In our last update on the build, we showed how the new slab had been successfully laid on time. This was a key milestone in the production plan, and allowed the metalwork construction team to move on-site earlier than expected. Click here to see the post https://www.falconprecision.co.uk/news/building-extension-update

Once the construction team were on-site the extension was watertight within a week. All parts fitted first time and were finished to a high standard, testament to the quality of the work done previously. The main electrics and lighting have now been fitted and the metalwork painting has been completed.

Benefits

• All sheet metal will now be stored directly next to the main three work centres that use it. Currently only our most frequently used materials were stored next to these work centres due to a lack of space. To process other materials, pallets needed to be transported between two separate roller doors. The Bystronic fiber laser, Motorum CNC turret punch and the guillotine operations will all benefit. This reduction in down-time means that more of the operator’s time can be spent at the machine, cutting parts.
• Two additional closed off bays will be added to our sheet metal fabrication area. A welding bay and a separate grinding/polishing bay will be added alongside our current work centre. This increase in our sheet metal fabrication capabilities is a reflection of a number of successful years in this department.
• Our in-house assembly work centre will be gaining more floor space. Falcon has seen a rise in customers wanting us to pre-assemble their sheet metal computer cases. This can be to aid quality checks, reduce the shipping/storage size or to speed up assembly in their production line. This extension will allow us to take on more of this type of work, with our reputation as a specialist in sheet metal fabrication growing year on year.
• Our ‘key walkways’ will all be widened throughout the factory. All key walkways will now be wide enough for a large pallet to move easily to all work centres. These will also be clearly colour coded for health and safety considerations.

We are now in the process of moving our existing equipment around to better streamline our manufacturing procedures. A final post on the fit out will be listed here in the coming weeks.

The extension is the second major improvement to be carried out at Falcon this year, with high spec LED lighting having been fitted in February 2019. This has proven to be a popular decision with both our staff and our customers since the installation. See our post from earlier this year for more information. https://www.falconprecision.co.uk/news/led-floodlights-sheet-metal

CNC Laser cutting, CNC punching, CNC machining, welding, metal fabrication, assembly & more all under one roof. Click the link below to contact us directly.

The post Building Extension – Complete! appeared first on Falcon Precision Sheet metal work & Machining in Hampshire.

2019 has been another hugely successful year in our 30 year history of British manufacturing here in Hampshire. We would like to thank all of our staff, customers, sub-contractors and suppliers for all their continued support in this time. We plan to push on in 2020, and have a lot to look forward to in the coming year.

We will be posting a review of 2019 in time, but for now, have a wonderful Christmas and a happy new year.

The post Christmas shutdown 2019 appeared first on Falcon Precision Sheet metal work & Machining in Hampshire.

Building work on the 1,250ft² extension will commence in the coming weeks & once completed will benefit all aspect of our manufacturing capabilities. Once the extension is complete we will be using this as an opportune moment to organise the entire factory. Increasing the floor space of certain key work centres & improving the work flow helping to reduce in-efficiencies across production.

Benefits

• All sheet metal will now be stored directly next to the main three work centres that use it. Currently only our most frequently used materials were stored next to these work centres due to a lack of space. To process other materials, pallets needed to be transported between two separate roller doors. The Bystronic fiber laser, Motorum CNC turret punch and the guillotine operations will all benefit. This reduction in down-time means that more of the operator’s time can be spent at the machine, cutting parts.
• Two additional closed off bays will be added to our sheet metal fabrication area. A welding bay and a separate grinding/polishing bay will be added alongside our current work centre. This increase in our sheet metal fabrication capabilities is a reflection of a number of successful years in this department.
• Our in-house assembly work centre will be gaining more floor space. Falcon has seen a rise in customers wanting us to pre-assemble their sheet metal computer cases. This can be to aid quality checks, reduce the shipping/storage size or to speed up assembly in their production line. This extension will allow us to take on more of this type of work, with our reputation as a specialist in sheet metal fabrication growing year on year.
• Our ‘key walkways’ will all be widened throughout the factory. All key walkways will now be wide enough for a 1200 x 1200mm pallet to move easily to all work centres. These will also be clearly colour coded for health and safety considerations.
• The extra space will also facilitate the purchase of new machinery over the coming year,s to further modernise and increase production.

The extension to the factory is the second major improvement to be carried out at Falcon this year, with high spec LED lighting having been fitted in February 2019. This has proven to be a popular decision with both our staff and our customers since the installation. See our post from earlier this year for more information. https://www.falconprecision.co.uk/news/led-floodlights-sheet-metal

The extension is set to be completed early 2020 and will only minimally impact operations at Falcon as work progresses. We will be updating our site with pictures of the build over autumn/winter.

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CNC punching is the process of creating a hole or other shape in a piece of sheet metal by applying a high force through a tool and die, to shear or indent the metal. This process is repeated using a variety of custom precision made tools to make a wide range of parts. Punching is often, but not always, the most efficient way of producing sheet metal parts, though this depends on the part geometry and materials used.

The abbreviation CNC stands for Computer Numerical Control. This means that the machine is being controlled by a program (typically G-code), and not an operator. As well as having a CNC punch, Falcon also has a CNC fibre laser and CNC milling machines.

What materials can be CNC punched?

Falcon Precision can punch aluminium, steel, stainless steel, brass, copper and many others. Typically, the maximum thickness we like to punch is 3mm. Whilst we can punch thicker than this, it can dramatically reduce the life span of the tooling used.

CNC punching or laser cutting?

Both manufacturing techniques have their own strengths and weaknesses, and the process we use for your parts will depend on a variety of factors.

CNC punching strengths:

CNC punching diagram

– Generally faster run times – suits larger volumes. Up to 500 punch strokes per minute!

– More economical to produce simple forms. E.g. countersinks, louvres, dimples, thread forming, dunces, bridges, symbols, ribs, locking tabs – the list is endless!

– Can create entire parts in a single punch with custom tooling.

– Cluster tools can be used to punch large grid patterns, creating multiple holes/slots in a single punch stroke.

Laser cutting strengths:

– The space between parts on a sheet is smaller, giving a more economical sheet utilisation which can result in cheaper parts.

– Can cut a wider range of material thicknesses.

– Faster set-up times to suit smaller volumes

– Can laser etch serial numbers, product codes or revision statuses into components for trace ability.

At Falcon we believe it is essential to have both processes to offer a complete manufacturing service to customers.

Tips for CNC punching

– Hole diameters or rectangular slots should be the same gauge as the material thickness.

– Distance between holes/slots/edges should be the same as the material thickness, however we can go smaller in some circumstances if required.

– Some features are not economical to produce on a CNC punch such as convoluted curves. If your part doesn’t have any aesthetic requirements, make sure it uses straight lines and edges in its geometry so it is suitable for CNC punching.

– It can take less than 0.5 seconds to countersink a hole on a CNC punch turret compared to roughly 10-15 seconds for an operator to manually enter one on a pillar drill. To benefit from these cost

CNC punch turret

savings, make sure the rest of your part is suitable for CNC punching.

– Cluster tools can punch a number of holes in a grid at the same time, drastically reducing run times. This can be used very effectively for ventilation grilles or LED panels.

– As a CNC punch typically takes longer to set up compared to a laser cutter, consider increasing your order volumes to reduce the unit price. This will also reduce the amount of distortion in the part.

– Punch forming can produce some useful features very economically. Louvres for air vents, dimples for locating positions, bridges for slide rails or back stops can all be produced in a matter of seconds.

– If your part is smaller than 88.9mm in diameter (3.5″), we may be able to punch it in one punch stroke with custom tooling. If you are buying parts in their hundreds this is an often underused technique to help economise, however it may not be perfectly flat.

– Some customers have worked with Falcon to help create a ‘nest’ of their parts, similar to how a model of a plane would come in a box. The customer benefits from having a economical collection of parts which they can ‘break-out’ and use as required. This also works with laser cutting.

For more tips on sheet metal design, visit our latest in a series of new design pages here:

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1. Reduced lead times

This is the number one reason why companies stick with UK manufacturing, consistently low lead times. We regularly have customers needing a rush job due to an unexpectedly long lead time from another country. Our customers are regularly quoted 8-14 weeks, often coming out more, whilst our lead time is just four weeks. We know of customers who have missed delivery deadlines due to receipt of late parts and have then had to air freight the parts despite only quoting for sea-freight. These types of situations can quickly add on tens of thousands, very often as a hidden cost that shows up when it’s too late.

2. The ‘green’ option

As much as has been written about UK manufacturing in recent years, more has been written about human impact on the environment. It is not just the shipping of your products that have an impact on the environment, it is the way in which those parts are made. There are numerous studies which show how product/material recycling, packaging and processing is more environmentally efficient than having parts made in a number of countries abroad.

3. Tighter control over quality

We regularly welcome designers, buyers and quality control inspectors into Falcon to go through our processes. For the majority of our customers this can be done in less than two hours and is well worth it. In January 2019 we shipped over 50,000 parts with a reject rate of less than 0.3%.

4. Smaller MOQ

More and more companies are moving over to a ‘leaner’ production structure and understand the hidden costs and drawbacks of stock. Due to our low MOQ set-up, our customers are able to react quickly to demands and opportunities as they arise, very often winning them more business.

5. No hidden fees

There are no import fees, taxes or air-freight charges when you buy from us. Over 99% of our parts are either delivered by one of our vehicles, or are shipped for overnight delivery.

To see how UK sheet metal manufacturing can help your company’s requirements, click the link below to contact us directly.

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Falcon currently offer 3 work-shifts to our production employees, a day shift, a night shift and an early shift to cover the early hours of the morning. The night shift is set up to run the ‘key’ manufacturing cells like the fibre laser, CNC punch and CNC folding. Their work brief is to target the long running, larger orders where the production workflow has been tried and tested. This allows the early shift and the day shift to concentrate on the new jobs or rush jobs to hit a customers deadline. This system has proven a hit with many of our customers, but equally importantly it also benefits our staff who can work on a shift pattern that suits their lifestyle.

Bystronic Laser

Fast reaction times

24 hour production allows Falcon to react quickly to customers needs. Our current lead time is just 4 weeks, however we regularly hit tighter deadlines when it is required. It allows us to design a part for a customer during the day, then have a prototype or pre-production worked on over night ready for inspection or testing at the earliest opportunity.

To see how Hampshire’s leading sheet metal manufacturing company can help your requirements, click the link below to contact us directly.

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Datron M35

Falcon’s high speed 3-axis Datron M35 was first bought in 2004 and has since gone through a number of upgrades to keep pace with customer demand. The recent upgrade includes a brand new 60,000rpm 2kw digital spindle and a new water cooling system. This enables the operator to remove more material per cut, decreasing machining time and cost to the customer. The new water cooling system keeps the spindle from overheating, improving accuracy and reducing maintenance downtime.

The Datron M35 is perfect for sheet metal machining, allowing customers to mill pockets, chamfer edges or engrave text onto thin sheet metal. The high speed of the spindle means the cutter leaves a high quality surface finish, making it ideal for engraving front panels, modifying plastic enclosures or machining bespoke heat sinks.

Dugard Eagle 760

The Dugard Eagle 760 is our heavier duty 3-axis mill. Designed for taking heavier cuts, it is used for machining small to medium sized aluminium and steel billets. We manufacture high quality custom enclosures, precision brackets, large heat sinks and can modify cast boxes.

By having on site CNC machining capabilities, Falcon can react to orders fast as a one-stop service for customers. This means we can modify sheet metal parts without having to fit in with a sub-contractors work schedule. Other customers benefit from us making sure that their sheet metal lid fits perfectly with their machined enclosure. Falcon have been manufacturing sheet metal components for 30 years and have been CNC machining for 15 years. Few companies on the south coast can boast this level of experience and expertise. And with our customers returning year after year, we may see further investment in this area soon.

Get in contact with us using the button below to see why our customers return year after year.

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Falcon Precision have recently completed our successful transition to the new ISO 9001:2015 standards.

ISO 9001 is an internationally recognised standard that specifies requirements for a high level quality management system (QMS).

The standard is based on a number of principles applicable to any successful business such as customer focus, leadership, risk management and continual improvement. The benefits of this QMS are experienced mutually by both Falcon and it’s customers:

• Cost reductions – The methods in the ISO 9001 standard enables Falcon to streamline the sheet metal fabrication process, without affecting product or service quality, therefore reducing costs.

• Productivity improvements – By following best practice, ISO 9001 certification ensures all Falcon employees understand their roles within the organisation, reducing margin for error.

• Customer loyalty – ISO 9001 certification enables Falcon to continuously meet the needs of our customer, increasing customer satisfaction.

We are always aiming to improve all procedures and standards of our business at Falcon Precision. This ISO 9001:2015 certification will help guide decisions that will benefit ourselves as well as our large customer base.

Click here to view our ISO9001:2015 Certificate

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