Metal Work

Mastering the Art of Metal Transformation

The transformation begins with the careful selection of high-grade alloys, ensuring consistency and optimal mechanical properties. Our metalwork is a multifaceted discipline, encompassing several core sub-processes—each chosen for its suitability to the intended application and design complexity. Whether we employ sand casting for its ability to create robust shapes, investment casting for intricate details, forging for unparalleled strength, sheet metal stamping for precision, or bespoke fabrication for unique requirements, our metalwork team approaches each task with skill and exactitude. The synergy of tradition and modern technique is ever present, as each method imparts distinct qualities to the finished piece.

Sand Casting

Sand casting is an age-old technique, revered for its versatility in shaping complex forms. Notably, this method excels in time and cost-effective production of small volumes, making it a preferred choice for bespoke or limited runs. The journey begins with the creation of a pattern, an exact replica, accounting for shrinkage, of the final component. This pattern is pressed into specially prepared sand to create a cavity—our mold. Molten brass, heated to over 900°C, is then carefully poured into this receptacle. After cooling, the sand mold is broken away, revealing a raw casting that carries the essential geometry of the design. Sand casting is prized for its adaptability and efficiency in handling custom pieces. Our artisans meticulously clean, trim, and inspect each casting, ensuring only the highest-quality forms proceed to the next phase.

Investment Casting

For hardware that demands intricate detailing and superior surface finish, we turn to investment casting—a process rooted in precision. It starts with the fabrication of a wax model, which is encased in a ceramic shell. Once the shell hardens, the wax is melted out, leaving a perfect cavity. Molten metal is poured in, capturing the subtlest nuances of the original model. Investment casting enables the realization of designs previously thought unachievable by conventional means. Our rigorous control over temperature, timing, and cooling guarantees consistency, while post-casting inspections ensure each piece is a flawless embodiment of the designer's intent.

Forging

When strength and durability are paramount, forging stands out as the preferred process—especially for larger volume production. By subjecting brass billets to intense pressure, either hot or cold, forging reshapes the metal without melting it, aligning its grain structure and vastly improving mechanical properties. This method is ideal for producing consistent, resilient hardware at scale. Depending on the size and complexity, we employ both traditional hammer-forging and precision press-forging, ensuring each piece meets exacting standards for dimensional accuracy and surface quality. The result is a collection of components that offer enduring reliability and strength, crafted efficiently for substantial production runs.

Sheet Metal Stamping

Sheet metal stamping is the cornerstone of producing thin, uniform, and intricately contoured hardware components. Using custom-designed dies, flat metal sheets are formed, punched, and embossed with remarkable precision. Our presses, both mechanical and hydraulic, accommodate runs from bespoke prototypes to large-volume orders. This process enables high repeatability and tight tolerances, making it indispensable for handles, hinges, escutcheons, and decorative plates. After stamping, each piece is deburred and checked for conformity to design specifications. The outcome is a collection of parts that marry efficiency with elegance, ready for further refinement.

Fabrication

Fabrication is where versatility and artisanry converge. Here, elements are joined, bent, cut, or assembled into complex assemblies that go beyond the capabilities of casting or stamping alone. Pipe bending is an essential process in this stage, allowing for precise curves and shapes to be formed for specialized applications. Our skilled fabricators wield torches, saws, pipe benders, and presses with equal command, transforming raw or semi-finished components into bespoke solutions. Whether it is custom hardware for heritage restoration or innovative contemporary designs, our fabrication workshop thrives on challenge and creativity. Diligence is paramount: each joint is seamless, each curve intentional, and every finished form is subjected to rigorous inspection before moving forward.

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Metal work is just one part of our comprehensive manufacturing journey. Explore our complete craft process.

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