Metal fabrication involves some complex processes, incl. cutting, forming, welding, machining, and surface treatment. In other words, it can turn metals into spare parts or products required by customers, with a wide range of applications now. As an indispensable part of modern industrial manufacturing, it takes on several trends below:
⇲ Growing market size year by year ⇲ Increasing important innovation in technology ⇲ Diversified demands from customers
Industry Challenges
01
Diverse Materials & Thicknesses
Metal fabrication workshops process carbon steel, stainless steel, aluminum, and other alloys with varying thicknesses.
02
High Precision Requirements
Hull sections, decks, and bulkheads require tight tolerances for smooth assembly. Cutting inaccuracies lead to misalignment, excessive welding gaps, and costly rework.
03
Low Efficiency & High Labor Cost
Traditional cutting and forming methods rely heavily on manual operations, resulting in lower productivity and higher labor costs.
04
Increasing Customization Demand
Customers demand small-batch, high-mix, customized metal parts, challenging traditional tooling-based processes.
05
New production line expansion
Expanding the entire material preparation production line will increase brand competitiveness and premium pricing.
06
Enhanced environmental protection and safety
Environmental protection will serve as a core value to attract more outstanding cooperative projects.
DN Solutions
Sheet metal cutting solutions
Pipe Cutting Solutions
Bending Solutions
Laser Welding Robot
Handle laser Cleaning machine
Sheet metal cutting solutions
Traditional processing pain points: 1. Low precision of CNC plasma/flame cutting machines (error ±0.5-1mm), requiring secondary grinding; 2. Slow cutting speed, weak adaptability to complex shapes, making it difficult to meet "multi-variety, small-batch" orders; 3. High energy consumption and severe dust pollution.
DN Laser cutting solution: 1. Leading precision: Cutting error ≤ ±0.1mm, beveling in one step, no secondary processing required; 2. Increased efficiency: Cutting speed more than 30% faster than traditional equipment, supporting batch cutting of multi-shape and multi-specification parts; 3. Green and energy-saving: Energy consumption is only 60% of traditional equipment, no dust pollution; 4. Strong adaptability: Can process 4-15mm ship plates, meeting the processing needs of complex structural parts for high-end ships.
Pipe Cutting Solutions
Suitable for large-scale processing of various steel pipes and alloy pipes, its core advantages include:
1. High degree of automation: Enables a closed-loop operation of the entire process, from automatic feeding, length setting, clamping, cutting, unloading, finished product counting, and tail material output of bundled pipes, requiring no manual intervention and perfectly suited for large-volume continuous production.
2. Excellent processing accuracy: Utilizing a CNC system to precisely control the feeding length and cutting trajectory, coupled with a stable hydraulic/pneumatic clamping mechanism, the cutting tolerance can be stably controlled within ±0.1mm, resulting in a smooth, burr-free cut and avoiding vibration and accuracy deviations caused by pipe rotation processing.
3. Excellent efficiency and cost-effectiveness: Employing a cutting mode of rotating cutter and fixed pipe, it achieves significant energy savings and allows for simultaneous multi-blade processing. Daily processing capacity is increased by more than 50% compared to traditional equipment, tool consumption is reduced by 30%, and operating costs are significantly lowered;
4. Safe, stable, and easy to maintain: The equipment integrates a forced-flow water-cooling or oil-mist cooling system to effectively control processing temperature and noise. Combined with an integrated dust removal device, it reduces smoke and dust emissions, freeing workers from high-risk processing environments. The control system uses an industrial Ethernet motion control platform, ensuring high reliability and easy maintenance. It can also interface with MES systems to achieve automatic production data collection and monitoring, adapting to smart factory construction;
5. Wide adaptability: It can flexibly adapt to pipes of different diameters and lengths, as well as various materials such as carbon steel, stainless steel, and alloy structural steel. Through rapid changeover and programming adjustments, it can meet the customized processing needs of multiple pipe specifications.
Bending Solutions
Traditional processing pain points: 1. Low precision of CNC plasma/flame cutting machines (error ±0.5-1mm), requiring secondary grinding; 2. Slow cutting speed, weak adaptability to complex shapes, making it difficult to meet "multi-variety, small-batch" orders; 3. High energy consumption and severe dust pollution.
DN Bending solution: 1. Leading precision: Cutting error ≤ ±0.1mm, beveling in one step, no secondary processing required; 2. Increased efficiency: Cutting speed more than 30% faster than traditional equipment, supporting batch cutting of multi-shape and multi-specification parts; 3. Green and energy-saving: Energy consumption is only 60% of traditional equipment, no dust pollution; 4. Strong adaptability: Can process 4-15mm ship plates, meeting the processing needs of complex structural parts for high-end ships.
Laser Welding Robot
1. **Superior Precision:** Concentrated laser energy reduces the heat-affected zone to only 1/7 that of traditional welding, achieving welding deformation control accuracy of ±0.1mm, a weld formation coefficient ≥1.2, and joint strength no less than the base material. Combined with a 3D vision-based weld seam tracking system, it can correct path deviations in real time, ensuring consistency in long welds and achieving a yield rate exceeding 99.5%.
2. **Double Efficiency:** Welding speed is 3-5 times faster than traditional processes, supporting 24-hour continuous automated operation. Daily welding length is 5-8 times greater than manual welding. AI-optimized welding parameters and single-sided welding processes achieve equipment utilization rates exceeding 90% (compared to only 60% for traditional methods), significantly shortening the production cycle.
3. **Wide Flexibility and Adaptability:** The six-axis structure enables welding of complex three-dimensional trajectories such as straight lines, curves, and rings, reducing changeover time from 2 hours to 5 minutes. It is compatible with various steel materials from Q235 to Q690 and thicknesses ranging from 10-50mm, and can complete the welding of dissimilar materials such as carbon steel and alloy structural steel, catering to both large-scale and customized needs.
4. **Green, Intelligent, and Safe:** Non-contact welding combined with an integrated dust removal system reduces smoke emissions and electrode contamination; it replaces manual operations in high-risk environments, reducing labor intensity by 70%; it can be integrated with MES systems for data acquisition, progress monitoring, and quality traceability, adapting to smart factory construction.
Handle laser Cleaning machine
Traditional Processing Pain Points: 1. Sandblasting or chemical cleaning generates large amounts of dust and waste liquid, failing to meet environmental standards; 2. Manual grinding is inefficient (0.3-0.5 m/min) and easily damages the substrate; 3. Uneven surface cleanliness (around Sa2 level), affecting subsequent welding and painting quality.
DN Rust and Paint Removal Solution: 1. Environmentally Friendly and Pollution-Free: No dust or waste liquid emissions, complying with green manufacturing policies; 2. Highly Efficient and Non-Destructive: Cleaning speed reaches 1-2 m/min, without damaging the sheet material and preventing substrate thinning; 3. Quality Upgrade: Surface cleanliness reaches Sa3 level, enhancing weld joint strength and paint adhesion, reducing the risk of later corrosion; 4. Flexible Adaptability: Can handle complex curved surfaces and confined spaces without disassembling parts.
This portable, user-friendly handheld laser welder with ergonomic design delivers precise low-heat welds for multi-metals; no professional certification required.
Ideal for compact workshops, the automatic side-mounted laser tube cutting machine offers high precision and efficiency. With automated loading/unloading and compatibility with multiple tube materials, it minimizes burrs and manual intervention for consistent, high-quality cuts.
Full enclosed structure ensures top safety; high cutting precision with stable performance, eco-friendly and energy-saving, durable and widely applicable to various metals.
The compact portable cobot MIG welding system is an all-in-one mobile solution with collaborative safety, ±0.02mm accuracy, wheeled cart and 30–80% productivity boost for diverse workpieces.