AF Switchgear, the UK’s largest privately owned switchgear manufacturer, has invested in three
Trumpf CNC sheet-metal processing machines over the past year — a TruBend 5130 press brake, a TruPunch 3000 punch press and, most notably, a TruMatic 3000 fiber punch/laser combination machine. The latter is driving new part-processing workflows at this progressive manufacturing business, helping to boost production by 50% over two shifts.
With a strong tradition of engineering excellence and customer care, AF Switchgear employs around 400 people and generates annual turnover in the region of £100 million. The company designs and manufactures all products entirely in-house, ensuring complete control over quality, innovation and delivery. While its core focus is the datacentre industry, AF Switchgear also serves clients across healthcare, banking, finance and telecommunications. Family values run throughout the organisation, with its commitment to building strong, long-term relationships proving the reason so many customers continue to choose the company as their trusted partner.
AF Switchgear and Trumpf both celebrated their 50th anniversaries in 2024, making it fitting that these two industry leaders partnered over the past 12 months in a series of machine investments. Marking a significant step forward in production capacity and capability, the arrival of the new machinery means AF Switchgear is now a 100% Trumpf shop for all 2-D cutting and bending operations. Gary Taylor, fabrications engineering manager, said: “As a business, we work really hard to maintain flow through manufacturing. We recently set about increasing our production to ensure we could achieve internal production demands and deliver right-first-time products to customers.”
With Trumpf punch presses and press brakes already performing well on-site, AF Switchgear had no hesitation in returning to Trumpf for its latest investments. The company selected new TruBend 5130 and TruPunch 3000 machines to increase capacity, particularly for the manufacture of switchgear cabinets. However, the stand-out investment is a large-format TruMatic 3000 fiber, the first punch/laser combination machine on-site.
Combined laser cutting and punchingMr Taylor added: “We had a stand-alone laser cutter from another manufacturer for over 10 years and wanted a replacement that would advance our manufacturing operations. The Trumpf TruMatic 3000 fiber was chosen because we knew it would provide combined laser cutting and punching and the recent introduction of tapping heads that increase capacity with faster cycle times and higher throughput. It offers quick unload/load, rapid tool-change capability and a noise-reduction bed, which is important in our fabrications department. The machine also saves space and avoids the cost of purchasing a separate laser cutter.”
The Trumpf TruMatic 3000 fiber offers exceptional flexibility, productivity, efficiency and reliability in sheet-metal processing. It also achieves outstanding part quality thanks to the descending die and is easy to operate with its touchpoint HMI. The arrival of the machine at AF Switchgear is driving a 50% gain in machine availability and increasing daily production hours over two shifts.
Although the fibre laser machine and its 3kW laser can process sheet thicknesses up to 6mm (5mm aluminium), AF Switchgear typically processes 2, 2.5 and 4mm thick CR4 carbon steel, while other materials cut on site by the machine include stainless steel, galvanised steel and aluminium. All Trumpf machines are fully operational across AF Switchgear’s two-shift working week. The company also produces parts ‘lights out’, ensuring full utilisation.
Mr Taylor continued: “Along with an increase in production of 50% over our two-shift operation, impressive part accuracy means we can supply our customers with right-first-time components. Our customers now benefit from quality parts programmed and produced entirely using Trumpf machinery and software.”
AF Switchgear describes its experience of working with Trumpf as “a professional service from delivery and installation to final commissioning, sign-off and training”. Mr Taylor said: “Full training was provided on both machine programming and operation. Training took place at Trumpf UK in Luton and at our premises here in Nottinghamshire. Our employees have all been receptive and embraced the need for the change and investment within the fabrication department.”
The new Trumpf machines clearly reinforce AF Switchgear’s commitment to innovation, quality and remaining at the forefront of production technology. He concluded: “With these recent investments, we can ensure full control over our manufacturing operations. The Trumpf machines have increased throughput and stabilised production to ensure we achieve all expected customer delivery dates.”