Photofabrication Company - News Archive
Photofab Newsletter March 2005: COMPANY PROGRESSION. Download a FREE copy in PDF format.
News Archive
For further information on any of these news stories, please contact us.
Problem: A potential customer needed a price sensitive screening can to be manufactured. The set comprised of 3 parts, each different in design and forming. One part was to be spot welded. The base metal was mild steel, which was to be hot tin dipped. Solution: After considerable thought and communication, we proposed changing the plating from hot tin to dull nickel. This would then enable us to etch the parts in sheet form, using retaining tabs and dull nickel plate the parts in sheet form, reducing the lead time and the cost of plating. We would then form the parts on fly presses. Finally we needed to spot weld the fence. Spot welding is usually performed pre-plating. There is a general fear that the plating will be compromised if spot welding is carried out post-plating. However, when spot welding dull nickel plated mild steel, the spot weld process creates a nickel iron alloy, which offers an improved corrosion resistance compared to that of iron alone. As the environmental application of this part was neither hostile nor external, this was the perfect solution.
Our customer was interested in creating several modifications of the same chemically etched component, the difference between each part was negligible, but obviously finding a dimensionally correct component was crucial. At this prototyping stage, keeping costs low was a priority. We were able to create a single mixed photo-tooling and by doing so, produce all our customer’s designs at the same time. Our solution to prototyping manufacture reduces costs significantly and moved our customer’s project along swiftly, as all design modifications were supplied simultaneously.
Our customer required chemically etched formed springs, produced from .004” thick sheet metal. The thickness of the metal and the design of the spring, meant that when the parts were processed through our etching plant, they became tangled and distorted and as a result, the secondary operation of forming the parts, could not be carried out. We therefore, designed the parts to be etched in sheet form, using ‘twist’ style retaining tabs. The parts, reached our in-house forming department, where a simple twist of the part released it from the sheet and it could be successfully formed. This solution reduced rejects dramatically, improved costs and lead time for our customer.
Metal Business Card Demand Surges - August 2004
Month on month this year there has been an increase in the demand for metal business cards. Demand which could be attributed to many things:-
These are just a few of the reasons given for choosing metal rather than cardboard business cards.
"It's reassuring to know that in ten years time customers will still have these metal cards, cardboard ones would have been put in the bin years before."
PMP (Essex) Ltd
With this increased interest Photofabrication are developing an "on-line business card designer". This will allow the user to view different styles, layouts, and finishes. Watch this space for developments!
Collection of metal business cards and invitations
High Tolerances - June 2004
In June 2004 we sent an email to all of our customers asking for their thoughts on the need for tighter tolerances. I would like to thank everyone for their time in completing the few short questions.
With this "goal" in mind Photofabrication are investing in a total refurbishment of the etching facility, and will have new state of the art machinery in place at the turn of the year. This will allow us to reduce our tightest tolerance, and improve variability across a batch.
Print Room Investment - February 2004 Photofabrication have recently made a substantial investment in a clean room Printing Area. This has included automated handling of metal sheets through the new cleaning line into the Print Room. This automated handling, together with a new photo resist developer, have made Photofabrication one of the most advanced photo chemical milling companies in the world; it is "a state of the art" facility.
This key investment improves dimensional consistency and cosmetic appearance. Increased efficiency in material handling is achieved using automatic sheet loaders and conveyers to minimise labour input. The investment provides customers with improved quality, faster lead times and increased consistency.
To see the Print Room's critical role in the chemical etching process, take the "The Process Tour", or if you would like to inspect these new facilities in person, please contact us for further information on 01480 226699.
Photofabrication exhibit at Nepcon
Photofabrication will be exhibiting at Nepcon in Brighton Metropole Centre on 11th and 12th June 2003. This two-day exhibition is the UK’s most successful electronics manufacturing show case. It is focused on providing an easy to attend, inexpensive show. Photofabrication will be delighted to meet existing customers and welcome new customers to their stand number U115. A wide range of products and services will be on display. If you would like to attend, please register here.
External Decorative Frieze for Lazards Bank - April 2003 Photofabrication has manufactured decorative panels for the prestigious new headquarters of Lazards Bank in London. The external frieze consists of 40 etched stainless steel panels depicting 20 images of the British Isles. The images were made from original drawings, watercolours and etchings by Norman Ackroyd, Royal Academican. The drawing below shows one of the sketches by Norman Ackroyd used for the project.
New website launched - January 2002 Photofabrication have invested heavily in the design of a new website to improve the information available to their customers. Many engineers want to know more about a process which is often new to them. This has been achieved unusually by the use of a story board which provides a light but informative method. Design tolerances is another area of concern to engineers, again this has been displayed graphically. It is planned in 2003 to use the website to allow customers to track their orders from start to finish through the Photofabrication etching process; another way that Photofabrication is improving customer service!
JobBOSS production control system development - November 2002 Photofabrication has embarked on the installation of the latest version of the JobBOSS production control system which will significantly improve the information level available for the manufacture of etched components. More details on this will be available shortly. Neil Shorten, Commercial Manager, has commented that he expects the new system to greatly improve customer service by having detailed information available at the touch of a button.
You're doing a fine job! HM Queen - October 2002
The picture shows the Queen admiring a new viewing point panel manufactured by Photofabrication for The Jubilee Walkway in London. A small part of Photofabrication's business is the manufacture of decorative etched and paint in-filled panels, plaques, labels and business cards. See Decorative Products
HM Queen unveiling Photofabrication decorative panel
On the unveiling day last October, Chris Bowers, one of our New Business Development Executives, was introduced to the Queen. Her Majesty commented that we had done a " fine job".
Office reorganization - February 2002 The offices at Photofabrication have recently been reorganized to facilitate improved communication between production and sales. They have also greatly improved working environment for the staff. This has included installing full networking facilities and Internet connection using Broadband. This will help provide better levels of customer service. Account Manager, Lorraine Wilton, comments 'this has really helped communication throughout the organisation and allows us to give our customers an even better service'.
Account Managers in action in the reorganised offices
New equipment installed at Photofabrication - September 2001 During September 2 new etching lines have recently been installed in the factory at Photofabrication. These etching lines have been installed to increase the amount of production available to reduce deliver times besides offering better levels of control. This allows increased accuracy of etching. The new equipment is fitted with acid regeneration units to reduce the operating costs and to be environmentally friendly. Managing Director, Simon Lane, comments 'this is the just the start of improving the level of service to our customers. Further investment is on the way which shows our commitment to our staff and customers.' Photofabrication acquired by the Hooker Manufacturing Group - July 2001 On 9th July the Photofabrication (Services) was wholly acquired by the Hooker Manufacturing Group. The existing directors, Mr. Hugh McCallion and Mr. Donald Sumner retired immediately but remained in touch with the company to help oversee the transition period and to ensure customers received continuity of service. Simon Lane, the new MD, of the business said 'this is a new and exciting time for Photofabrication. This company has a great future and I intend expanding the operation with investment both in equipment and customer services. I am delighted with the reception and cooperation I have been given by both the staff and customers. The Hooker Manufacturing Group has a long experience in the manufacture of custom made parts. We understand the need to provide high level customer service and quality.' For further details on the Hooker Manufacturing Group, please visit their website at www.hookergroup.co.uk
Home | The Company | Chemical Milling Process | Chemical Milling Process Tour | Products & Services | Short Lead Times | Customer Focus | Quality Control | Environment | Top FAQs | Contact Us
The photo chemical machining or milling etching process. Thin sheet metal components etched chemically (photo etched metal). Photochemical machining (photoetching) is suitable for etched metal components used in EMC/RFI shielding, encoder disc, actuator, switch contact, screening can, shim, solder mask, rotor lamination, lead frame, filters, heat sink, mesh, connector, applications.
