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iMetal cuts into market with new laser |
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by Jerry Cook
No one has to explain to Danny Zoldos, general manager of iMetal Inc., Toronto, ON the importance of having inhouse laser cutting capabilities.
“The need for a laser cutting system is inherent for almost any metal
fabricator these days in order to compete in the marketplace. I have
wanted a laser for years and I don’t know how we survived without one,”
says Zoldos.
That’s why iMetal recently installed a TRUMPF TRUMATIC L3050 two-axis,
5 kW laser cutting system (TRUMPF has subsequently renamed the L3050
laser system the TruLaser 5030). The laser system was supplied by
Advanced Fabricating Machinery Inc., Mississauga, ON (afmcanada.com).
The company began operations in 1962 as Toronto Kitchen Equipment Ltd.,
specializing in manufacturing products for the institutional and
industrial food service equipment market.
However, Zoldos notes that the firm recently changed its name to iMetal
Inc. to reflect the company’s evolution beyond serving its traditional
food service equipment market. “We have become quite diversified.
Today, we have become an architectural metal fabricator and entered
into a number of new markets including museum-related work such as for
exhibits; the pharmaceutical market; custom store fixtures; and more.”
Today, the company has 50 employees at its 45,000 sq. ft. facility in
Toronto. iMetal works with a variety of materials including mild and
stainless steel, brass, aluminum, copper, and more. iMetal’s sales are
split approximately 90%-10% between domestic versus export sales
respectively. iMetal’s part runs range from one-offs and prototypes up
to hundreds of thousands of pieces.
In addition to laser cutting, the firm offers a variety of services
including CNC machining, waterjet cutting, press brakes, shears, and
more. “To the best of our ability, we’ve tried to become a one-stop
shop (for our customers). As well, because of our background in gas
refrigeration and electrical work, we’ve also been able to take on
other facets of fabrication such as electro-mechanical assemblies,” he
says.
According to Zoldos, in recent years more and more of the company’s
work required laser cutting. Previously, “We would either outsource the
laser cutting work or send this work to our existing machines which
wasn’t necessarily the most cost efficient method.
“For example, I could look at pricing as far as outsourcing the laser
cutting work versus our own internal costs associated with (doing the
same job using) punching, nibbling, and deburring and it wasn’t cost
effective, particularly on the volume driven work,” he explains.
Cost effectiveness wasn’t the only issue. Both outsourcing the laser
cutting work or doing it inhouse on other equipment posed other
problems, he states.
For instance, “Previously, (using the punch press or shear) the edge
quality (we obtained) required deburring or taking the sharp edge off
the punch. You were limited by different edge quality issues that have
now been eliminated by the laser. The laser is much more reliable and
consistent in terms of edge quality,” says Zoldos.
Outsourcing the laser cutting work was also becoming a problem as far
as controlling schedules and deliveries, he adds. “We are a fabricator
that is very responsive to our customers, many of who have very short
deadlines. Our ability to respond to our customers is a competitive
advantage for us.
“The laser cutting system allows us to be even more competitive because
now we can process jobs faster. In the past, we’ve had to run our
waterjet cutting system through the night which we don’t have to do now
with the laser system.
“For prototyping work, the laser has allowed us to be even more responsive to our customers,” he says.
Installing the TRUMPF laser cutting system has also assisted iMetal in
its ability to handle high volume production while at the same time
opening up new opportunities for production work.
“There is always pressure in the marketplace to reduce our costs for
production work. We’ve had to find ways to do this in order to keep the
work and the laser has enabled us to do this.
“Previously, with our existing technology, we were limited on some of
the production work that was out there. We didn’t have access to this
production work unless we relied on outside vendors to assist us,” he
says.
For example, one market segment that the TRUMPF laser has helped
iMetal to compete in is store fixturing. “Store fixturing is more of a
volume driven sector. We had received quotes in the past but because of
our internal technology at the time, we didn’t seem to be successful in
getting that work.
“With the laser cutting machine, our part runs have actually increased
and we’ve been able to take on more volume driven work.,” notes Zoldos.
According to Zoldos, the new laser system is also proving to be
invaluable for a major contract that iMetal is currently working on.
The firm is fabricating custom architectural metal works for the
Newseum, a museum dedicated to the history of news, in Washington, DC.
“There are a number of galleries in Newseum and we are doing various
metal fabrications for all of the galleries including such things as 30
ft. towers for the journalist’s memorial exhibit and much more.
“It is a very prestigious project and I don’t think we’ll ever be
involved in another project of this magnitude and scope. The laser is
helping us to keep on time with the project even though timelines are
tight ,” says Zoldos.
According to Zoldos, when he initially began looking for a laser
cutting system, he looked at a number of competing laser cutting
systems before he selected the TRUMPF system. “I think that TRUMPF’s 5
kW technology is leaps and bounds beyond many of the other laser
manufacturers. I truly believe that TRUMPF (offers) the best laser
machines, especially in terms of support and the technology they have
developed to put into their laser systems.”
In particular, Zoldos was impressed with the speed that the L3050
offered. “When the system isn’t cutting, it travels at 11,800 ipm. Of
course, the thickness of material will obviously affect the length of
cut time but it is a machine that sets itself apart from others.”
Training on the new TRUMPF laser cutting system was a relatively simple
and straightforward process, he says, adding that he sent four
employees to TRUMPF’s head office in Farmington, CT for one week of
training on software and machine operation.
afmcanada.com
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