Facilities and Services

Tool-room

Our Tool-room uses the latest machining equipment and software to design and develop new products; after which they manufacture high-quality tools, dies, clipping tools, injection moulds and machining fixtures/jigs to be used for the manufacture of products. Damaged or worn tools, dies, clipping tools and machining fixtures/jigs are also repaired and refurbished in the Tool-room.

Solidworks (3D software)	Design and edit 3D models used for manufacturing of tools, dies and jigs.
Mastercam (3D software)	Design and edit 3D models used for manufacturing of tools, dies and jigs.
Deckel Maho 70V	Manufacture and repair tools, dies and jigs.
Tongtai Machining Centre	Manufacture and repair tools, dies and jigs.
Spark Eroder	Create complex shapes tools, dies and jigs.
Surface grinder	Prepare tools, dies and jigs before manufacture or repair.
Lathes and milling machines	Manufacture and repair tools, dies and jigs.

 

Tool-room CNC machines

State-of-the-art Deckel Maho machine

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Foundry

Our Foundry has the capacity to produce 125 tons of material in the form of billets and castings each month. All material is analysed using our Spectrometers before casting to ensure conformity to specification.

5 Gas crucible furnaces	Manufacture castings in both sand and gravity dies.
2 Horizontal Conti-caster furnaces	Continuously manufacture billets of brass and special copper alloys.
2 Induction furnaces	Furnace 1: 500kg, 250Kw Furnace 2: 1800kg, 500Kw
1 Vertical Conti-caster furnace	Manufacture special alloy rod (copper base).
1 Aluminium pressure die caster (400T)
Sand mould manufacturing plant	Manufacture sand moulds for use by the Foundry to cast sand mould products.
2 Spectrometers	Analyse the chemical composition of brass and aluminium to ensure conformity.

 

Foundry casting

Crucible casting process

Continuous casting process [video]

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Extrusion and Reeling

Cast billets from the Foundry are extruded into various shapes (round, square, hex, sections) and sizes ranging from 15mm to 90mm. The rods (round extrusions only) are then reeled to straighten any curves in the rods.

500 Ton Extrusion Press	Extrusion of rod up to 30mm diameter.
1600 Ton Extrusion Press	Extrusion of rod up to 90mm diameter.
Reeling machine	Reel material into straight rods up to 100mm diameter.

 

Extrusion machine

 

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Forging, saws and clipping

The saws cut material to the correct length for forging (or machining). The cut billets are formed into various shapes and sizes using the forging presses; clipping presses then remove any excess material.

5 Band saws	Cut material to length.
2 CNC saws	Cut material to length.
23 Forging presses (90-530 ton)	Manufacture forgings (hot-forging and cold-forging) in various shapes/sizes.

 

Forge-shop with 23 forging presses

Saw cutting process

Saw cutting process [video]

Forging process

Forging process [video]

Clipping process

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Finishing

We offer a range of finishing options (including multiple finishing) depending on the product application and customer requirements. 

Fettling/linishing	Excess material is removed after forging or casting.
Acid dipping	Dipped in acid for a smooth, clean finish.
Shot-blasting	Fine satin shot-blasted finish.
Polishing	Polished to a shine.
Electro-plating	Nickel, tin and silver plating.
Hot dip galvanising	A zinc coating to protect iron, steel or aluminium from corrosion.
Powder coating	Tough paint covering to protect products.
Plating plant	Tin and nickel plating .

 

Shot-blasted clamps

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Machining

Our Machine-shop precisely machines each product to specification. All products are inspected to ensure conformity.

16 CNC Lathes	Machining of products.
10 CNC Machining Centres	Machining of products.
3 Special purpose machines	Machining of products.
Drilling and tapping	Drilling holes and tapping threads.

 

CNC Lathes and CNC Machining Centres

State-of-the-art 5-Axis Machines

CNC Machining process [video]

 

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Plastic Injection moulding

Our plastic injection plant manufactures plastic parts from all injection-mouldable plastics.

Demag Injection Moulding Machines	175 ton, 240 ton, 420 ton injection moulding machines.
CLF Injection Moulding Machine	125 ton injection moulding machines.
DR Boy	30 ton and 50 ton injection moulding machines.

 

Plasting injection moulding machines

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Assembly

We are capable of assembling thousands of simple and complex parts per month at in our Assembly bay.

 

Assembly process [video]

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