At the beginning of the century, for many shops in the metal fabricating world, laser cutting capability was never a prerequisite to success. Or so they thought. The older generation were trained as craftsman and had the technical skills to work with manual equipment. To many, manual machines, in the owners’ minds, were better suited for the one-off parts and repair work. They never envisaged long runs of the same component. These components typically didn’t require much repeatability or pre-programming, which are the primary advantages of CNC machining, cutting or bending.
“It’s like talking about the millennials and Generation Z. For many years, we’ve heard about millennials and seen many of the trends, challenges and peculiarities associated with their age group. More recently, some of that coverage has shifted to Generation Z – the age group after the millennials. Researchers typically reference the late 1990s and early 2000s as the birth years of members of Generation Z. They are digital natives that have used computers, the internet and social media technology since they were old enough to reach (and click) a mouse,” explains Sergio Maffia (47).
MB Laser have acquired a Bodor 12kW fibre laser with a bed size of 3 000mm by 1 500mm, which was installed in March 2024 by Integral Machine Tools
“The same can be said about all forms of manufacturing and the equipment and systems that are used. When my father Pasquale started his business in 1981 the equipment they used was very much manual. They relied on manual mills and lathes for machine shop business and conventional welding equipment providing traditional, short-arc processes was used. Before machines came along, if someone wanted to bend sheet metal, they’d attach an appropriately sized piece of sheet metal to a mould or a 3D scale model of the desired sheet metal shape, anvil, dolly or even a forming bag, which was filled with sand or lead shot.”
“Using a T-stake, ball peen hammer, a lead strap called a slapper, and tools called spoons, skilled tradespeople pounded the sheet metal into the desired shape, like into the shape of a breastplate for a suit of armour. It was a very manual operation, and it’s still performed today in many autobody repair and art fabrication shops.”
“As the manufacturing and fabrication industries evolve, so must equipment. Besides addressing the needs of processing newer materials, such as thin-gauge, advanced and high-strength alloys, and coated materials, these processes can help companies stay competitive as they work to improve productivity and quality.”
The Bodor fibre laser is equipped with leading manufacturer’s components for the critical working components
“In fact, many companies today are turning to advanced processes to help increase plant capacity, often with less labour, and to expand their capabilities. This means they now can process multiple part designs and use materials they may not be as familiar with. The benefits of advanced equipment can help smooth the transition, ultimately allowing companies to enter into new markets and grow their business.”
Adopting emerging technologies
“The desktop computer revolution, in full swing in the mid-1980s, found a place in manufacturing, making CNC equipment easily programmable. This, combined with the introduction of electrically driven equipment, drove big changes throughout manufacturing.”
“It is incredible to think servomotors and ball screw drives revolutionised manufacturing when they were introduced in the 1990s.”
“Cutting and bending sheet and plate has also evolved. It was not so long ago when CO2 cutting was introduced. Fibre laser cutting was only introduced in 2008 and then it catered for the thinner gauge material. CO2 cutting was on its way out. As the technology has improved so has the speed and quality of cut.”
Brothers Giuseppe and Sergio Maffia
“Another interesting project that we are currently busy with is the manufacture of trolleys for the go-karting industry. The purpose designed kart trolley is as a result of Sergio’s involvement in the industry. He used to race and now he has got his son interested. The kart is used to easily move the go karts and tooling around on race day or at the workshop.”
“Application of high-powered lasers is becoming more commonplace in industrial environments and manufacturing as more applications of these lasers are discovered and developed. More manufacturers are realising how reliable and repeatable industrial laser systems can be. Like any other machine tool, the technologies surrounding the laser system have advanced significantly over the past several decades.”
Right timing, right price, right size
“It took us five years of decision making before we finally acquired our Bodor 12kW fibre laser with a bed size of 3 000mm by 1 500mm. There were many different reasons why but ultimately it does come down to affordability. So the desire to purchase a laser cutting machine was solid, but what kind of machine would it be? We didn’t want to spend a large amount of money on a new piece of equipment and then be disappointed.”
“But we did want to transcend into the era of modern equipment that would be accompanied by an impressive increase in production capability. It is proven that modern machinery has increased throughput in many metalworking and fabricating companies tremendously.”
“Dad was born in Italy and trained as a boilermaker. He emigrated to South Africa in 1966 with Mum Antoinetta, who still works in the company, and got married here.”
“He spent 15 years as an employee before starting MB Fabrication with partner Derrick Bolson. The MB is derived from the first letter of the surnames of the two partners. They started off in a small factory in Jeppestown and their main focus was on steel fabrication for the mining industry.”
“We manufactured 40 trolleys for the recent African karting championship at Zwartkops and as a result we have acquired many more orders.”
In the welding department MB Laser have a variety of welding equipment that can be used for a range of applications. They use a CO2 to weld plates and mild steel sheet at up to 450amps. TIG welders are used for thinner plates (0.6mm / 0.8mm) with small runs. They also have ARC welders running up to 500amps and are able to weld 20mm steel plates and other materials. The company have a portable machine for a variety of other, smaller jobs
“While working for companies such as Turin Motors and Coronet Engineering, Dad did build up a network of contacts. This certainly helped to get work and contracts in the early days of the company.”
“The company soon outgrew the space and moved to bigger premises in Stormill before moving to the current factory in Leader Road, Robertville, Roodepoort.”
Elder brother Giuseppe (55) joined the company in 1996 after studying electronics and working in the electronics field for a number of years. Like most sons of immigrants involved in the mechanical engineering industry Giuseppe had been to his father’s factory many times while still at school and was very comfortable with the environment and the machines. Besides Mum was a full-time employee.
Giuseppe continues: “The move west of Johannesburg also allowed the company to increase its capabilities and equipment repository.”
“The shop utilises a number of different machines used for fabrication and assembly of steel. Our guillotine has front and rear functions which allows for quick and accurate cutting of plates ranging in thickness from 0.5mm to 8.5mm with a 2.5 metre width. We cut mild steel, stainless steel and aluminium on this machine.”
“We also acquired a 160 ton bending brake that has the ability to bend sheet up to 8mm and up to 3 000mm wide.”
“In the welding department we have a variety of welding equipment that can be used for a range of applications. We use a CO2 to weld plates and mild steel sheet at up to 450amps. TIG welders are used for thinner plates (0.6mm / 0.8mm) with small runs. We also have ARC welders running up to 500amps and are able to weld 20mm steel plates and other materials. We also have a portable machine for a variety of other, smaller jobs.”
“Our drill machines and sectional cutters drill through plates up to 200mm.”
“And our plate roller can roll steel up to 12mm thick and 25 metres in length.”
Profiling
“One of the workhorses in the company has been our high-definition plasma cutter that can cut mild steel plate up to 50mm. The profiling machine has reduced lead times but at the same time it has given us trouble with too many breakdowns. This is a primary reason why we have gone the fibre laser route.”
The company was focussed on fabrication and assembly of steel and will continue to do so
MB Laser have acquired a 160 ton bending brake that has the ability to bend sheet up to 8mm and up to 3 000mm wide
“However, we also wanted to expand our portfolio, increase our presence, and become a stronger overall supplier. To accomplish all three goals at once we had to make a wise investment.”
“Fabricating and assembly has always been the primary focus of the business but we will now have excess capacity and we will be concentrating on expanding and filling capacity.”
“We are a very broad-based company in that we are able to complete large and small fabrications. The list of projects that we have completed have involved pipework and flanges for pipelines, electrical transformer boxes, radiators, staircases, mezzanine floors, trade exhibition stands, tanks, outdoor signage and structures.”
“You can’t put us into one box even though in the beginning there was a concentration on the mining industry and then enclosures for anything electrical, including transformers.”
“We also believe that we were the first in South Africa to build a vacuum oven. We manufactured this for Revive Electrical Transformers, one of the leading transformer manufacturers in South Africa.”
“A vacuum oven is used to cure the resin poured into transformer components, under vacuum. Cast resin dry-type transformers are used in high-moisture areas. These primary and secondary windings are encapsulated with epoxy resin (non-hygroscopic). The encapsulation prevents moisture from penetrating the winding.”
“But like many industries the transformer industry went through a transformation and we had to adapt.”
The company also has a guillotine and a plate roller that can roll steel up to 12mm thick and 25 metres in length
“One of these industries that we have entered into is the outdoor billboard arena. We have had some interesting projects to engineer, manufacture, project manage and erect. We can proudly say that we have billboards on the way to OR Tambo Airport in Johannesburg and at the entrance and exit roads at Cape Town International Airport.”
“Another interesting project that we are currently busy with is the manufacture of trolleys for the go-karting industry. The purpose designed kart trolley is as a result of Sergio’s involvement in the industry. He used to race and now he has got his son interested. The kart is used to easily move the go karts and tooling around on race day or at the workshop.”
“We manufactured 40 trolleys for the recent African karting championship at Zwartkops and as a result we have acquired many more orders.”
Niche area with fast delivery
“As I said it took some time to order the Bodor 12kW fibre laser with a bed size of 3 000mm by 1 500mm. But we finally came up with an impelling strategy.”
“We have been in the fabrication industry for some time. Myself since 1996 and Sergio since 2011. Even though we have a profile cutter there is always a call for laser work of sheet to be done. As the years have moved on so have the delivery times, especially if you are only ordering small quantities like us.”
“A service centre might manage hundreds, perhaps thousands of jobs at any one time. And it is only natural that there are going to be bottle necks, there is going to be prioritising, favoured customers are going to jump the queue and more. The smaller guy will generally miss out and his delivery times will also miss out and the frustrations will grow between him and his client.”
The company has recognised an area to be involved in where there is a need for high mix but with a short delivery date and on time. This is one of the main reasons they have purchased a Bodor 12kW fibre laser
“We have recognised this as an area to be involved in where there is also a need for high mix but with a short delivery date and on time. If you look at the speed and quality of cut on our Bodor fibre laser, which these days are equipped with the leading manufacturer’s components for the critical working components, we can compete in these areas and be cost competitive because of our relatively low overheads.”
“We will also not go the route of traditional manufacturing thinking, in which workers produce more than is needed to reduce the number of setups and maximise the efficiency of all resources. The forecast, after all, says these parts will be needed eventually, so why not produce them now? The problem is, of course, that sales forecasts are notoriously inaccurate, so those parts may never be needed. Also, producing so many unneeded parts floods the floor with work-in-process (WIP), while jobs in queue sit for days or weeks waiting for large batches to work their way through.”
“Additionally, the software available for operating the machine, quoting, nesting and other services is so efficient these days you can save heaps of time in this area.”
“We might not be the biggest but we have big ambitions. Be careful the Maffia boys are in business to get it done.”
For further details contact MB Laser on TEL: 011 474 3610 / 3629 or Giuseppe on 082 852 2299 or Sergio on 083 607 3776.
