Laser-like precision with SIFCO process

Out of the groove

Die tooling specialist, Lasercomb Dies produce steel counter plates lined with grooves that are used to form creases in carton packaging. However, when one of the creases became wrongly aligned this resulted in aesthetic damage to the stainless steel die print piece. Initially, Lasercomb was unsure as to whether the component was still fit for use and was considering replacing it but, after exploring the time and cost implications of producing a replacement component, it became clear that carrying out a repair was a more viable option.

A lasting impression

To minimise downtime and any subsequent impact on productivity, a quick turn-around was required. Given the nature of the issue, there were relatively few options available, these being selective plating and tank plating. The problem with the latter was that it offered relatively little control of the deposit and since the damage was limited to a small area, it would have needed a vast amount of masking, hence, selective plating was the more practical option. This method was preferable on the basis that it offered control when applying the deposit by being able to fill the damage dress back, apply the cap and blend into the finish.

Initially, the damage was Copper filled with Copper H/S Acid. This copper fill was then dressed back, and a final Nickel Cobalt (Semi Bright) cap was deposited and blended. This deposit was used because it was the solution that would achieve the closest match to the existing surface finish. The procedures were carefully carried out to ensure the best possible surface finish, given that the repair was for aesthetic reasons.

Built to last

SIFCO ASC’s selective plating process was so successful that they were able to restore the component to perfect condition within one hour which is a time saving of more than 90 percent compared with manufacturing a new component. The overall savings included £2,500 – the cost for a replacement component - and perhaps even more significant is the minimal impact the repair had on productivity. Had Lasercomb been unable to salvage the component, they would have needed to produce another one which would have taken somewhere in the region of 30 hours costing £1,350 in labour. As well as incurring extra cost for materials and the associated production costs, this would have negatively impacted workflow and therefore Lasercomb’s capacity to meet agreed customer deadlines, potentially adversely impacting customer relations and Lasercomb’s reputation.

Kevin Holmes, Quality Manager at Lasercomb, explained: “We are extremely grateful to SIFCO ASC for providing an effective solution to a potentially tricky issue. By taking the time to assess the options available to us, SIFCO ASC was able to identify the most appropriate way to rectify the problem, saving us considerable time and money. Above all, the quality of the repair was outstanding to the extent that it was impossible to tell that the component had ever been damaged. We were extremely satisfied with the service we received and would be happy to use them again moving forward.”  

Mark Dorgan, Sales Manager at SIFCO ASC, commented: “Our focus, irrespective of the scale of the project, is to help our customers meet their selective plating requirements while providing first-class sales and technical support throughout the process. Our customer feedback speaks for itself and goes some way to explain why we are the global leader in our field.”