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Zintec hanging brackets for track light fittings

Thursday, May 10th, 2012

Zintec hanging brackets for track light fittings

Support brackets manufactured from Zintec mild steel ready for hanging light fittings

Not all lighting installations are permanent. A lighting scheme is often used for only a short length of time and then needs to be removed or reconfigured to suit a new layout. This can be the case where an exhibition stand needs lighting for just a few days and then needs to be quickly removed or perhaps in a museum exhibition where specific points of light are needed for just a few weeks. Lighting is often changed in retail outlets where different displays are created as the seasons change.

One solution for this requirement for flexibility is to install lighting tracks where the individual light fittings can be moved along the track to any given point and angled to highlight any object. Hanging brackets such as those shown here can be used to support the runs of tracking from a ceiling of frame work structure simply and cheaply. These particular brackets are manufactured from Zintec and can be powder coated to suit any installation colour. The hoop has been formed on a CNC press brake and the joint has been tack welded shut to maintain its shape and increase its strength.

This type of bracket work is typical of the sheet metal work that we are often called upon to manufacture and help design. Perhaps you have an idea for a supporting bracket or angle and need a little help to finalise your design or advice on materials, please give us a call and we will be happy to discuss it with you.

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Professional audio equipment chassis

Monday, April 16th, 2012

Audio chassis assembly

Professional audio equipment chassis

We are really excited to be able to help our customer develop a new range of high end hifi and studio audio equipment. The entire range has been developed over the last 2 years and is growing thanks in a small part to the flexibility of manufacturing with sheet metal. We have been able to offer advice on the most efficient design for manufacturing with sheet metal and swap data in 2D and 3D. All the chassis parts, front panels and covers have been produced in relatively small numbers so far but when the quantities grow we will easily be able to expand our production with the same CNC driven manufacturing equipment. This flexibility has proven invaluable to several of our customers when prototyping new product ranges and then running in larger volumes.

Audio front panels

If you have a new project that needs sheet metal components and you want some advice on the best manufacturing option or a design that needs refining to cut costs, please give us a call or e-mail a drawing for review.

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LED display boards for car parking

Monday, March 12th, 2012

LED display boards with mild steel sheet metal housings

Sheet metal fabricated LED display boards for car parking signage

Sheet metal work can be so versatile with today’s powerful CNC manufacturing equipment. We have produced a series of sheet metal mild steel housings, covers and LED chassis plates in various sizes for LED signs. These particular signs have been used to indicate empty spaces in multi-storey car parks in a range of countries in Europe and further afield. Once a basic design format has been established and proven different lengths and widths of housing and associated parts can easily be manufactured from existing developed blank data within our Radan software. This offers the advantage of mixing some standard units and special sizes together in manufacturing without stopping the flow of work and maintaining the lowest cost price per part.

With any bespoke manufacturing project work the emphasis has to be on flexibility and for us this means the ability to change from one sheet metal part to another with little machine setting up time in between. With the design of the Trumpf CNC punch press single head design system we can change from job to job in minutes enabling us to punch out sheet metal prototypes within the mix of standard production work without any appreciable delay.

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LED display boards with sheet metal enclosures

Monday, January 23rd, 2012

Sheet metal LED display board housing

When manufacturing bespoke LED display boards where the length, width, height and LED PCB layouts can change from project to project CNC punched sheet metal work is the way to go. With the ability to take previous CNC programs and adapt them to suit using parametric programming techniques new sheet metal fabrication projects can be created quickly with the knowledge that past cut sizes which have been proven to be correct can be retained as the basis for each new project. Our customer often has little time to get the initial order, write the software, design the LED PCBs and the mechanical parts for their LED display projects so knowing that the sheet metal work is sorted easily is a great help. Our relationship with the customer is such that the detailed drawings are given to us as DXF files with no dimensions and we are left to work from previous proven examples and take what data we need from the DXF. This saves our customer lots of time and enables us to solve our own problems using their DXF for sizes.

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Sheet metal inserts, bushes and studs

Monday, January 16th, 2012

Sheet metal inserts - Hank bushes

Using screws and nuts to fasten sheet metal components together has been a production method used for centuries. To speed up the assembly process or to fix a nut in an awkward or blind place is where self-clinch and anchor rivet buses really come into their own. We use a Haeger bush inserter and various manual and hydraulic fly-presses to press the fixings into our sheet metal work in all sheet materials from 0.7mm thick and upwards. Single side approaches, such as tubes, can also be dealt with by using Avdell style single side bushes.

As well as standard metric and imperial thread bushes we regularly insert stand-offs, studs and many specialised inserts into our sheet metal work for example captive thumb screws. Have a look at our Haeger bush inserter webpage for more information on this plant and links to more detailed information on self-clinch and anchor rivet bushes. If you have an odd requirement and are not sure whether there is a sheet metal insert solution available for you give us a call and we can investigate it for you.

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