Operational Capabilities

Closed Die Forging (0.01 kg – 10 kg)

Closed die forging, also known as impression die forging, is a precise manufacturing process where heated metal is shaped within the confines of a specially designed die set. This method is ideal for producing components ranging from 0.01 kg to 10 kg, ensuring high dimensional accuracy and excellent mechanical properties. The process is suitable for various metals, including aluminium, brass, copper alloys, alloy steel, and stainless steel, allowing for a wide range of industrial applications.  

Materials Processed

• Aluminium: Lightweight, corrosion-resistant, and ideal for automotive and aerospace components.
• Brass: Offers good machinability and corrosion resistance, commonly used in fittings and decorative parts.
• Copper Alloys: Known for excellent electrical and thermal conductivity, used in electrical and plumbing components.
• Alloy Steel & Stainless Steel: Provide high strength, toughness, and resistance to wear and corrosion, suitable for demanding mechanical applications. 

Presses Utilized 

• Screw Presses: Deliver controlled, high-energy blows, ideal for precision forging and intricate shapes.
• Pneumatic Presses: Use compressed air for rapid, consistent forging cycles, enhancing productivity and repeatability. 

Furnace Classes 

• Class 2, 3 & 4 Furnaces: These furnaces are designed for efficient heating of forging billets and dies, ensuring uniform temperature distribution and optimal material properties. They can include batch, continuous, and specialised heating systems tailored for forging operations. 

In-house Die Design & Tool Room 

A dedicated in-house die design and tool room enables rapid development, modification, and maintenance of forging dies. This ensures

• Customisation for client-specific requirements
• Quick turnaround times for new product development
• High-quality, consistent tooling for reliable production 

Summary 

This comprehensive forging setup supports the production of high-quality, precision components across a range of metals and sizes. The integration of advanced presses, efficient furnaces, and in-house tooling capabilities ensures flexibility, quality, and cost-effectiveness for diverse industrial  

Sand & Gravity Die Casting (Aluminium & Brass) 

Sand and gravity die casting are versatile manufacturing processes used to create complex and high-quality metal components from aluminium and brass.

Sand Casting: 

Sand casting involves creating a mold by packing sand around a pattern of the desired part. The pattern is removed, leaving a cavity into which molten metal is poured. Once the metal solidifies, the sand mold is broken away to reveal the casting. This method is particularly suited for producing prototypes and complex profiles, as it accommodates intricate shapes and varying wall thicknesses. Sand casting is widely used for both aluminium and brass components, offering flexibility and cost-effectiveness for low to medium production volumes. 

 Gravity Die Casting: 

Gravity die casting, also known as permanent mold casting, utilizes reusable metal molds. Molten aluminium or brass is poured into the preheated die solely under the force of gravity, resulting in castings with improved dimensional accuracy, better surface finish, and higher mechanical properties compared to sand casting. This method is ideal for producing medium to large volumes of parts with consistent quality and is well-suited for complex geometries.

Prototyping for Complex Profiles 

Both sand and gravity die casting are capable of producing prototypes with complex profiles. Sand casting, in particular, excels at rapid prototyping due to its mold flexibility, while gravity die casting can deliver higher precision and repeatability for intricate designs.

Independent Melting Furnace for Various Grades (Impurities Control) 

An independent melting furnace allows for the processing of different aluminium and brass grades separately, minimising the risk of cross-contamination and ensuring tight control over impurities. Key quality control measures include:

• Monitoring furnace temperature and maintaining optimal melting conditions.
• Regular removal of dross, slag, and oxide layers from molten metal to prevent inclusions and defects.
• Using refining agents and cleaning the furnace regularly to ensure metal purity.
• Testing and verifying the composition of each melt to meet specific grade requirements and mechanical properties. 

This approach ensures that each casting batch meets stringent quality standards, resulting in reliable and high-performance components. 

Precision Machining Capabilities 

CNC Turning, VMC, and EDM Our state-of-the-art machining facility is equipped with advanced CNC Turning, Vertical Machining Centres (VMC), and Electrical Discharge Machining (EDM) systems. These technologies enable the production of highly precise and complex components across a wide range of materials and applications. 

• CNC Turning: Delivers high-precision rotational parts with tight tolerances and exceptional surface finishes.
• VMC (Vertical Machining Centre): Offers versatile 3-axis and 4/5-axis milling for intricate geometries and multi-face machining.
• EDM (Electrical Discharge Machining): Ideal for shaping hard metals and intricate profiles that are difficult to machine using conventional methods. 

Multi-axis Machining 

Our multi-axis machining capabilities allow for the production of complex parts in a single setup, reducing lead times and ensuring consistent accuracy. This technology supports the creation of intricate features, undercuts, and compound angles, making it ideal for aerospace, medical, and high-precision industrial components.

Ultra-Precision Tolerances 

• Tolerance: ±5 microns (0.005 mm)
• Surface Finish: Ra ≤ 0.4 μm 

These ultra-tight tolerances and superior surface finishes ensure that every component meets the most demanding industry standards, suitable for critical applications that require exceptional accuracy and reliability.

In-house Full Scale Tool Room

Our comprehensive in-house tool room is equipped to design, manufacture, and maintain all necessary tooling, jigs, and fixtures. This capability ensures:

• Rapid response to design changes and prototyping needs
• Consistent quality and repeatability in production
• Reduced downtime and enhanced process control 

Design Shop with CAD/CAM, Simulation & AI Tool Facility

Our dedicated design shop leverages the latest CAD/CAM software, advanced simulation tools, and AI-driven optimisation: 

• CAD/CAM: Enables efficient design-to-manufacture workflows, reducing errors and accelerating project timelines.
• Simulation: Validates tool paths, machining strategies, and part performance before production, minimising waste and rework.
• AI Tools: Optimise machining parameters, predict tool wear, and enhance overall process efficiency for continuous improvement. 

Summary: With cutting-edge machining technology, ultra-precision capabilities, a fully equipped tool room, and advanced design and simulation tools, we deliver high-quality, complex components tailored to your exact specifications—on time, every time.

Heat Treatment & Surface Finishing Services 

Heat Treatment 

Our comprehensive heat treatment services are designed to enhance the mechanical properties, durability, and performance of metal components. Through controlled heating and cooling processes, we tailor the hardness, strength, and ductility of a wide range of materials to meet precise application requirements. This ensures optimal performance and longevity in demanding environments.

Surface Coating Solutions 

• Zinc, Tin, Silver, Nickel & Customised Plating:Provides excellent corrosion resistance and a bright, attractive finish. Ideal for protecting steel components from rust and extending service life.
• Anodising:Primarily used for aluminium parts, anodising increases surface hardness, wear resistance, and corrosion protection. It also allows for decorative finishes in various colours.
• Blackening:Also known as black oxide coating, this process enhances corrosion resistance and provides a uniform, matte black appearance, often used for aesthetic and anti-glare purposes. 

Chemical Conversion & Passivation 

• Chemical Conversion:Converts the surface of metals (such as brass, copper, aluminium and its alloys) into a thin, protective layer, improving corrosion resistance and paint adhesion.
• Passivation:A chemical treatment for ferrous alloys that removes surface contaminants and enhances the natural oxide layer, significantly improving corrosion resistance. 

Certified & Approved Vendor Network 

All our heat treatment and surface finishing processes are carried out by a network of certified and approved vendors. This ensures

• Consistent, high-quality results
• Full compliance with industry standards and customer specifications
• Reliable traceability and documentation for all treated parts 

Summary: 

We offer a complete suite of heat treatment and surface finishing services—including zinc plating, anodising, blackening, chemical conversion, and passivation—delivered exclusively through certified and approved vendors. This guarantees superior quality, enhanced performance, and total peace of mind for every component we process.