Case Studies

Project Brief

Our client was looking to enhance specific aspects of their supply chain and had identified key issues requiring attention, including reducing lead times, improving powder coat finish, and enhancing general communications with their supply chain.

Core Processes Used

Manufacturing this air treatment unit involved multiple processes. The client’s files were uploaded to our Trumpf business management software platform. Production began by sending the nested files to our Trumpf 5kw fiber laser cutter for cutting the assembly kit. Thanks to the Trumpf software, we optimize sheet utilization and minimize waste.

After cutting, certain pieces required stud and nut insertion, accomplished with our Heagar nut insertion machine. Other parts needed folding, a task carried out on one of our three Trumpf folding machines, featuring the best Trumpf Series 5000 multi-axis CNC Press Brakes with a press force of up to 130 tons over 3.2 meters.

Panels for this project also underwent welding. At Elecon, we have the capability for both MIG, TIG and Laser welding, depending on project requirements. With the base unit fully welded, it moved to our pre-paint preparation area, where it underwent our phosphate wash—an excellent alternative to sandblasting, ensuring all metal surfaces are clean and degreased for powder coating.

Elecon’s in-house powder coating facility provides full control over lead times, allowing us to apply a range of powder coat finishes and colour match any RAL colour or individual colour swatches. Our large automated industrial oven is ideal for high-volume projects where finish and consistency are critical.

The painted unit moved to our assembly area, where our experienced staff handled the final stage, including electrical looms and PAT testing. The completed unit underwent a final QC check before proceeding to our packaging and distribution department, offering multiple packaging solutions and distribution options.

Client Feedback

After the project delivery, we sought feedback, and here’s what our new customer shared:

“From my first interaction with Elecon, the team showed great interest in our project. At each step, the Elecon team communicated with us, providing regular updates. The project was completed on time, significantly reducing our lead times. The quality of the finished unit was excellent, and the paint finish was perfect. I would recommend Elecon to any company seeking a fine metal fabrication subcontractor.”

What we Improved

• Shorter Lead Times – 3 weeks
• Consistent Powder Coating Quality
• Excellent Client Communication
• Competitive Pricing

Supporting the Lighting sector

As a seasoned supplier with a proven track record, Elecon takes pride in supporting commercial lighting companies by manufacturing metal-fabricated lighting components. Whether it’s for bespoke projects or standard stock products, we bring precision and expertise to every facet of the process. Here are some areas we have supported our lighting contracting clients:

Client-Centric Approach

At Elecon, we understand the unique requirements of the commercial lighting industry. Our commitment to excellence begins with working closely with clients to understand their specifications. We tailor our fabrication processes to ensure that every component meets the highest quality standards.

Exacting Quality Standards

Quality is a non-negotiable aspect of our operations. We adhere to meticulous quality standards throughout the fabrication process, ensuring that each component reflects the superior craftsmanship that defines Elecon. Our dedication to quality control guarantees that the lighting components we supply contribute to the overall excellence of the final lighting fixtures.

Flexible Lead Times for Seamless Installations

We recognise the importance of flexible lead times in the fast-paced world of lighting installations. Elecon is committed to meeting the dynamic needs of installation timelines. Our streamlined processes and efficient workflows enable us to provide flexibility without compromising the precision and quality that define our work.

Ready for Your Lighting Vision

Whether you have a unique, bespoke project or require components for stock products, Elecon is ready to bring your lighting vision to life. Our specialised expertise, client-centric approach, and unwavering commitment to quality make us the ideal partner for commercial lighting companies seeking excellence in metal fabrication.

Contact us today to discuss your specific requirements and discover how Elecon can enhance the brilliance of your lighting projects through precision-crafted metal components.

Our client was looking to design and build an interactive screen for the children’s education sector. The client had been underwhelmed by previous subcontract fabrication partners and was in the market to find a better solution, with an opportunity to improve quality, communication, and a partner that could react quickly and keep up with demand.

Elecon was engaged right from the early design stage and offered concepts to get the project underway, which once approved by the client led onto the prototyping stage. The design incorporated a combination of metal fabrication, high-tech touch screens, and required an extremely high commercial powder coat finish.

Once the final design was approved, and commercials were agreed, Elecon moved to the production stage, and these are the core processes required.

Processes Elecon Used:

• Design and Prototyping: Collaborated on creating the design brief and shared ideas on concepts and designs to kickstart the project.
• File Upload and Management: Utilised a Trumpf business management software platform for efficient file handling.
• Laser Cutting: Employed a Trumpf 5kw fibre laser cutter to precisely cut assembly kit components while optimising sheet utilisation and minimising waste.
• Nut Insertion: Used a Heagar nut insertion machine for inserting studs and nuts into certain parts of the assembly kit.
• Sheet Folding: Utilised Trumpf folding machines for bending and shaping components using multi-axis CNC Press Brakes with a high press force.
• Welding: Employed MIG or TIG welding as required for different project specifications.
• Pre-Paint Preparation: Utilised a phosphate wash process to clean and degrease metal surfaces before powder coating.
• Powder Coating: Operated an in-house powder coating facility with the ability to apply various finishes and colours, ensuring full control over lead times and quality.
• Assembly: Completed assembly of the base with a powder coat finish prior to the second fix of electronic components and high-tech touch screens.
• Quality Control (QC): Conducted a final QC check before moving the completed unit to the packaging and distribution department.
• Packaging and Distribution: Provided multiple packaging solutions and distribution options, including large curtain-sided vehicles and a smaller fleet of delivery vans.

Client Feedback:

The client expressed satisfaction with the project execution:

• Communication throughout the project was described as timely, consistent, highly informative, and going the extra mile.
• Quality surpassed previous experiences.
• The project met all commercial requirements, and the product was successfully launched in the market and is still being sold today.
• Elecon has gone on to work on numerous technically challenging projects.
• Elecon has developed a strong relationship over the last four years.

Achievements:

Elecon successfully achieved the following outcomes for the client:

• Successfully supported the design and prototyping stages.
• Transitioned from concept to market launch with a commercially viable product.
• Achieved a consistent powder coating quality, ensuring a premium finish.
• Demonstrated excellent communication and support with the client throughout the project.

Client Testimonial: Any business looking to source a fine-limit metal fabrication subcontract company with a high level of technical knowledge should look no further than Elecon.

Appreciating the work we undertake for clients is of a highly confidential nature, we are happy to organise references with the clients referred to in our case studies, but subject to prior our client approval.

Elecon has extensive knowledge and experience in the Computing sector having worked with specialist companies who design, build and support computing and electronics requirements. Elecon’s forte lies in delivering comprehensive fabrication expertise, manufacturing tailored solutions that precisely align with the unique demands of individual projects. From conceptualisation to realisation, our skilled team guarantees precision and quality throughout.

Elecon’s key offerings go far beyond fabrication expertise, and bring comprehensive support services that define Elecon’s commitment to excellence and understanding of the computing sector.

Some of the projects we have partnered on

• Bespoke Custom Computers: Tailored solutions that have unique design and functionality
• Specialist Rack-Mount Systems: Precision-engineered solutions for optimum performance.
• Server Frames, Casings, and Cabinets: Intricately fabricated structures meeting the highest industry standards.

Elecon takes pride in offering more than conventional sheet metal fabrication and our role as a specialist partner for OEM computing extends to:

• Prototyping and Pre-production Runs: Bringing concepts to life swiftly and efficiently.
• In-House Core Processes: Laser cutting, shaping, welding, powder coating, assembly, and distribution management.
• Component Fitment: Seamless integration of diverse elements.
• Meticulous Quality Control: Stringent measures for meeting the highest tolerances.
• Premium Powder Coat Finish: Enhancing durability and visual appeal.
• Quality management: Our internal quality management systems and ISO accreditation ensure not just repeatability and consistency but full traceability for every project.

This allows Elecon to operate as a go-to partner, providing a seamless turnkey solution and ensuring a consistent, reliable approach in an industry that constantly evolves.

Client Testimonial:

“Elecon has been our consistent partner, delivering exceptional quality with unwavering dedication. Their in-house capabilities and turnkey solutions make them a standout subcontract partner. We confidently recommend Elecon to businesses seeking professional and trustworthy metal fabrication services.”

With a decade-long commitment to the automotive sector, Elecon stands as a trusted second-tier supplier, providing crucial support to OEMs. Our unwavering focus on quality assurance is integral to our supply operations, ensuring that every product we manufacture meets the highest testing criteria.

Quality You Can Count On

At Elecon, consistency is our hallmark. The products we deliver undergo rigorous testing, guaranteeing the repeatability of our high-quality standards. Our commitment to maintaining these standards is paramount to our success and the success of our partners in the automotive industry.

Full Traceability for Seamless Supply Chains

Recognising the importance of traceability in the automotive supply chain, we offer full traceability as an integral part of our customers’ operations. This ensures transparency and reliability, contributing to the efficiency of the entire supply chain.

A Decade of Proven Expertise

Elecon has proudly supported the automotive sector for over ten years. Our track record speaks to our dedication and ability to consistently deliver on the unique requirements of this dynamic industry.

Partner with Elecon for Automotive Excellence

Whether you require components for OEMs or seek a reliable second-tier supplier, Elecon is your partner in automotive excellence.

Client Feedback

We have worked with Elecon for over ten years now and they have a great track record as our fabrication partner and we continue to enjoy a robust and healthy working relationship/ If you are looking for a trustworthy, consistent, reliable fabrication partner Elecon are a good choice.