Manufacturing Processes | Saddlers Court MFG

The Manufacturing Process

The process of heavy steel fabrication from start to finish is a complex endeavor that requires meticulous planning, skilled labor, specialized equipment, and a commitment to quality. Companies undertaking such projects must possess a comprehensive set of capabilities to effectively navigate each stage of the fabrication process. Let's explore the typical steps involved:

Design and Build Partner

It all begins with understanding the client's requirements and specifications. We can assist you at every stage of the design and manufacture of your product. From the initial enquiry to the finished part, we are constantly on hand to help with any technical issues to ensure your product is on spec, on time and on the way. Our CAD/CAM facilities can import all major graphic and design files to expedite orders and implement modifications or changes very rapidly throughout the system. Our in house MRP software guides us efficiently and effectively from taking your order to shipping it out the door.

Material Supply Chain

Strip Mill & Reversing Mill Plate Products we purchase from major Mill Owned Stockholders based within the UK and Europe, where we can secure a degree of price fixity.
Forgings we procure from major suppliers from Italy, Asia & the UK, with a degree of price fixity.
Engineering Bar we purchase from major UK stockholders, where we can secure a degree of price fixity
Engineering Bar “Specialist Peeled Bar” ( For Pivot Pins) we purchase from major Mills in Europe, where we can secure a degree of price fixity.

High Definition Plasma and Gas Cutting

Our ability to cut our own components cost-effectively from steel plate is the start of a complete manufacturing service to our customers.

At the heart of this ability is our high definition CNC plasma cutting machine that has the ability to cut up to a 35mm thickness with a bed size of 10m x 2.5m and our four headed oxy-propane CNC flame cutting machine with a bed size of 5m x 2.5m that can cut up to a 120mm thickness.

When used in conjunction with our Lantek Expert nesting and cut shop management package we ensure that as little material as possible goes to waste, again passing more savings on to the customer and making our turn around of parts faster and more efficient.

Machining and Finishing

Machining steel parts involves the process of shaping, cutting, or finishing the cut steel blanks to achieve specific dimensions and surface qualities. This process is commonly used in various industries such as construction, material handling, arial platforms, mechanical engineering and automotive. With our extensive array of machining centres we can achieve the following processes:

Turning

Involves rotating the workpiece while a cutting tool removes material to create cylindrical shapes.

Milling

Utilizes rotary cutters to remove material from a workpiece, creating various shapes and features such as slots, holes, and pockets.

Drilling

Creates holes in the steel part using a rotating cutting tool.

Finishing Operations

Once the desired shape is achieved, the steel part may undergo additional finishing processes to improve surface quality and dimensional accuracy. This can include processes like deburring, polishing, heat treating, or coating to enhance properties such as hardness, corrosion resistance or appearance, and this can be achieved in house or by one of our many outsourcing companies who we have worked closely with for many years.

Throughout the machining process, factors such as cutting parameters (speed, feed rate, depth of cut), tool selection, coolant usage, and machine rigidity are carefully controlled to optimize efficiency and achieve desired results while minimizing waste and maintaining safety standards.

Fabrication

Once all the cut parts and have been machined, formed and kitted up fabrication can begin. Our team comprises builders and engineers who possess a wealth of experience in the art of steel fabrication. With meticulous attention to detail and a commitment to excellence, they bring every project to life with craftsmanship that exceeds expectations. At Saddlers Court, we thrive on innovation and customization and tailor our fabrication solutions to meet the unique needs and specifications of each client. Rigorous quality control measures, including comprehensive inspections and testing protocols, ensure that every fabricated steel product meets the highest standards of durability, functionality, and safety.

Jigs and Fixtures

Our welding fixtures are designed specifically for each customer to ensure fabrication of components to a high degree of accuracy and repeatability. This jig has been designed and built by ourselves for a vehicle chassis. To assemble parts successfully, each component must be positioned and held firmly in place during the plate or weld process and this must be done, reliably, again and again. Our best weld fixtures are designed taking into account material type, loading and unloading requirements, tolerances and type of production run.