One of the most exciting tasks of the past period was the production of a welded sheet metal construction assembled from several parts. During manufacturing had to face many challenges, and we used almost all the technologies available to us. 
We are talking about a complex, spot-welded structure made up of 5 sub-parts. Its uniqueness is revealed by quite a few clearly visible details, but there are things that remain hidden from the naked eye and can only be found in the technical documentation. Also, it remains hidden only if the construction is of high quality and the aesthetic requirements are fully met, if we do not see any parts where the continuity is not adequate or the light refraction reveals defects during the visual inspection of the final surface treatment.
1, This sheet metal part assembly is an article where the end users can directly "encounter" the upper surface of the unit, which is why the customer demands an immaculate surface quality from the manufacturer - from us. The raw material of the part is 1.5 mm DC01 steel, for the production we use 1.5 x 1500 x 3000 sheets. Every single element of the construction is built from this material quality.
2, Laser cutting is performed on our 6kW Fiber laser machine, naturally using nitrogen cutting gas. After the cutting phase, quality control colleagues check the cut flat parts. When it comes to products of special importance, we have built-in quality steps in our ERP system, which do not allow the products to be processed further without quality control.
3. After the quality control and approval of the cutouts, we perform the edge bends on the parts, per lot. As it is a metal part that is integrated as part of a feeding mechanism, the dimensional accuracy of the product is extremely important, therefore the bent dimensions must also be accurate to a tenth of a millimeter. The tolerance field generally applied to the product is +- 0.1 mm. Bending is done with R0.6 and R12 bending tools. Production is supported by technological work instructions and tooling drawings, which are the result of production preparation activities of our technologist team and our bending colleagues. These internal technical documentations are essential in the production of reoccurring parts.
4, Once the edge bending tasks are completed, the metal parts are moved onto welding, to undergo complicated corner and edge design operations. Perfect execution is supported by the welding technology and welding specification settings in the production documentation. The main part is prepared by arc welding, where avoiding thermal deformations is the most essential requirement.
5. After the welding, we make the welding areas smooth and aesthetic by grinding. High-quality welding requires little grinding. The individual parts are surface treated with galvanization and then joined by spot welding using templates. Spot welds must not be seen from one side - the visible side. We take care of this even during welding by using the appropriate tools. With grinding our colleagues create a surface of such quality that even with the application of glossy powder coating, no surface defects are noticeable.
6. After the spot welding, the powder coating process follows as the final surface treatment process, and then marking/labeling is the final step before packaging.
7. The final production technology is quite complex and unusual. It is rare that we spot weld after galvanizing and not the other way around. We do this so that during spot welding there is no corrosion on the surfaces that do not fit perfectly, and even years later, a corrosion problem, which could unfortunately occur otherwise.
We love creating such beautiful products! The complex sheet metal part construction above is a good example that it is possible not only in small series.
3. After the quality control and approval of the cutouts, we perform the edge bends on the parts, per lot. As it is a metal part that is integrated as part of a feeding mechanism, the dimensional accuracy of the product is extremely important, therefore the bent dimensions must also be accurate to a tenth of a millimeter. The tolerance field generally applied to the product is +- 0.1 mm. Bending is done with R0.6 and R12 bending tools. Production is supported by technological work instructions and tooling drawings, which are the result of production preparation activities of our technologist team and our bending colleagues. These internal technical documentations are essential in the production of reoccurring parts.4, Once the edge bending tasks are completed, the metal parts are moved onto welding, to undergo complicated corner and edge design operations. Perfect execution is supported by the welding technology and welding specification settings in the production documentation. The main part is prepared by arc welding, where avoiding thermal deformations is the most essential requirement.
5. After the welding, we make the welding areas smooth and aesthetic by grinding. High-quality welding requires little grinding. The individual parts are surface treated with galvanization and then joined by spot welding using templates. Spot welds must not be seen from one side - the visible side. We take care of this even during welding by using the appropriate tools. With grinding our colleagues create a surface of such quality that even with the application of glossy powder coating, no surface defects are noticeable.
6. After the spot welding, the powder coating process follows as the final surface treatment process, and then marking/labeling is the final step before packaging.
7. The final production technology is quite complex and unusual. It is rare that we spot weld after galvanizing and not the other way around. We do this so that during spot welding there is no corrosion on the surfaces that do not fit perfectly, and even years later, a corrosion problem, which could unfortunately occur otherwise.
We love creating such beautiful products! The complex sheet metal part construction above is a good example that it is possible not only in small series.
