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.

Want more? Click below

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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What is it?

The TruPunch 3000 is an automated large format CNC Punch, designed for punching and profiling sheet metal from 0.5mm thick, up to 6mm thick. Materials that can be punched include, but are not limited to:

• Mild Steel
• Aluminium
• Stainless Steel
• Brass
• Copper
• Zintec
• Pre-Galvanised Steel
• Pre-Painted Steel

After a week long installation and training, the punch and sheet loader and tool grinder is now fully operational. The punch has been installed in our extension completed in January 2020, see our post on it at the time here.

As part of the CNC Punch installation, we have taken the opportunity to move our CNC milling machines into the new extension. The desire was to keep them in a cleaner part of the factory to help keep the machines running smoothly and to help workflow through the factory.

Over the coming weeks will be putting up more posts on what this new acquisition means for sheet metal CNC punching at Falcon Precision. Looking more in depth to what is achievable and how this can benefit our end customers. If you wanted to get in touch with us before then we are inviting current customers and their designers into Falcon to better understand how they can implement strong design for manufacture to cut waste and add value to their product/parts.

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

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Fibre lasers are the most efficient way for laser cutting. The laser beam is created by an active fibre and transmitted over a transport fibre to the machine cutting head. Fibre lasers are signifi­cantly smaller than CO₂ lasers and generate several times the power for the same current. A fibre cutting system is primarily suited for processing thin to thick sheet metal from steel, stainless steel, aluminium and also other non-ferrous metals (copper and brass). See our 3Kw fibre laser in action:

What are the benefits to Fiber Laser Cutting?

• Cost. Fiber laser is delivered through a laser optic cable instead of mirrors and channel used by CO2 laser cutting machine. Reducing power loss and increasing energy efficiency, lowering production costs.
• Cutting Edge. Falcon Precision are well known as a specialist in manufacturing electronics cases for many industries, including medical, industrial computers & military. This requires a high volume of thin sheet metal to be cut quickly. Our laser can cut a variety of materials with clean edges, requiring no additional deburring.
• Interchangeable beds. Our fiber laser machine has a dual interchangeable platform where materials and finished cutting sheets can be loaded/unloaded whilst the machine is still cutting. Reducing downtime.
• Maintenance. Our fibre laser requires less maintenance and downtime than a CO2 laser, saving worry and money. A CO2 laser machine requires regular and annual maintenance, including component replacements, which can cost thousands of dollars per year.
• Reflective Material. One of the major problems when using a traditional laser is in regards to reflective material. There is the chance a laser may bounce off the reflective material, which in turn will damage the equipment. Due to this, traditional lasers are not often used when cutting brass, aluminum and copper. With fiber optic lasers though, this reflective material problem is no longer an issue, which in turn allows for the cutting of these materials.

Click here to see the type of work we can offer in our showroom.

How to take advantage

One goal in designing for manufacturing is to achieve a simple solution rather than a complex one. After all, complex designs are more challenging to manage, increase the risk of errors, and generate waste in the form of materials, energy, labour, and time. Laser cutting is a suitable tool for creating components of all shapes and sizes and is one of the most efficient and cost-effective fabrication methods. Complex cuts with superior edge quality can be accomplished accurately with fibre laser cutting. Precision laser beams can create close-tolerance components quickly, cleanly, and efficiently, with minimal operator intervention.

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

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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.

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