Already a key manufacturer in the sheet metal sub-contract industry south of England, this latest investment will support Falcon’s expected continued growth in the coming 5 years.

What is it?

The Xpert Pro is an industry leading press brake used to fold a huge range of sheet metal jobs. In-line with Falcon’s recent machinery investments, the Xpert Pro will greatly increase both our capacity and our capabilities in this key work centre.

Taking delivery

What can it do?

High-tech bending

Whether simple or complex parts – the highest repetition accuracy is guaranteed. Dynamic crowning and patented Pressure-Reference technology ensure consistent quality.

More bending in less time

Bend faster than ever. Not only does the Xpert Pro works rapidly, but the sheet metal bender is also impressive when faced with high demands. Intelligent assistant functions and patented bending technology ensure consistently high quality – from the first to the last part of the order. 

Offline & online programming

All process steps on one touch screen: The Xpert Pro intuitively and conveniently understands your CAD files with BySoft Cell Control Bend. The intelligent software creates optimal bending processes and suggests appropriate tools for the operator to use. Keeping consistency between production runs, reducing staff training and setup times, improving our tool lifespan and ultimately keeping the machine working whilst programming is done in the background.

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Shop floor layout

Falcon Precision are committed to continuous improvement, we judge all top level decisions against this commitment. As part of this we are taking this exciting opportunity to re-do our shop floor layout, with the aim to reduce key wastes of travel and lost resources, alongside improving safety. We are fully re-building and re-wiring our welding and grinding bays, ahead of further investment there in the coming weeks, putting in additional lighting and much more.

We will be adding more updates on training and installation as the weeks progress, to keep up to date with all Falcon’s news, follow our Linkedin page here.

https://www.linkedin.com/company/falcon-precision-limited

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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.

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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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Sheet metal fabrication can seem like a specialist industry with a broad range of inside knowledge. Falcon’s success is built on having 30 years experience of working with customers and their designers to deliver quality products. We still get most of our business through word of mouth passed on by satisfied customers. This often comes directly from the designers, happy with the quality and delivery of their parts. Falcon intends to strengthen this relationship by making more more key information readily available to designers.

In the coming months designers will be able to check what radius bars we stock on our press brakes. Engineers will be able to check what our recommended tolerances are for each fabrication process. These little benefits can help reduce cost, lead time and reject counts across a product life-time. The process of uploading this content has already begun. For tips on sheet metal design, visit the latest in a series of new design pages here: https://www.falconprecision.co.uk/design-features/sheet-metal-design

We will also be uploading media to our showroom page to see how other customers are having their parts made. Whilst Falcon are known as a specialist sheet metal fabricator to the computer industry, you will see we make a lot more than that! This can be very useful for design inspiration or problem solving, as well as understanding what it is we do. Make sure you check back in a few months to see what we’ve been working on!

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

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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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1) Minimum Bend Radius

The minimum bend radius of a part must be the same as the thickness of the material being formed. We can bend parts to a variety of radii but the minimum must be the same as the thickness of the material. Consider what is required for your design; using the minimum bend radius is considered standard for the industry but a larger radius will generally give a stronger part.

      Bend Radius Example

2) Minimum Edge Distance

Keep all holes and cut-outs at least the thickness of the material away from other edges. It is possible to go under this recommendation with some materials but this is a good starting point.

     Minimum Edge Distance Example

3) Design for Punch or Laser?

This consideration is often overlooked at the design stage and is regularly just an afterthought. Punching a part will almost always be cheaper than laser cutting, however laser cutting allows more convoluted shapes and can generally cut thinner gaps than a punch. Does your part have a lot of countersunk holes? It takes less than 0.5 seconds to countersink a hole on a punch, whilst it takes 12 seconds for a pillar drill to do the same job! Try to design for punch if that is the case by changing over to a simpler design with less curves.

Counterpunch Example

4) Design for Scan Cut

Falcon Precision are known for being specialists in fabricating boxes for the computer industry. A common design feature of this type of work is a large number of rectangular cut-outs that are often used for air vents or grills. This feature is perfect for Falcon’s Bystronic Fibre Laser ‘Scan Cut’ feature, which can cut steel parts much faster than the normal pierce cut > outline cut method used most of the time. Many of Falcons customers benefit from the reduced laser time on their parts; see the video below for a display of what scan cutting can do (seconds 0>20).

Scan Cut Example

To use this feature, parts must be made from mild steel or stainless, and must be no thicker than 1.5mm.

5) Take advantage of our In-house CNC Milling

Very often computer cases have a dozen sheet metal components, yet customers commonly only interact with the front panel. Make your products stand out from the competition by having your company logo engraved on the front face, or incorporate a small recess to perfectly house that custom connector. The ‘feel’ of the product is often what makes it, so make sure your product doesn’t fall short in this area.

CNC Milled Front Panel

For more on sheet metal design at Falcon, click on the link below.

Design & Reverse Engineering

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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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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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