Manufacturing Die, knife and water cutting.

Manufacturing
Die, knife and water cutting.
World class engineering solutions
Die and knife cutting
Avon Group offer die cut gaskets, oscillating knife cut high
temperature insulations, water cut fibres and rubber. These
advanced technologies are both versatile in terms of material
and flexible enough to adapt to high and low volumes.
Our focus on improving quality,
repeatability and production efficiency
is centred around our manufacturing
plants in Bristol, Norton Canes,
Brynmawr and the Czech Republic.
High speed CNC travelling head
presses (large shapes)
We can produce shapes straight from
sheet or rolls, maximising material by
rotating the heads 360 degrees with
multi-cavity tools. We typically produce
thousands per hour dependent on our
clients’ particular requirements.
Small washers to tight tolerances
Avon Group produces over 100 million
washers a week. We have a series
of high-speed, die cutting machines
dedicated to the production of high
tolerance volume washers. Typical
runs of hundreds of thousands are
produced using precision steel
die tools.
Oscillating knife cutter
This offers the very latest cutting
technology without the need for
tooling. Using CAD, we are able to
optimise any shape and/or design
requirement for you. This process is
innovative, fast and accurate and
can be used for a range of materials,
from sponge rubbers to fibres and
insulations. By switching the knife
head to a routing head, we are able
to produce intricate chamfered
insulating boards.
Semi automated packaging
Kits of seals and gaskets are fed into
our high speed automated bagging
machines. This enables us to pack a
wide range of products, bar-coded,
straight into cartons.
Press cut gaskets
Avon Group are able to provide a full
range of pipeline table gaskets in both
metric and imperial sizes. Traditionally
we have produced on hydraulic cutting
presses and these still serve us well
today which allows us total low volume
flexibility. As an alternative however,
we can cut bespoke sizes using knife or
water cutting technology. Our range
of materials is very comprehensive,
broadly consisting of non-asbestos
fibres for above ground heating,
pipelines and petrochemical with
EPDM for below ground potable
water pipes.
Avon Group is a
partner
Water cutting
Avon Group was among the first companies in the UK to embrace waterjet cutting
technology, one of the fastest growing machine processes in the world due to its
versatility and ease of operation.
Profile cutting by waterjet means that
there are virtually no limits to what
materials can be cut. Greater quality,
efficiency and productivity levels can
be achieved.
How it works
Water is pressurised to 60,000 psi
(4000 bar) or more and passed at
high velocity through a tiny opening
to cut a variety of soft materials such
as paper, gasket materials, rubber
and foam. When small amounts of
abrasive particles are mixed into the
jet stream, the resulting ‘abrasive
waterjet’ can cut virtually any hard
material such as metal, composites,
wood, stone and glass.
Quite literally ‘cutting edge’, Avon
Group’s modern waterjet machines
are computer controlled, enabling the
use of CAD/CAM technology.
Benefits:
• Able to routinely cut precision
parts to tight tolerances (typically
0.1mm or better)
• Cuts virtually any shape, in any
material, up to 150mm thickness
• Items can be nested which
improves raw material usage and
reduces waste
• Improved productivity and efficiency
• No tool changes or replacement
required
• Rapid set-up times and minimal
operator intervention
• Environmentally friendly process
with no toxic gases or fumes created
during the cutting process
Advantages over traditional
cutting methods:
• Able to cut a wide variety of profiles
and materials with just one tool
• No direct contact between the
cutting head and the material,
minimising any distortion
• 100% perpendicular cut edges
irrespective of material thickness
• Virtually no induced tension or
micro cracking
• No heat affected zones to work
harden, melt or distort cut edges
• No mechanical stresses as caused by
other cutting methods
• Superior edge quality
• Dust reduction by cutting
with water
Applications:
•Aerospace
• Air systems/compressors
• Auto, aviation and marine
•Automotive
• Bathroom and construction
• Heat containment and insulation
• Pipelines
Fabrication and assembly
Avon Group has developed an excellent reputation for packaging kits and fabricated
assemblies. We can supply kits for all types of industry, from washer and O-ring
sets containing just a few pieces, to very large packs of insulation material for high
temperature domestic appliances.
Avon Group is able to pull together
many different gasket types in
various materials and pack them
as a complete kit. Examples include
compressor seal sets and joint sets for
the pipeline industry. We are able to
print labels directly onto the packaging
to exact customer requirements or
print individual numeric barcodes to
ensure full traceability and accuracy.
Our clients rely on us to
accurately assemble
these kits for direct
international shipment.
Our computer aided
design and advanced
software maximises the
material utilisation and
minimises waste.
Scott Lamerton
CAD designer
Avon Group Manufacturing,
Bristol.
By using the very latest technology, Avon Group is able
to machine to extremely tight tolerances. Our computer
aided design and advanced software maximises the
material utilisation and minimises waste. This means we
can offer excellent repeatability and value. Our attention
to detail and the responsibility we take with the material
are just some of the many factors which sets us apart
from our competition.
Material range
Avon Group’s portfolio comes as a
direct result of our experience within our
Fabrication department.
We can supply any material, in any size and
thickness, packed and ready for retail.
Many materials are currently supplied
to national builders’ merchants and
on-line catalogue companies. These
include our traditional materials, such
as non-asbestos sheeting, rubber
sheeting and mouldings, high
temperature insulation (boards, paper
and blankets), sealing tapes and strips.
We also supply the newest material
ranges, which include Nomex, Formex,
Mica and Mylar films (which have
excellent insulation properties).
Suppliers
Wherever possible, we try to source
British manufactured materials. All our
tools are manufactured in this country.
We go direct to the manufacturer for
our materials to ensure our prices are
the lowest possible. This establishes
a reliable source of raw material,
ensuring we always have a readily
available supply.
• Did you know Avon Group cut over
10,000 shapes?
• Did you know Avon Group hold
at least 100 different materials
on site?
• Did you know Avon Group stock
40 thicknesses of material?
• Did you know Avon Group
materials are available
in 14 different colours?
• Did you know Avon Group have
our own transport and drivers?
Manufacturing technologies
Avon Group has a reputation for pioneering many
innovative manufacturing technologies. This has
broadened our client portfolio to appeal to some
of the leading manufacturers in the world.
Surface coasting
Allows assembly to
have, for example
high or low friction
properties.
Base material
Choose from EPDM,
Neoprene, Polyethylene,
Polyurethane etc to
suite various
applications including
anti-vibration parts,
dust and waterproofing
seals, gaskets and general
cushioning.
Adhesive backing
Coverage may be partial or
selective from a range of
specialist adhesives to suit
every application, including
temperature to water
resistant, permanent to
peelable, aggressive to low
tack, etc.
Finished
components
Multi-material
laminates
Multiple shapes
laminated together can
give different physical
properties to different
areas of the assembly,
eg sound, particle or
fluid filtration.
Backing sheet
Waste removed and
precision punched to
suit various automatic
assembly systems.
Available to suit
customers’ own
specifications.
Complete materials preparation service
Components can be formed to your exact specifications, which includes precision
die-cutting of high performance plastics, multi-material lamination, partial
adhesive backing, surface coating and skeleton waste removal - all formatted for
manual or automated assembly.
Avon Group is a supplier of a wide
range of quality products to the
industrial markets. Our flexible
management and production team
gives us the ability to produce
customer-specific parts in a short
lead-time. With our technical
knowledge and experience, we can
offer our customers the highest
levels of support to overcome any
technical and design issues.
Our investment in technology
has equipped us with the latest
tooling and software to provide all
manufacturing solutions required.
We can select the technology to
meet our customers needs and we
will meet tolerances, volume output,
repeatability and efficiency that our
customer’s production demands.
Processing capabilities
•Aerosol, gaskets & seals
•Die cutting/kiss cutting
Avon Group Manufacturing Ltd.
30 Vale Lane,
Bedminster, Bristol
BS3 5RU
United Kingdom
AER Stafford Ltd.
Bellsize Close, Norton Canes,
Cannock, Staffordshire
WS11 9TQ
United Kingdom
Tel: +44 (0)117 904 3355
Fax:+44 (0)117 904 3366
[email protected]
Tel: +44 (0)1543 270002
Fax:+44 (0)1543 278046
[email protected]
Avon Engineered Rubber Ltd.
Maerdy, Ferndale,
Mid Glamorgan,
South Wales
CF43 4FP
United Kingdom
Avon TSA Ltd.
Blaenant Works,
Brynmawr, Gwent
NP23 4BX
United Kingdom
•Extrusion & lathe cut washers
•NVH solutions
•Phosphating, rubber to metal
& plastic bonding
•Plastic injection moulding
(rigid & flexible)
•Rubber 2K & rubber overmoulding
•Technical rubber & polyurethane
foam moulding
•Textile shapes & assemblies
•Tool production & technical design
•Vacuum forming (rigid & foam)
•Water cutting
Tel: +44 (0)1443 735000
Fax:+44 (0)1443 735209
[email protected]
P & D Manufacturing Ltd.
Unit A11, Fiveways Trading Estate,
Westwells Road, Hawthorn,
Corsham, Wiltshire
SN13 9RG
United Kingdom
Tel: +44 (0)1225 812900
Fax:+44 (0)1225 812600
[email protected]
PP Injection
Moulds & Mouldings Ltd.
Lower Bevers Brook Industrial Estate,
Redman Road,
Calne, Wiltshire
SN11 9PL
United Kingdom
Tel: +44 (0)1495 312666
Fax:+44 (0)1495 312819
[email protected]
Avon Engineered Rubber Inc.
843 Commerce Parkway,
Carpentersville, IL.
60110, USA
Tel: 001-224-293-6170
Fax:001-224-293-6172
[email protected]
United Polymers s.r.o.
Továrni 605,
P.O. Box 114
753 01 Hranice
Czech Republic
Tel: +420 581 699 511
Fax:+420 581 699 519
[email protected]
Tel: +44 (0)1249 823100
Fax:+44 (0)1249 823103
[email protected]
www.avon-group.co.uk
Every effort has been made to ensure that the information contained in this brochure is accurate as of November 2013.
Avon Group reserves the right to introduce at any time modifications, or changes to their products. E&OE.
Please recycle. Printed in the UK on paper from sustainable sources. © 2014 Avon Group. All rights reserved.
AG-M-01-10.13