Technologies

Cutting

Matic Ltd. Technologies - Cutting
Professional cutting technologies, modern machine park.

Tube laser cutting

Matic Ltd. Technologies - Tube laser cutting
Matic Ltd. installed the HD-TC 60170 fiber tube laser machine in 2020-2021, thus expanding the range of products manufactured by the company.
DURMA HD-TC laser is a high-speed machine for cutting closed sections, profiles, and tubes. Material feeding and unloading are automatic. It cuts tubes and closed sections extremely precisely and quickly, enabling unique and highly efficient series production of products made from a wide range of sections of high quality.

Maximum precision is achieved during cutting because the centering collet chuck (which is located closest to the cutting head) rotates in sync with the revolving collet chuck. During the cutting process, the automatic feeder system measures each workpiece arriving in the bundle and sends them to the cutting line until the cutting is in progress, and the feeder system prepares the next workpiece. The cutting head is equipped with a capacitive distance sensor that continuously adjusts the distance between the nozzle and the workpiece with the fast-axis control of the "Z" axis. It is protected against overheating by water cooling. The machine is controlled by a Sinumerik SL84OD CNC control system based on a 64-bit microprocessor. It has its own Durma interface and a complete cutting setting database. Based on reference values, you can easily adjust the cutting quality.

General usage areas: agricultural machinery manufacturing, protective devices for shopping centers, rack systems, supporting structures, frame structures for electrical cabinets, internal reinforcements for covers, as well as decorative elements, candle holders, and accessories for home use.

We undertake the laser machining of round tubes and square profiles in the following range with tube laser cutting:

Material type

Minimum outer circle diameter (mm)

Maximal outer circle diameter (mm)

Minimum wall thickness (mm)

Maximal wall thickness (mm)

Dosable raw material max. length (mm)

Finished workpiece max. length (mm)

Carbon steel

Pipes min. diameter: 20

Pipes max. diameter: 170

Welded profiles min.: 20x20

Welded profiles max: 120x120

Brick profiles min.: 25x20

Brick profiles max.: 150x100

0,5

10

6500

4500

Stainless steel

0,5

6

6500

4500

Aluminium

0,5

8

6500

4500

Flat laser cutting

Matic Ltd. Technologies - Flat laser cutting
Laser cutting is a CNC-controlled thermal cutting process in which various thicknesses of metals can be cut (carbon steels, stainless steels, acid-resistant steels, and various brasses) using a laser beam focused through a lens to provide the necessary heat energy for cutting.
Products of any shape can be cut with their contours reproduced. Our company uses the latest 2D and 3D (Solid Edge) software for contouring, along with the appropriate bending factor setting, to create the most precise flat pattern designs. The programming team uses the latest Trumpf and Mitsubishi software to lay out the parts on the sheet plans and write the programs, thereby achieving more efficient use of our machines. The better the utilization, the more competitive we can be, so we continuously train our employees to stay competitive. The manufacturing process of parts is made possible by the Enterprise Resource Planning system!

Our company uses modern cutting machines that enable the production of high-precision parts with short turnaround times. The material required for production is provided by our sheet metal warehouse, which has a huge inventory, but we also process material provided by the customer.

Machine

Max board size

Carbon steel

Stainless

Aluminium

Brass

Copper

Trumpf CO2

2000x4000 mm

20 mm

12 mm

8 mm

-

-

Mitsubishi 8 kW

1500x3000 mm

30 mm

30 mm

30 mm

18 mm

10 mm

Stanc cutting

Matic Ltd. Technologies - Stanc cutting
In this area, we distinguish between four machines: three die-cutting machines and one combination machine, the latter of which is equipped with a 3 kW fiber laser source.
The efficiency of this area is characterized by reducing cutting and finishing costs. In addition to contour cutting, machining with tools enables efficient perforating, countersinking, threading, and other cold forming techniques, such as eyeleting.

The machine's machining capabilities are as follows:

Machine

Max board size

Carbon steel

Stainless

Aluminium

Brass

Copper

Stanc

1250x2500 mm

3 mm

3 mm

3 mm

5 mm

5 mm

Combined

1250x2500 mm

3 mm

3 mm

3 mm

5 mm

5 mm

Edge bending

Matic Ltd. Technologies - Edge bending
Edge bending is a cold forming process in which 3-dimensional parts are produced from 2-dimensional sheet metal layouts that have been laser-cut or die-cut.
Our toolset includes edge bending tools manufactured with radii of R0.6, R0.8, R2, R3, R4, R5, R8, and several larger customized tools up to a radius of R50. In addition, our automatic machine solves tasks up to R200. For individual requests, our tool-making workshop is at your disposal.

Over the years, we have strived to be prepared for every task and inquiry in the field of fine sheet metal edge bending. This is reflected in the quantity and quality of our diverse tool sets and our versatile machine park, which includes two 30-ton Amada machines, one 22-ton Cone machine, two 2-meter Amada machines, one 3-meter Amada machine, and one 320-ton Durma edge bending machine. For high-volume recurring machining tasks, our Salvagnini panel bending machine provides an efficient and productive solution to bring your ideas to life.

DURMA AD-S 30320 Hydraulic CNC Edge Bender
In December 2020, Matic Ltd. installed the AD-S 30320 edge bending machine, increasing capacity and expanding the range of products manufactured by the company.

Our AD-S 30320 CNC-controlled edge bending machine represents state-of-the-art technology with (Y1-Y2, X1-X2, R1-R2, Z1-Z2) axes, working with high precision and force. This means that even less experienced machine operators can produce parts with the most complex bending requirements. Thanks to our expertise and excellent technical equipment, even the most complex sheet metal parts and other products can be bent without any problems. For the bending tasks we undertake, 320 tons of pressing force is available over a length of 3 meters, enabling the edge bending of sheets up to 10mm thick per meter. Our primary goal is to achieve the smallest radii possible using the smallest tools.

Our edge bending machine is driven by CNC-controlled motors on every axis, allowing for precise adjustments, collisions, and measurements, ensuring flawless execution for our clients. The key element for perfect bending is a stable and accurate rear stop system.

During our expert technical preparation, we use computer-aided design and model creation to create sheet metal layouts optimized for bending parameters, ensuring perfect parts after bending.

Our machine works with EURO type upper and lower tools, which are easily obtainable, making tool procurement stress-free for new projects. Additionally, the quick tool clamping system allows for fast tool changes.
One safety feature is the laser intrusion protection, and the other is the front sliding sheet holder, which ensures proper sheet support.

Panel bending

Matic Ltd. Technologies - Panel bending
In early 2019, Matic Ltd. installed the Salvagnini P4Lean-2120 panel bender/edge bender, expanding the range of products manufactured at our company.
The P4 Lean panel bender is exclusively developed and manufactured by Salvagnini, representing a universal and nearly fully automated branch of sheet metal bending. During the bending process, an automatic manipulator handles the movement and rotation of the sheet, minimizing the time between two bends. When the sheet is in position, an automatic gripper adapted to the sheet's geometry securely fastens the material to the table. Then, two universal bending tools (one upper and one lower) perform the necessary bends on each side. Everything is automated with the help of manipulators and actuators.

The biggest advantage of these machines is their universal tools, which eliminates the need for setup and tooling time. The machine adapts to the geometry based on the 3D model (stp) generated program and creates the planned bends on the finished product, resulting in maximum production without scrap and with parts meeting design specifications.

An interesting feature of the machine is that it requires less than 20 liters of oil to operate, as it has both electric and pneumatic drives.

The machine is easy to operate and its user interface is user-friendly on all platforms.

Salvagnini P4Lean-2120 panel bender/folder
Main features:
► MAC 2.0: Adaptive bending correction system. During the bending process, the machine measures the force, compares it to the necessary force in the database, and performs the necessary corrections if there is any deviation due to changes in material quality.
► Rolling precision bending, which completely eliminates damage during bending.
► Ability to bend partially or fully enclosed edges.
► Ability to bend painted or foil-coated sheets without damage.
► Possibility to take unique reference points.
► Ball screw-driven manipulator, ensuring speed and precision.
► Integrated sheet thickness measuring system.
 
Bending parameters:
► Maximum longitudinal dimension of incoming material: 2495 mm
► Maximum transverse dimension of incoming material: 1524 mm
► Maximum diagonal dimension of incoming material: 2500 mm
► Maximum bendable length: 2180 mm
► Maximum bendable height: 200 mm

Material type Minimum material thickness (mm) Maximal wall thickness (mm) Dosable raw material max. length (mm) Max. length of tools Max. length of the inner bend (short side) Max. length of the inner bend (long side)
Carbon steel 0,4 2,5 6500 2180 mm 30 mm 45 mm
Stainless steel 0,4 2,5 6500
Aluminium 0,4 4 6500

Fiber sanding

Matic Ltd. Technologies - Fiber sanding
With 20 years of experience, we have expertise in creating, delivering, and packaging decorative surfaces, which is fundamentally contributed by our Kuhlmeyer type double-fiber sanding machine.
The advantage of the machine is that with two belts, sanding can be done in a single grip. Both smaller and larger workpieces can be processed automatically and manually. For simpler components, a flat table is used, while for more complex welded structures, a pneumatic rotator is utilized. Multiple endless sanding belts are available to achieve the desired surface finish.

Laser engraving

Matic Ltd. Technologies - Laser engraving
In most complex assemblies, it is important to mark the parts, indicate the drawing numbers, and apply pictograms even after surface treatment.
For this purpose, we use two laser engraving machines that are suitable for durable marking on anodized, powder-coated, stainless steel, aluminum, copper, and curved surfaces. In addition, it plays a crucial role in the life of our powder coating plant, as we prepare the necessary special and unique masking materials for every surface that needs to be protected from powder coating.

Spot welding

Matic Ltd. Technologies - Spot welding
Spot welding is a special technology in pressure welding processes.
The parts to be welded are placed between two electrodes, one of which is movable and the other is fixed. The ohmic resistance between the materials at the transitional point is particularly high, and at this point, the temperature between the materials approaches the melting point due to the effect of electric current, which the electrodes simultaneously compress to create an insoluble welding bond. It is important that the bond focuses on one point per weld. Spot welding is generally suitable for creating overlapped joints of parts with a thickness of 0.05…6 mm. Our machine park has 4 machines suitable for steel processing and 1 machine set for aluminum processing. In addition, a multi-functional machine is also available, where we can spot weld parts up to 2-3 meters long, and using modern technology, we can easily handle the most complex assemblies. In this case, a water-cooled and completely flat brass table provides the lower electrode of the machine.

The process is practically divided into three stages:
1. By switching on the current (I), an electrical contact is created between the workpieces. The solid metal heats up and expands, thereby increasing the gap between the workpieces. Then, under the effect of electrode force, the molten metal is squeezed out into the gap between the workpieces, forming the closing zone of the weld.
2. The contact area continues to increase, and a lens of diameter depending on the thickness of the workpiece is formed. The surface oxide layer breaks up and mixes with the molten metal, which further expands and undergoes plastic deformation.
3. After switching off the welding current, the metal cools and crystallizes. The crystallization process can be regulated by the change of pressing force. The thermomechanical stress of the welded metal affects the properties of the lens and the metal in its immediate vicinity.
 
In spot welding, different welding cycles can be set according to the material quality, thickness of the workpieces, the type of the bond, etc. The welding cycle is mainly determined by the current strength, pressing force, and welding time.

Stud welding

Matic Ltd. Technologies - Stud welding
Our company uses both arc drawing and stud welding technologies, so we can weld fasteners with the highest quality requirements on carbon steel, stainless steel, and aluminum plates.
Most of the weldable studs are available in stock, but the procurement sources can also deliver up-to-date, so we can serve our partners with short lead times.

Technological description: (source: www.soyer.hu - accessed: 04/01/2023

Arc drawing technology:
In this welding process, a welding power controller serves as the energy source, which introduces a continuous arc that can be controlled in duration and current. The welding time is usually 0.1 - 0.2 seconds. It is possible to use shielding gas or a ceramic ring as an auxiliary device.

The welding pin touches the welding surface.

The welding pin moves away from the welding surface, the arc ignites.

The welding pin is immersed in the melt, the melt solidifies, and the joint is created.

Stud welding technology:
In this stud welding process, the current source is provided by a capacitor that discharges its voltage through the tip of the welding stud in an extremely short period of 1-3 ms (0.001-0.003 seconds). The use of auxiliary devices such as a ceramic ring or shielding gas is not necessary.

The tip of the welding pin touches the welding surface.

The arc forms a thin melt layer between the welding pin and the work surface.

The welding pin is immersed in the melt, the melt solidifies, and the joint is created.

(Source: www.soyer.hu - access: 01.04.2023)

Fastener pressing (Pinning)

Matic Ltd. Technologies - Fastener pressing (Pinning)
This technology is one of the cheapest ways to fix fasteners to plates.
Due to the precision of laser cutting and stamping, fasteners can be positioned very accurately, and the strength of screw connections approaches that of welded joints. We recommend the technology primarily for internal components, as without post-processing (complex surface treatment), the machining is visible on the other side.

Riveting

Matic Ltd. Technologies - Riveting
Riveting means fixing two plates with an insoluble bond.
The so-called rivet pull is performed with pneumatic rivet pulling machines of various sizes, so we are prepared for any riveting work in the world of thin plates. The most common fasteners, including rivet nuts, POP rivets, steel-steel, aluminum-steel, and stainless steel rivets, are available in our inventory.

Welding

Matic Ltd. Technologies - Welding
The aim of welding is to create an insoluble bond, or "cohesive bond," between two separate materials (metals) in a molten state. This can be achieved using various techniques.

Manual arc welding

Matic Ltd. Technologies - Manual arc welding
This technology represents a very complex world of metalworking, with a lot of literature dealing with this technology.
Our company only has Migatronik and Fronius machines, with which we also do welding on carbon steel, stainless steel, and aluminum substrates.

In addition, our company has ISO3834 welding shop certification, where the most common welding processes are validated, our employees have all the relevant certifications, and new requests are processed with the help of our welding supervisor.

Robot welding

Matic Ltd. Technologies - Robot welding
In the case of recurring orders, we can use our ABB welding robot to perform the welding process, providing stable quality and productivity.
The robot is serviced by a rotating table, which is also programmable, so the welding process is not affected by changing the parts, the two operations can be done at the same time.

Laser welding

Matic Ltd. Technologies - Laser welding
Laser welding is a technology that is becoming increasingly popular due to its ease of use and high speed.
The increasing use is due to the low heat input and reproducibility. Since the heat input is low, the parts/assemblies can be produced with a narrow heat-affected zone and low deformation. In laser welding, the surface of the component is not directly mechanically stressed, and the energy is supplied contactlessly, so that no deformation of the material occurs. This allows welds of the highest quality to be produced. The process is fully controllable and the equipment is small and easy to move.

Advantages:
► Much less distortion compared to other welding processes
► Faster and more precise process
► The heat is concentrated on the focal point generated by the laser
► Narrow heat-affected zone
► Easy integration into a process
► Significantly less post-processing effort
► The welding head is also a cleaning head (2 minutes conversion time)
► The welds produced in this way are more cost-effective

Disadvantages:
► High machine acquisition cost
► Thickness of the sheet metal sets limits

Matic's machine park has a 2 kW machine that can weld the following sheets without any problem:
Carbon steel / stainless steel sheet: up to 8mm
Aluminum: up to 6mm

The machine is equipped with a combined head, which, with a quick changeover, provides us with a full-fledged laser cleaning device.

Manual grinding, weld seam processing

Matic Ltd. Technologies - Manual grinding, weld seam processing
Manual grinding means that the grinding tool or machine is manually operated on the workpiece.
Despite the most modern technology, hand-guided machine grinding is still essential for most applications. All welding seams are processed with post-processing indicated on the drawing in a designated area where pneumatic manual grinding machines are used for post-processing of welding seams.

Pressing

Matic Ltd. Technologies - Pressing
We have both hydraulic and eccentric presses at our disposal.
In hydraulic presses, the forming is carried out by a tool attached to the hydraulic piston, with the forming force transmitted by high-pressure oil.
We distinguish between four and two-column hydraulic presses, as well as closed and framed ones.

Mechanical presses:
Among the various types of presses, we have eccentric presses up to 250 tons. We are talking about single-station eccentric presses that are designed for more general purposes, such as cutting and shaping sheet metal in our case. The frame of the machines is "C"-shaped, and the most important thing is that the flexible deformation of the frame of single-station presses is significantly greater than that of other press types. The main shaft is located perpendicular to the table, so the eccentric is located at the end of the main shaft. The machines require purpose-built tools necessary for the machining task, which can be single and combined (multi-stage) press tools. This machining format is worth choosing for mass production, and we can provide assistance in tool making in-house.

Sandblasting

Matic Ltd. Technologies - Sandblasting
With the help of a high-performance compressor, we use compressed air at 8 bar pressure to apply the surface treatment material from a tank through a blasting hose onto the surface.
Depending on the quality of the material and the design requirements, various abrasive materials can be used, such as sand, steel grit, glass beads, corundum, or their mixtures. The technology belongs to traditional blasting methods, and the result of surface treatment is an absolutely homogeneous surface, which can be used for surface treatment preparation in the case of carbon steels or as a final decorative surface for stainless materials.

Abrasion

Matic Ltd. Technologies - Abrasion
This is also a traditional surface treatment method, where the machining is done in an open vessel that is part of the abrasive machine.
The connection between the machine and the work area is ensured by a spring bed that transmits the vibrating motion generated by the electric motor. Various abrasive bodies of different composition and size can be placed in the vessel according to the machining task. This technology is primarily used for the deburring of mass-produced sheet metal parts, with separate materials used for each material group.

Powder coating

Matic Ltd. Technologies - Powder coating
Officially called electrostatic powder coating or simply powder coating, this method has the advantage of a more durable and environmentally friendly coating compared to solvent-based painting.
The process involves electrostatically charging the particles of the coating material, with the object being painted serving as the negative pole and the powder receiving a positive charge. As a result, the metal object attracts the powder, which can be either polyester or epoxy-polyester based. One of the great advantages of this technique is that the layer thickness can be controlled using the electrostatic powder spraying technique. The cost-effectiveness of the method comes from the fact that any powder that does not adhere to the metal surface is suctioned off by an extraction system, separated by a cyclone device, and the coating material is recycled for reuse, resulting in close to zero waste.

CNC disk sawing

Matic Ltd. Technologies - CNC disk sawing
This technology uses a simple, multi-toothed circular cross-section cutting tool with hard metal blades for material processing.
The machine can be used in two speed ranges, 1700 and 3400 revolutions per minute. The thread feed can be automatic or semi-automatic, but for workpieces with varying lengths of the same thread material, a separate program can be written. The thread is held pneumatically, and precise dosage is ensured by a ball screw with a stroke length of 600 mm and a stepping motor.

Our machining capabilities are as follows:
For circular cross-sections, the maximum diameter is D120mm. For square materials, the maximum dimensions are 100x100mm, and for rectangular materials, the maximum dimensions are 180x70mm. For solid materials, the machine can be used for up to 80x80mm.

We have several solutions for reducing or eliminating material waste.

A lubrication spraying system ensures the quality of cutting and the productivity of feed.

Mechanical and electronic assembly

Matic Ltd. Technologies - Mechanical assembly
Matic Ltd. has decades of experience in the field of mechanical assembly, complex sheet metal processing, and component manufacturing, particularly in the production of cash drawers, safes, and vaults.
Today, our company is a supplier for several large European corporations, offering not only the production of the components but also complex assembly (we are able to meet the needs of customers already in the prototype manufacturing phase).


Matic Ltd. Technologies - Electronic assembly
In addition to mechanical assembly, we also perform electrical assembly on the machines we manufacture. Our engineers check all documentation received from our customers for manufacturability and assembly. Our company management system helps us manage the entire manufacturing process. Mechanical and electronic assembly requires great expertise and precision. Our highly trained assembly staff, with decades of experience, guarantees that the finished product will be made according to the technical drawing.
We ensure the speed and impeccable quality of mechanical and electronic assembly with our assembly department equipped with professional hand tools, measuring equipment, and assembly templates. Appropriate personnel and material conditions are ensured.

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Matic Industrial Services Ltd.

Headquarters

  • H-6066 Tiszaalpár, Alkotmány u. 7.
  • +36 76 424 015
  • +36 76 424 139
  • ,
  • www.matic.hu
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