag lasers. However, we use fibre lasers for all of our laser cutting projects here at Salamander Fabrications because fibre lasers provide smoother cutting, quicker speeds, greater flexibility, and less waste from our projects thanks to their increased efficiency.
What are CO2 lasers used for?
CO2 lasers are most commonly used for skin and dermatology. A CO2 laser cutter is most frequently used to cut materials like wood, cardboard, paper, cork and some plastics. A CO2 laser cutting machine relies on a focusing lens to direct the CO2 laser beam on the localised area of a material.
Does laser cutting require oxygen?
An assist gas, which may be active or inert, is required for laser cutting. The typical active assist gas for laser cutting carbon steels and metal is oxygen. Oxygen is often known as the cutting gas by many.
Is laser cutting harmful?
When exposed to a laser beam, you could suffer from skin burns or extreme eye damage. If used improperly laser cutting can inflict severe injuries or cause fires. However, laser cutters pose very little risk and are extremely safe when used appropriately and properly. To avoid any harm, ensure you use laser cutters as directed.
How deep can a laser cutter cut?
The laser beam will completely penetrate and cut right through the material if more heat is applied to the targeted area than can be dissipated by heat conduction. Although some laser cutters can cut material up to 20 mm thick, the majority of machines operate on materials that are closer to 0.5–12 mm in thickness, based on the type of cut being performed.
Working with Salamander Fabrications for Custom Laser Cutting Services
Are you interested in our work or require this procedure for an upcoming project? To learn more about laser cutting and the work we carry out – or to begin your next project with Salamander Fabrications, don’t think twice to get in touch with our remarkable sales team who can give you the support you need. Just give us a call at 01484 843599 or email us at sales@salamanderfabs.com today! We’d be more than happy to help.
When it comes to finishing and protecting your sheet metal fabricated products, powder coating is one of the best options on the market! But what is powder coating? How does it work? And why should you choose it?
At Salamander Fabrications, we’ve been mastering the craft of powder coating on our metal fabrication projects for over four decades. At this point, we’d confidently say there’s nothing we don’t know about the process and are committed to ensuring our customers can rely on our quality sheet metal products for years to come.
In this guide, we’ve rounded up our expertise and put together everything you need to know about powder coating. You’ll find out:
What powder coating is
Exactly how the powder coating process works
Different types of powder coating available
Choosing the right colours and finishes
The pros and cons of powder coating vs paint
Got a specific query? If you’d like more than just to read about it, get in touch with our friendly team on 01484 843599 or at sales@salamanderfabs.com and we’ll be able to give you tailored advice to meet your precise needs.
What Is Powder Coating?
Powder coating is a colour-finishing technique used on thousands of different everyday materials, including sheet metal, concrete, steel and plastic surfaces.
Powder coating is often used instead of traditional liquid paints. It can be used indoors and outdoors, and offers a high-quality, long-lasting and durable finish to products of all shapes and sizes!
Examples of powder coating application for everyday products:
White goods like fridges and freezers
Stands and display units
Cars and auto assembly parts
Indoor and outdoor furniture
So, How Does Powder Coating Work?
Powder coating, as the name implies, uses a dry powder instead of traditional paint. This powder is sprayed onto the objects to be coated and is then heated and cured to form a harder, thicker and more consistent coating than painting.
This protective coating can be used in indoor and outdoor applications. It continues to be extremely popular as a manufacturing process due to it ticking many boxes. It is:
Water resistant
Heat resistant
Weather resistant
Corrosion resistant
Impact resistant (to a degree)
It also creates a uniform finish and a customised visual appearance.
The Powder Coating Process – What Is Powder Coating Application?
Powder coating is a dry finishing process that can be carried out on many different products or structures. As sheet metal fabricators, we at Salamander usually work with powder coating on metal, but it can also be applied to other materials such as concrete, plastic, etc., to protect them from the elements.
Powder coating requires a considerable amount of equipment, but the process itself is relatively simple. Broken down into five easy Cs:
Step-by-Step Powder Coating Process
Cleaning – The material surface needs to be manually cleaned, as well as go through a chemical cleaning. This ensures that any grease, dirt, imperfections or oils have been removed and that the surface is as smooth as possible. This will help the powder coating finish stick to the structure.
Coating – The product is then coated, usually using a powder coat gun, which is a type of spray gun. Polyester powder coating (or other materials) uses an electrostatic gun application method, which coats the entire surface of the product.
Charging – The metal product is connected to a power unit, which helps the powder particles attach to the metal as they are shot out of the gun. The power unit gives off an electrostatic charge, and the powder particles are then attracted to this charge, helping them stick for a smooth finish.
Curing – Finally, the coating is cured, which is where a chemical reaction takes place. During the heat curing process, the powder melts slightly and bonds with itself to create a strong coating. In some cases, powder finishes also bond with the metal to improve the durability of powder coats. This curing happens in a specialist ‘oven’, which heats the coated surfaces to around 200°C for 20 to 30 minutes (product dependent).
Cooling – The structures are then allowed to cool which further strengthens the bonds before they are ready to be shipped out. The dry powder coating process is now complete!
Different Types of Powder Coating
Sometimes, the question ’what is powder coating?’ isn’t as easy to answer, as there are so many different types of powder coating! Depending on the type of finish needed, powder coating can be made with a few different materials. Polyurethane, epoxy, polyester and acrylic are some examples of commonly used powder-coating materials.
Thermoplastic coatings become liquid during the heating process, which means they don’t actually chemically bond to the object being coated. This makes the coating reusable, reversible, and thinner than thermoset powder coating.
For objects that might need to be recoloured, recycled or reused in a different context, thermoplastic coatings are a better option.
Thermoplastic coatings typically provide a thicker layer, which makes them more durable when compared to thermoset powders. This type of coating is used more regularly on household items, automobile parts and metal objects.
Thermoset Coating
Thermoset coatings are a thinner type of coating. When cured, thermoset powder chemically bonds to the material it is coating, which means that it cannot be recycled, but also makes it less prone to chipping or cracking.
The key advantage of thermoset powder coating is that it is incredibly heat resistant, so it’s very suitable for protecting metal structures in high-heat areas.
Choosing the Right Colours and Finishes
One of the advantages of powder coating is the incredible range of colours and finishes that are available. Most powder coating providers will stock a range of colours (using RAL colour codes), making colour ordering quick and easy! Each RAL colour is also available with a few different levels of gloss, creating even more options!
Gloss particles can be added to most colours to provide different levels of shine. Unlike RAL colours, however, gloss levels are not uniform across manufacturers. It’s the brand of coating powder used that will impact what gloss and textures are available to you.
The team at Salamander Fabrications are highly experienced and can work with you to create a finish that works perfectly for your products, regardless of colour or brand!
Gloss Finish
Gloss finishes are the most popular in the industry, and have a gloss level of about 70%.
This kind of powder coating has a great level of shine and you can see reflections of most things, though they aren’t super-defined. It isn’t a mirror finish, but it does have a lovely reflective surface.
It is also very easy to clean due to the smooth surface!
High Gloss Finish
A high gloss finish will help your structures stand out no matter what! These surfaces have gloss levels of above 80% and offer a smooth, incredibly easy-to-clean surface.
Important to note, however this application process will result in visible imperfections if the underlying material isn’t completely smooth. This means that more surface preparation is required before the process of powder coating can be carried out.
Matte Finish
Matte or flat powder coating has a low gloss level – usually around 30%. It will reflect light in some capacity, but you won’t be able to see clear reflections, and only in high levels of light.
That the matte coating nullifies reflection to this degree is great for products that might have some smaller surface imperfections on the metal – they will be hidden. However, matte coating can be harder to clean than some glossy surfaces so this is worth bearing in mind.
Matte coating is great for use in areas like offices and retail as, though cleanliness is important, the standard is not incredibly rigid. However, in industries – such as the science or food industry, where powder coating is commonly used – where cleanliness is of great importance or where cross-contamination is possible, a matte finish is less ideal. This is because the textured matte surface can have tiny crevices or dips, which make it trickier to clean.
Sand Texture Finish
As well as matte, gloss and high-gloss finishes, texture can be added to powder-coated products. Like matte finishes, textured finishes are great for hiding any imperfections in the underlying product surfaces and are also great for providing additional tactile support (improving accessibility) and grip/friction (particularly on outdoor surfaces).
Sand texture is the least obtrusive texture and is fairly similar to matte textures. Sand texture, like the name implies, feels like sandpaper to touch.
Wrinkle Texture Finish
Similar to sand texture, wrinkle texture is slightly rougher. It has a lot of surface area due to raised grooves, bumps and wrinkles in the surface texture. This makes it excellent for use outdoors and provides a strong level of grip where needed. Wrinkle texture is usually the roughest option when powder coating products and is great for use in industrial applications.
Hammered Texture Finish
Hammered texture finishes have a similar level of texture to wrinkle textures, but with a higher gloss finish. It is very durable and allows customers to request a gloss finish without having to worry about any imperfections on the metal surface of the product.
For this reason, it doesn’t need as much surface preparation when compared to gloss coatings.
Powder Coating vs. Paint
One of the follow-up questions we often hear after ‘What is powder coating?’ is ‘Is it better than conventional paint?’, and it’s a good question!
There are lots of different factors that can affect which coating is the right one for your project, but, in general, spray painting is more affordable upfront, while powder coating is a more efficient, high-quality and long-lasting product.
Durability – One of the biggest advantages of commercial powder coating over spray paints is the protective feature that powder coating technology provides. Powder coating creates a hard, solid layer that encases the object it is applied to and protects it from heat, cold, ice, water, UV rays, bumps, scratches and dents. Powder coats are not only more durable than paint coats, but they also help fabricated products last longer.
Environmental impact – Unlike some traditional spray paints, powder coating doesn’t release volatile organic compounds (or VOCs) into the air. It’s actually a very eco-friendly process, as any excess powder can generally be reused, and thermoplastic coatings are also recyclable!
Range of colours and textures – There is a vast range of powder coat colours and textures. While spray paint finishes also have a range of colours and gloss/matte options, there is no way to emulate sand, wrinkle, or hammered textures with paint.
Cost efficiency – While paint coating is cheaper upfront, powder coating services are very cost effective when looking at their lifetime cost. While the process of application and protective gear needed for powder-coated parts is more expensive, the lifetime costs are relatively similar.
Wastage – There is also considerably less wastage associated with powder coating, as excess powder or powder that doesn’t stick during the coating process can be reused again. With spray paint, any wastage is lost and cannot be reused.
Quality of finish – As powder coating uses electrostatic processes to cure the coating, the finish is generally smoother and more consistent. When painting an object, the paint may run down the sides or be coated unevenly, whereas powder coating guarantees a smooth metal finish.
Powder Coating with Salamander Fabrications
At Salamander Fabrications, we’ve been working in sheet metal fabrication and the powder coating industry for over 50 years. We pride ourselves on our expertise and attention to detail when it comes to all aspects of the projects we undertake, including powder coating metals to help strengthen them, protect them and create a high-quality finish.
To learn more about the work we do or to get started with your next project, please don’t hesitate to get in touch with our friendly sales team on 01484 843599 or at sales@salamanderfabs.com.
By nature, the construction industry comes with risks. Construction workers are regularly handling hazardous materials, working at heights, carrying heavy loads and working in environments that pose long-term health risks. This means that the rules and regulations surrounding health and safety in construction are – and need to be – incredibly stringent and comprehensive and should be followed by every single person on-site.
Employers, site management, contractor clients, and business owners all have a duty of care to those working on their sites to protect them from hazardous substances and safety risks wherever possible. This is where the extensive range of safety requirements and safety regulations for the construction industry come in.
At Salamander Fabrications, we work with a wide range of organisations in the construction industry to improve safety processes and help site managers meet the legal requirements asked of them. Our products have helped ensure the safety of workers all over the country for decades. We’re experts in designing and creating products that help to support safety professionals to ensure that construction activities of all kinds can be carried out safely and efficiently.
To learn more about how we can use sheet metal fabrication services to help support safety management in construction or to learn more about health and safety in construction, keep reading!
The Importance of Site Health and Safety
The Health and Safety Executive (HSE) is the regulator responsible for health and safety in the UK. There are health and safety requirements in every industry and the key principles are very similar in many instances. HSE regulations cover not just physical health and preventing injuries to workers but essential health/daily health, mental health/psychological health, environmental management, work-related illness, the control of hazardous substances and workplace hazards, and the duties of employers to protect workers from all of these, among others.
Health and safety on construction sites are of the utmost importance, as there are significant unavoidable risks that are part and parcel of working in construction. Health and safety regulations exist to minimise these risks and prevent potential accidents from happening as much as possible. Deaths on sites and injuries on construction sites are always a possibility, which is why site health and safety exist – to prevent work-related accidents and keep all workers safe while they do their jobs.
How poor health and safety can impact construction businesses
As well as the risk to safety and life on construction sites, incidents, injuries and sickness can also reduce the productivity and profitability of a business. By improving safety, you reduce the likelihood of incidents and allow site workers to get on with their jobs safely and efficiently.
A lack of relevant health and safety provisions also opens organisations up to considerable legal challenges. Health and safety regulations are, more often than not, enshrined in law. This means that not following them is illegal, and the penalties for doing so can be heavy. Companies not following health and safety regulations are likely to invoke hefty fines from the HSE, and in more severe cases organisations can have their memberships and accreditations from industry bodies revoked, or even be banned from operating. Companies are also open to civil suits from employees, their families, or members of the public who have been affected by errors made by companies.
Key Risks to Health and Safety in Construction
There is an extensive list of health and safety legislation that must be followed on construction sites (more on that later!), but there are five key categories which make up the majority of incidents on construction sites today. Companies need to take special care when it comes to these incidents in particular:
Falls from height – responsible for 50% of fatalities on construction sites and 19% of non-fatal injuries (over double that of all industries).
Being trapped by something collapsing or overturning – responsible for 13% of fatalities.
Slips, trips or falls on the same level – responsible for 26% of non-fatal injuries.
Being struck by a moving, falling or flying object – responsible for 12% of non-fatal injuries and 11% of fatalities.
Equipment needs to be tested and analysed to ensure it is as safe as it can be and passes all safety assessments. All equipment should work to minimise risk to workers and to do this in the best way possible. Equipment should also be maintained regularly, and all equipment that needs it should have strict maintenance processes and schedules to ensure that safety law is followed and the risk of injury is as low as it can be.
As well as having the right equipment to carry out the job required of them workers must be able to recognise hazards on-site. Health and safety inductions for all staff should be comprehensive and carried out by a qualified and competent health and safety specialist. Workers should also be upskilled on their health and safety knowledge at any given opportunity – not only does this benefit individuals and provide them with job satisfaction, but it also means that issues are likely to be picked up considerably faster, allowing site owners and managers to rectify them before they cause an incident.
Creating a Consistent Strategy for Health and Safety in Construction
Comprehensive health and safety doesn’t just happen overnight. It requires a complete strategy based on relevant legislation and a safety culture that puts workers and their health first. Risk assessments and method statements are required to understand how to build safe systems on each unique site. The legislative requirements of different sites and projects will impact the overall health and safety strategy that is implemented, and shortcuts cannot be taken in this area.
Key Rules and Regulations in the Construction Industry
There are hundreds of different pieces of legislation that go into health and safety in construction, which is why making a safety plan can be a complex task! These are some of the most important pieces of legislation that anyone working on or with a construction company should be aware of:
The Health and Safety at Work Etc Act– the Health and Safety at Work Act is not a specific set of regulations, but it is a piece of legislation that covers many other specific health and safety regulations and is how those regulations are enforced in law.
The Health & Safety (First Aid) Regulations – these regulations apply to every workplace in the country. However, because the construction sector is a higher-risk environment, there are additional first-aid requirements in place.
The Manual Handling Operations Regulations – these regulations cover the processes required for safe lifting and carrying at work, something that is key for almost every construction site!
The Health & Safety Signs and Signals Regulations – signs and signals to warn construction workers of different hazards are standardised in the UK so that everyone clearly understands the safety measures that must be taken in different areas of a site.
The Management of Health & Safety at Work Regulations – this is a key set of regulations for employers. This set of regulations applies to every workplace and requires risk assessments to be carried out and for those risks to be managed and mitigated wherever possible.
The Control of Substances Hazardous to Health Regulations – also known as COSHH, this is not an exhaustive piece of legislation, but many harmful materials have rules on how they should be handled, and they are laid out in these regulations.
The Working at Height Regulations – As we’ve discussed, working at height is one of the riskiest parts of work on a construction site. The Working at Height Regulations are intended to minimise the risks associated with working at height wherever possible and need to be followed strictly by all construction workers and employers.
The Supply of Machinery (Safety) Regulations – UK manufacturers are required to comply with this piece of health and safety legislation, and to have their machinery inspected, if necessary. At Salamander Fabrications, these regulations are something we work in full compliance with. This is particularly important when supplying to the construction industry, something we have extensive experience with.
Metalwork and sheet metal fabrication are industries that have been around in some form or another for hundreds of years! Modern sheet metal fabrication involves a range of metal fabrication techniques and can use many different types of sheet metal. In fact, it’s one of the most versatile production processes on the market today.
Because of how versatile the processes and techniques associated with sheet metal fabrication are it is easy to get confused! That’s why we’ve created this guide to all the basics of sheet metal fabrication, what it means, the different stages of the process and what fabrication services can be used for!
To find out more keep reading or get in touch with Salamander Fabrications! Our expert team are on hand to help with any questions you might have or to help you get started on your next sheet metal fabrication project.
What is Sheet Metal Fabrication? What does it mean?
Sheet metal fabrication can be used as quite a broad term that encompasses several different production processes. When you hear the term “sheet metal fabrication” it can be referring to one of two things:
The entire fabrication process, which features a range of different steps and processes to create metal products.
Any of the steps within the manufacturing process including cutting, punching, bending, welding, assembly, powder coating and other forms of metal fabrication.
The purpose of this type of manufacturing is to produce a wide range of different parts for use in a wide range of industries. To assemble these components both small and large, techniques like welding are often used to create strong bonds and ensure that they remain intact during their lifetime.
Sheet Metal Fabrication Uses
One of the biggest advantages of sheet metal fabrication is the sheer number of products and parts that can be created! While there are some restrictions on what can be done the vast majority of the designs we receive can be created using sheet metal fabrication processes!
As a precision sheet metal fabrication company we work with companies in hundreds of different sectors including transportation (automotive and aerospace), construction, health and safety, food processing, science and technology, consumer, retail and leisure, to name just a few!
Custom sheet metal fabrication can be used to produce products which require mass production and high volume, but also incredibly technical, precise, and complex metal products which makes sheet metal services incredibly versatile. The high level of precision combined with the high level of efficiency makes sheet metal one of the most diverse and popular methods of production for many organisations and suppliers.
Sheet Metal Fabrication Techniques – the Stages of Production
Sheet metal fabrication services can be easily tailored to the needs of whatever project it is we’re working on.
As we’ve discussed, there are several different steps involved in the steel metal fabrication process, which helps fabricators to create a wide variety of different objects, from bespoke screws, hinges and components to larger structures like sheet metal enclosures and other custom sheet metal parts, as well as meeting the design specifications for thousands of different products.
Some projects will only require the input of metal fabricators for one or two stages of the process, while others will require end-to-end production, from design to delivery.
Designing
The design stage is the first step in any sheet metal fabrication project. Starting with a comprehensive design process helps to set any project up for success. Concept design for metal components is usually done using digital design software like CAD design. This is an area we specialise in at Salamander Fabrications, and we have a wealth of industry experience to draw on when it comes to creating quality bespoke designs.
CAD designs can show the shape, size, colour, and dimensions of a finished product in both 2D and 3D formats, taking many careful design considerations into account. However, CAD engineering design also contains a wide range of technical data and requirements which are compatible with advanced manufacturing solutions and machinery. This means that when designs are approved, they can be instantly input to CNC laser cutters and punching/bending machines, speeding up the production process significantly.
In addition, bespoke design briefs like these contain information on the sheet metal materials to be used (mild steel, aluminium alloys, yellow metals etc.), as well as the processes needed to create the product, tolerances and dimensions of each of the product parts, and any assembly services required.
The success of the entire project rests on the quality of the design so it’s incredibly important to get it right – from design to prototyping – before moving on to manufacturing services.
Laser Cutting and Metal Punching
Laser cutting and punching are the processes that allow our team of fabricators to turn metal sheets into templates that can then be bent, pressed and welded into their final form. We work with a variety of materials, including mild steel, stainless steel, aluminium sheets and some yellow metals. We can also work with a wide range of metal thicknesses, in line with the designs of your product.
Laser cutting uses fibre or CO2 lasers to cut out shapes or cut holes, forms and spaces in metal sheets. This sets out the key forms and shapes of the pieces of metal and does it quickly, cleanly and smoothly.
A metal punch is another one of the metal fabrication tools at our disposal. It works similarly to laser cutting in many ways but uses mechanical means to get the job done rather than using a laser.
Using both laser cutting and punching technologies in-house allows us to carry out every job in the most efficient way possible, which helps us maintain a competitive price.
Bending and Press Brakes
Once sheet metal has been cut it is then bent and folded to create 3D structures from 2D sheets of metal.
CNC press brake machines are used to accurately bend and shape the metal into the right dimensions before they are welded together.
For smaller, more precise elements of metal fabrication, spot welding can be used to create multi-piece metal structures.
Assembly
The assembly stage of a sheet metal fabrication project is often one of the most complex steps and needs an experienced assembly department to ensure the safety of products with electronic components. As well as the installation of electrical components, the assembly stage also includes:
Quality testing
Electrical safety testing
Secure packaging
Delivery to the customer
Complex assembly should only ever be carried out by experts with the skills to install electromechanical parts and ensure the longevity of these products once they leave the metal fabrication plant.
Powder Coating
Powder coating is one of the last steps in the process of sheet metal fabrication. Not all metal structures need powder coating but it can be used to help prevent wear or corrosion of steel and aluminium, particularly if structures are going to be used in outdoor environments or cold and damp environments.
During the powder coating process, an electrostatic powder is applied to the metal pieces and is then heat cured. The result is a hard-wearing and waterproof coating to the metal which comes in a range of surface finishes.
Powder coating can have a matte finish or gloss finish and comes in almost any colour you could choose, which also makes it perfect for “branding up” structures to be used in stores and offices, or for promotional materials.
The Sheet Metal Fabrication Process with Salamander Fabrications
At Salamander Fabrications our experienced team are professional sheet metal fabricators, passionate about exceptional quality standards and great British manufacturing.
We’re experts in the combination of quality alongside economical production methods for our customers whether we’re carrying out large-scale production, batch production jobs or bespoke, technical projects. We know how effective steel, aluminium and other sheet metals can be when it comes to creating a durable product that is fit for purpose every time.
To learn more about sheet metal fabrication and how our dedicated operations team can help bring your products to life, please don’t hesitate to get in touch! Our friendly team are always on hand to help kickstart new projects and get you the products you need.
With over 50 years’ experience in sheet metal fabrication, Salamander is always looking out for new opportunities and greater expertise. As a result, we’re extremely excited to announce the appointment of expert-rail-consultant Phil Brown, who is working to bolster our stance within the transport sector and secure large-scale projects. Here, we introduce Phil and discuss his thoughts on joining the Salamander family.
Who is our latest appointment?
Our new consultant, Phil Brown is a highly qualified sales director with more than 30 years’ experience in the UK rail and automotive industries. Having worked with original equipment manufacturers (OEMs), Tier 1 companies, SMEs and trade associations, Phil has held senior positions and helped various businesses achieve their targets.
With his extensive knowledge and expertise, Phil is poised to create new client relationships and secure business opportunities for Salamander within the rail industry.
What are our plans for the future?
After being awarded EN15085-2 rail certification, we are now able to bid for bigger and better contracts within the rail industry, providing new parts for vehicles throughout the UK and Europe. We have brought Phil onboard to open doors to these high-profile projects, and steer us in the right direction.
Phil is passionate about SME and joined us on a consultancy basis because he believed we had “an ambitious workforce that has embraced innovative ways in how to provide an even better customer experience – you only have to look at its range of automated technology to understand that fact. Rail will be a huge growth area for the firm and I’m looking forward to educating the team further so employees can build on their skillset and knowledge.”
Having already collaborated on a tender for an exciting contract that we’ll hopefully hear about in early 2021, we have no doubt that Phil will continue to help us achieve our goals within the transport industry.
If you have a sheet metal project, or would like to learn more about our capabilities for the rail industry and other sectors, get in touch and speak to an expert.
Salamander has always prided itself on being adaptable and flexible, frequently working with new clients in an array of sectors. Naturally, this has made our 50 years’ experience in sheet metal fabrication all the more valuable as we have constantly challenged ourselves.
Recently, we’ve worked behind the scenes to produce a brand-new brochure, fully highlighting our services, sectors and plans for the future. It’s been a long-time in the making, but as all business-leaders will know, sometimes you have to put yourself second to continue producing high-quality results for your clients.
Now, we’re delighted to offer our new brochure as an accessible download for everyone.
Expanding our services
Over the last 12 months, we’ve invested over £1.3 million in automated technologies to increase our efficiency and enhance our services. While our brochure contains more detailed information around our wider capabilities, many of our services have directly and quickly benefitted from these new, state-of-the-art technologies.
Our two Bystronic laser cutters are able to run 24/7 and connect to our automated warehouse in order to work around the clock to meet tight deadlines and meet high demand for projects requiring laser cutting. Our advanced software and technology allows us to rapidly produce designs which can be manufactured efficiently and accurately.
Project management
We can offer a truly end-to-end service for our customers with direct contact from the design stage all the way to after sales. Our investment in our internal processes and upskilling staff allows us to continuously improve our customer communications and project management operations.
Getting on track for the rail sector
We’re proud to work with a wide selection of industries, including science and medical, transport, and security and construction, and more. Now, having achieved EN 15085-2 certification, Salamander is working hard to become a leading manufacturer for the rail sector, recently joining Rail Forum Midlands and appointing industry-expert Phil Brown as a dedicated consultant.
The rail sector is an integral part of British history and demands the very best from its manufacturers. We work closely with contractors and frequently discuss projects with the biggest buyers in the industry to fully understand the critical requirements of the parts we produce.
We’re excited to continue building our portfolio in a range of sectors and diversifying our offering to meet ever-changing demands. With our new brochure, we hope to better demonstrate our versatility, innovative culture and drive new and exciting opportunities. Download our brochure and learn more about how Salamander Fabrications could help your business and project.
We know our manufacturing is just as important as our people. That’s why we want you to get to know them a little better.
So, next up is design engineer, Anthony Hunter…
Summarise your role at Salamander in just one paragraph
I design and process our customers’ information so they eventually receive a product that meets all their requirements. I also provide all the necessary detail to the shopfloor to allow them to manufacture in a quick and efficient way.
What’s your absolute favourite part of the job?
Not knowing which job is going to land on my desk next.
Share an interesting fact about you that we might not know
In my younger days, I used to race Karts with the likes of Jenson Button (F1) and Dan Wheldon (Indy Car).
Which one word would your Salamander colleagues use to describe you?
Efficient.
And the word you think best describes Salamander?
Ambitious.
Why do you personally think Salamander stands out from its competitors?
Its investment in people, machinery and systems.
The phone rings and it’s your dream client… who would it be?
I would say something motorsport-related — the Mercedes F1 Racing Team.
What’s the most personally satisfying moment in your Salamander career so far?
Building long-term relationships with new and existing customers.
What did you want to be when you were growing up?
An architect.
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
Overcoming the various obstacles presented by Covid-19 and Brexit.
We have become one of 21 manufacturers in the UK to be listed on the European Committee for Welding of Railway Vehicles following EN15085 certification. We are extremely proud and excited by this achievement and the opportunities it presents. Here, we discuss our latest certification, and what it means for Salamander moving forward.
What does this new certification do for Salamander and our clients?
By achieving CL2 standard, we have joined leading firms to further bolster our rail product offering. With this standard, and a new recruit in the form of responsible welding coordinator Mohammed Zubair, Salamander can now provide new parts for railway vehicles throughout the UK and Europe and can also be considered for high-profile projects, such as OEM’s Rosco’s, TOC’s and Network Rail, which only use certified companies.
The certification means that any new or existing clients can appoint us with confidence – knowing that we meet all of the relevant industry standards needed to manufacture safe and secure components for rail.
How we gained certification
The certification audit was 18 months in the making. Originally, it was set to take place in April 2020, but the unforeseen COVID-19 outbreak meant that it had to be postponed. Eventually, TUV Germany, with the assistance of Zoe Gallagher, a respected and experienced independent consultant, conducted an audit to see if we were up to the standard and concluded that “Salamander has significantly adapted and adopted the intense requirements to be certified. The team should be very proud of everything it has achieved.”
We were delighted by Zoe’s comments given the work we’d put into preparing for the audit, especially when she added: “I found the organisation’s systems to be some of the best I’ve ever worked with. It was refreshing to see everything linked up – from the client’s initial enquiry to the final project.”
What we think
While we have already supplied a significant number of component parts to one of the UK’s leading railway engineering companies, achieving the CL2 standard now opens up new opportunities for Salamander Fabrications. Having recently invested significantly in the latest automated technology which increases capacity and efficiencies, Michael Haskell, our managing director, says: “This should further evidence that we’re not afraid to make large investments in how we vastly expand our high-quality offering for customers. We’re incredibly proud to have achieved EN15085 status and be part of a select European database that allows access to some of the most globally recognised rail projects. This certification plays a pivotal role in our company growth plans and commitment to developing our workforce’s expertise.” Salamander Fabrications has more than 50 years’ experience in the sheet metal industry with an existing portfolio in the rail sector. To find out more, or to see the work we have done, get in touch.
It’s Liam’s turn in the spotlight this month – here, our apprentice sheet metal fabricator discusses his favourite part of the job, his dream client and what he wanted to be when he grew up…
Summarise your role at Salamander in just one paragraph
My role centres around developing my skills as a sheet metal fabricator. Day-to-day activities include welding, fabricating, collaborating with colleagues to gain experience and knowledge, as well as working safely and systematically in producing high-quality products for our customers.
What’s your absolute favourite part of the job?
I am really enjoying furthering my skillset, ensuring our customers receive a premium service, and presenting work to my teammates that I am proud of.
Share an interesting fact about you that we might not know
I spend a lot of time my free-time working on motorbikes with my dad — learning how to fix engines and making a bike look like it has come straight from a showroom!
Which one word would your Salamander colleagues use to describe you?
Determined.
And the word you think best describes Salamander?
Magnificent.
Why do you personally think Salamander stands out from its competitors?
The drive and determination of its workforce to complete each task to a high standard and the communication between colleagues to allow us to do so. Also, the advanced technology — including lasers and robot welders — which helps us to produce near-perfect results for our customers.
The phone rings and it’s your dream client… who would it be?
Triumph Motorcycles — I would love to help build and weld such an iconic motorbike.
What’s the most personally satisfying moment in your Salamander career so far?
Seeing my TIG welding skills improve to the point where my work is even and consistent.
What did you want to be when you were growing up?
I always wanted to be a person who made things.
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
Fighting the demands of Covid-19 while continuing to work safely and retain happy customers.
We’re pleased to announce we’re now members of the representative body of one of the largest group of rail companies in the world.
Rail Forum Midlands (RFM) was established in 1993 to support and grow the rail sector. It represents more than 200 rail supply businesses across the UK that contribute billions to the economy.
Salamander is excited to be able to take advantage of the benefits of joining, which include unrivalled networking opportunities, the chance to exhibit collaboratively at trade events and attendance at various conferencing and new business commitments throughout the year. But we’re particularly thrilled to benefit from closer links with groups including the Railway Industry Association (RIA), the Rail Freight Group (RFG) and the Civil Engineering Contractors Association (CECA).
We’re no stranger to the rail sector, having collaborated on numerous projects that have seen us fabricate, assemble and integrate products and components to ensure travelling passengers’ needs are met and their safety prioritised. However, we’re looking forward to working more closely within the Rail Sector supply chain.
Salamander is taking part in this year’s RVE Meet the Buyer event (now to be held online) in November. This industry-leading event gives suppliers the chance to pitch products and services to organisations from across the industry.
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