Precision Engineering Components Solutions
We craft complex parts and assemblies that require tight tolerances and exact specifications to achieve superior performance and quality.
Sheet Metal Fabrication
Sheet metal fabrication refers to the processing of metal sheets and tubes into intermediate metal products through various types of processes such as cutting, punching, bending, and welding. The fabricated sheet metal that we produce undergo more than one of these processes using various CNC machineries to reach the desired design, shape and form in the level of precision required by our clients.
Fabricated sheet metal may further undergo further finishing treatment such as grinding, buffing, sand-blasting or glass-blasting, surface conversion, anodising, plating, electropolishing, ultrasonic cleaning, painting, laser marking, powder coating and silk screening, if required by our clients. We do not perform these finishing treatments as they are only required by selected clients and for selected fabricated sheet metal that we produce. Thus, we outsource these finishing treatments to third party subcontractors. Where fabricated sheet metal require specialised processes such as metal casting or high tonnage stamping, such processes are also outsourced to third party subcontractors.
Once completed, the sheet metal components are either delivered to our clients or used as intermediate parts for our assembly of equipment and systems. We fabricate intermediate metal components such as industrial machinery components, enclosures and panels from metal sheets for our clients who are primarily manufacturers of semiconductor, telecommunications products and automotive vehicles.
The Processes
The processes that we perform for sheet metal fabrication include:
Cutting involves the use of fibre laser cutting machine and CNC milling machines to remove excess metal from the metal sheets and tubes to create metal components according to the specifications of its design.
Fibre laser cutting is a fast and efficient thermal cutting process that involves the use of a laser beam to cut the desired shapes into the metal sheet or to cut the metal sheet to the required shapes. When the laser beam is focused onto the metal sheet, the light energy is absorbed and converted to heat energy which causes the metal sheet to heat up and melt.
Our CNC laser cutting machines are able to cut metal sheets of up to 18 mm in thickness and metal tubes of up to 5 mm in thickness.
Bending is a process using a CNC press brake machine that applies force on a sheet of metal, causing it to bend at an angle to form the desired shape. The metal sheet is placed between a punch on the top and a die on the bottom and the machine is programmed to press the punch against the metal sheet into the die, exerting the required amount of force to bend the metal sheet to its desired angle. The CNC press brake machines we utilise enable us to bend the metal sheets to achieve a variety of bends at tight tolerances. The CNC programme also enables us to create unique bend radius profiles based on our clients’ requirements.
Welding is a process that joins 2 or more separate pieces of metal. The process involves fusing separate metal pieces and at times adding a filler to form a joint. We are capable of performing various types of welding, namely metal inert gas (“MIG”) welding, tungsten inert gas (“TIG”) welding, spot welding and laser welding. We provide different types of welding in order to cater to various product specifications.
MIG welding is a form of gas metal arc welding, which uses heat from an electric arc formed between a consumable metal electrode (also known as a filler) and sheet metal components. An inert gas is used as a shielding gas that protects the joint from contamination. MIG welding has a continuous feed of the consumable metal electrode resulting in a faster welding process and is suitable for welding larger or thicker materials.
TIG welding is a form of welding that produces a weld using a non-consumable tungsten electrode. An electric arc formed between the tungsten electrode and the metal pieces melts the metal and forms the joint. An inert gas is used as a shielding gas that protects the joint from contamination. TIG welding requires more skill to achieve proper precision. This form of welding is usually used for welding thinner-gauge materials. TIG welding also results in a better post-welding surface and less post-welding works are needed.
Spot welding is a form of resistance welding whereby 2 or more metal sheets are welded together without the use of a filler. The metal sheets are clamped between 2 electrodes that will convey an electrical current through the metal sheets. The heat from the electrical current causes the metal sheets to melt at the point of contact. Pressure is maintained after the electrical current is removed in order to join the 2 metal sheets as the molten metal cools and solidifies. Spot welding is usually used for producing smaller welds and joining thinner materials with less heat distortion.
Laser welding is a welding technique used to join pieces of metal through the use of a laser beam. The laser beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. Laser welding is used more frequently in industrial processes as it has wider application than traditional welding and creates less heat from the focused laser beam.
CNC Machining
We provide precision machining services to our clients to produce intermediate engineering metal and plastic components based on their requirements and specifications. We use CNC machining processes such as milling, turning and turn-milling to produce precision-machined components with close tolerance finishes in a precise and consistent manner. During CNC milling, metals blocks are formed into various shapes and sizes according to customer designs and required specifications. Thereafter, the precision machined components may further undergo various finishing treatments. In addition to CNC machining, we also provide machining services using conventional cam automatic lathe machines.
The Processes
The processes that we perform for CNC machining include:
During the milling process, a metal or plastic block is held stationary while a rotating cutting tool is used to remove excess materials to shape the blocks into engineering parts according to the desired designs and specifications. This process is suitable for cutting flat surfaces and deep cavities into the blocks. Our CNC milling machines can mill metal and plastic blocks of sizes up to 1.5 metres in length by 0.9 metres in width and height.
Turning is a process where the secured metal and plastic rods are rotated and a cutting tool is used to cut excess materials to shape the rods into engineering parts according to the desired designs and specifications. This process is suitable for producing cylindrical parts with varying diameters in different sections. We use either CNC automatic lathe machines or cam automatic lathe machines to undertake the turning processes depending on the level of precision required. Our automatic lathe machines work with metal and plastic rods with diameters from 3 mm up to 200 mm.
Turn-milling combines the processes of milling and turning using CNC turn-mill machines. A secured metal or plastic rod is rotated and a rotating cutting tool is used to remove excess materials to shape the rod into engineering parts according to the desired designs and specifications. Turn-milling is an efficient process as it reduces processing time and reduces the need for transferring the metal rod from 1 machine to another. We produce precision-machined components for our clients who are primarily manufacturers in the semiconductor, E&E, telecommunications, medical, automotive and oil and gas industries.
Plastic Injection Moulding
Plastic injection moulding is a manufacturing process for producing plastic parts by injecting molten material into a mould. We provide plastic injection moulding services for parts and components used for the assembly of electronic products.
Our plastic injection moulding process includes conventional moulding, two-shot (2K) over moulding and insert moulding.
The Processes
The processes that we perform for the plastic injection moulding include:
Conventional moulding involves melting plastic material inside the heating cylinder and injecting molten material into a mould tool which solidifies to create the intended moulded product.
Two-shot (2K) over moulding is a multi-step injection moulding process where 2 materials are moulded over one another. First, a base moulded material (otherwise known as a substrate) is moulded and allowed to cure. Over moulded substrates are often made of plastic. Then, a second layer is moulded directly on top of the first to create a single solid piece. Over moulding is commonly used to manufacture plastic parts that feature a rubber handle.
Insert moulding is another form of injection moulding where a secondary part is formed over a substrate. The differentiating factor between insert moulding and over moulding is that insert moulding is performed with a pre-existing substrate (base or inner component). A prefabricated part is inserted into a mould, and then a secondary layer is formed around it.