Services


Laser Cutting

The company operates 3 x Trumph flatbed CO2 laser machines with cutting beds of 4000mm x 2000mm. The Laser technology is combined with a CNC system (Computer Numerical Control) that allows for the precision cutting of materials with achievable tolerances of 0.2mm and with cutting speeds up to 10.5m/min. These laser machines are able to cut a wide range of materials that include Carbon Steel, Stainless Steel and Aluminium.

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Laser Tube Cutting

The Trumpf TruLaser Tube 5000 is one of the few dedicated Laser Tube cutting machines available to the general public in South Africa. This machine incorporates all the high tech laser technology and impressive cutting speeds commonly associated with flatbed laser cutting but with 2D axis cutting abilities that allows the machine to cut various types of round, square and rectangular tube up to 6m in length.

This high speed machine is ideal for all types of work from complex tube designs to large volume orders, such as the new King Shaka airport – all of the stainless steel balustrade and stanchions for this project were cut on the laser tube machine.

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Laser Cutting / Punch Combination

The Trumpf Trumatic 6000L Punching and Laser Cutting combination machine offers both the versatility of laser cutting combined with the speed of CNC punching. The machine is also capable of forming, tapping, counter sinking and beading in the single operation. The capabilities of this machine allow for a much quicker turnaround in the manufacture of components when utilising the various combinations.
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Plasma Cutting

The Koike plasma machine is capable of both high definition plasma cutting and Oxy fuel cutting. The cutting bed is 8m x 3m which allows for cutting of large parts. The high definition plasma is best suited for materials ranging from 10mm to 32 mm and the cutting process is performed using a plasma torch in which a gas is blown out of the cutting nozzle at high speed and at the same time an electric arc is formed through the gas from the nozzle to the material being cut, turning some gas to plasma.

The plasma is hot enough to melt the metal being cut and moves fast enough to blow molten metal away from the cut. Oxy fuel cutting is used for materials over 32mm and in this process pure oxygen is used to increase the flame temperature to allow localised melting (cutting) of the material, at 3,500 ͦC

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Punching

The Trumpf TruPunch 2020 machine is ideal for materials ranging from 0.9mm to 6mm. The machine has 17 tool holders and with the addition of a multi tool holder, up to 27 different tools can be used during a single punching programme. Such capabilities have proved to be highly effective and efficient in jobs such as the high volume manufacture of electronic enclosures and related parts for the Kusile power station.
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Bending

Laser Junction operates 3 x CNC Trumpf press brakes, a 130 ton press brake and 2 x 85 ton press brakes. These machines are all Computer Numerically Controlled (CNC) which allow automated and precise programming of the machine operations, which in turn result in high speed and efficient production.

These machines have a bed width of 3 metres and are capable of bending up to 4mm steel over this entire length. These press brakes are also equipped with tooling that allows the machines to bend to within a 0.3 degree tolerance.

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Tube Bending

Laser Junction operates 2 x tube bending machines and is able to bend a wide variety of mild steel and stainless steel tube ranging in from 12mm to 76mm.
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Welding

weldingThe fabrication department offers various welding solutions for a wide variety of customer requirements. Each department consists of several skilled staff led by an experienced Supervisor. The business is currently in the process of being certified according to the American Welding Standards.
MIG Welding
In this welding process, an electric arc is formed between a consumable wire electrode and the metal, which heats the metal, causing them to melt, and join together. MIG welding is ideal for welding thicker gauge material.

TIG Welding
TIG welding is a process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is applied.
TIG welding is a slower and more specialised process than MIG welding and is best used for the welding of complex parts that require high quality finishes. It is also mainly used for the welding of stainless steel and aluminium components.

Robotic Welding
The robot welder uses the MIG welding process and this generates a consistent, high quality weld and is ideal for the fabrication of high volume parts. The robotic system consist of three work stations, each of which can accommodate several parts in a jig and while one workstation is being welded, the other work stations can be loaded / offloaded.

SPOT Welding
SPOT welding can be used for material from 0.5 to 3mm in thickness. The contacting metal surfaces are joined together by the heat obtained from the resistance to electric current – the process is applied using two shaped copper alloy electrodes that concentrate a welding current into a small “spot” and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld.


Fabrication

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Powder Coating and Plating

Laser Junction offers a variety of anti corrosion finishes for metal products

Powder Coating is the most common process where a dry powder is applied to a metal surface electrostatically and is then cured under heat to allow the powder to flow and form a skin. Electroplating is another widely used process that essentially uses an electric current to apply a thin layer of protective metal to a surface, such as Zinc. Zinc is anodic to steel and it will corrode before the steel does, sacrificing itself for the benefit of the steel.
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Design

Laser Junction has an experienced team of designers who use cutting edge design software (such as AutoCAD, Autodesk Inventor, and Pro Engineer) to turn an idea into a fully-realised, production-ready design.

The team often works closely with the design teams of larger customers to assist with research and development, design issues and product realisation. The design team will actively review and analyse customer designs and specifications to ensure best manufacturing practice is applied and cost efficiencies are realised.

For smaller customers, the team will complete the design working from verbal instructions, a sketch or a sample part.