Advanced Materials Today Jul/Aug 2010 

 Advanced Materials Today Jul/Aug 2010

 July/Aug 2010

Contents
Visit our in-house Cover Story Technology
exhibition on 4 It’s Time for Africa 25 Future of Casting
3 & 4 November Corrosion Joining
8 The Good, the Bad and the ... 28 Nuts About Fasteners
Craft Machine Tools
Beautiful!
Tel: (011) 845 2030
Manufacturing
Fax: (011) 845 2041 Stockists and Service Centres 31 Chop, Chop Scissors
Email: 11 Steel Whenever, Whenever
info@thompsongroup.co.za Industry News
Web: Welding 34 Industry News
www.craftmachinetools. 15 Real World Training
co.za Endorsing Bodies
TDM Today • SAIMechE (SA Institution of Mechanical
(Tool, Die & Mould Making) Engineering)
17 Tooling Around • AFSA (Aluminium Federation of SA)
19 Tools for the Trade • CorriSA
22 TDM News • NTIP

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shall not be responsible or in
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omissions or inaccuracies Proprietor and Publisher:
PROMECH PUBLISHING DTP: Zinobia Docrat and
in the publication whether Sanette Lehanie
Tel: (011) 781-1401
arising from negligence or
Fax: (011) 781-1403 Disclaimer
otherwise or for any conse-
E-mail: editorial@promech.co.za Neither PROMECH Publishing
quences arising therefrom. Website: www.promech.co.za
The inclusion or exclusion of nor its endorsing bodies are
Managing Editor: responsible for the opinions
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board advocates or rejects its Raymond Campling Printed by:
use either generally or in any Advertising Sales: Typo Colour Printing
particular field or fields. Di Bluck Tel: (011) 402-3468

Advanced Materials Today Jul/Aug 2010 

COVER STORY

It’s Time for Africa

One of South Africa’s leading machine tool
suppliers is encouraging its customers to
expand their manufacturing reach across
borders and to capitalise on good sentiments
towards the country following the success of
the Fifa World Cup.

D
anny Thompson, a director of Craft Ma-
chine Tools, a division of the Thompson
Machine Tools Group, says the time is
now for the manufacturing industry to
look for international supply contracts. Negative
preconceptions about South Africa have been erased
and the world is potentially at our feet.
“The World Cup disproved a lot of negativity sur-
rounding the country and also illustrated that we
are, in fact, quite capable of producing at the highest
level. Now we want to work with our customers to
encourage them to look for new business locally
and across our borders.
“We feel that this is the best possible time to outfit
machine shops in order to take on new business.
Current lower volumes mean that more time can
be taken to plan improvements and optimise
workflow without negatively impacting on output,”
Danny says.

Good advice is hard to come by in an

age of easy money
Best laid plans
“The world-wide recession forced us to look for
new avenues of growth and we put a lot of focus
into tailoring our product offerings to meet current
market conditions.
“We looked at our customer’s future requirements
and in some cases we decided to discontinue
product ranges. In other instances, we sourced
new products to suit the current economic climate
and to enable our clients to capitalise on trends
locally and abroad.”
An example of this is the Craft range of heavy-duty
large spindle precision lathes for oversized work
pieces to rotate through the head on the spindle.
The lathes are capable of making items ranging from
oil rig components to heavy-duty shafts, items that
are in high demand across the globe.
Group activities
The Thompson Machine Tools Group comprises
Thompson Machine Tools, which is the used machine
tool division and founding company. Simultaneously,
Craft Machine Tools specialises in new machine

 Advanced Materials Today Jul/Aug 2010

 COVER STORY

group’s directors believe that a company must

Machines available from Craft Machine give something back to the community it serves.
Tools: In this way the Thompson Machine Tool Group
has developed a heart and actively participates in
Haco community activities with an emphasis on youth
• Press brakes development.
• Guillotines
• Plasma cutters
• Rolling
• Punching
• Universal iron workers

Bemato
• Saws
• Milling machines
• Surface grinders
• CNC machining centres

Feeler
• CNC lathes
• CNC machining centres

Dalian
• Lathes 2m – 5m

Craft
• Heavy-duty large spindle precision lathes
China / Czech
• Radial arm drills

tools imported from countries such as the United

Kingdom, Germany, Belgium, Czechoslovakia,
Taiwan, Hong Kong and China.
Interprovince Engineering Supplies is involved in the
supply of engineering supplies, parts and accessories
for metal working, while Trakmans Auctioneers will
sell almost anything that has a market value. As a
result, the group can profess to be a one-stop-shop
for manufacturers and engineering concerns.

The local market has many propositions

for would be buyers of machine tools

A company with a heart

Good advice is hard to come by in an age of easy
money, easy imports and a myriad of new-comers
to the South African market. But it is worth noting
that Thompson Machine Tools Group has been in
the same business for the last 40 years.
The company remains a stalwart to the industry it
serves. Its simple business philosophy remains to
provide very good machines at reasonable prices, good
service and backup, as well as honest advice.
At the core of the company are its people and the

Advanced Materials Today Jul/Aug 2010 

 Advanced Materials Today Jul/Aug 2010
 COVER STORY

Directors: Patrick Zackey, Philip, Fred and Danny Thomp-

son

Through its various companies, the group is a keen

sponsor and supporter of, particularly, local youth
soccer teams and road running. It also takes a
keen interest in small and new upstart businesses
and gladly lends expertise and planning support to
these companies with a long-term view of servicing
them through their infancy all the way through to The group can profess to be a
maturity.
one-stop-shop for manufacturers

“These relationships are built

on trust and respect and are
the cornerstone of the group’s
dealings.”
Time to build
The local market has many
propositions for would be buyers
of machine tools and engineer-
ing supplies. In order to make
the most of money spent, it
pays to know your options and
to seek advice from people that
have experience spanning good
times and bad.
“For this reason, we decided to
do something different this year
and instead of our usual stand
at Electra Mining we want you
to come join us on 3 and 4 No-
vember 2010 for our bigger and
better in-house exhibition.
“There is enough space to show
lots of new machines, as well as
special offers and prizes. Most
importantl,y there will be time
to discuss clients needs and
wants,” concludes Danny.
Craft Machine Tools, Danny Thomp-
son, Tel: (011) 845 2030, Fax: (011)
845 2041, Email: info@thompson-
group.co.za, Web: www.craftmachi-
netools.co.za

Advanced Materials Today Jul/Aug 2010 

CORROSION

The Good, the Bad and

the … Beautiful!
The five tier R2 billion Nelson Mandela
Bay Stadium was one of three coastal
stadiums built in anticipation of the
2010 FIFA World Cup. This was the first
time a world class stadium had been
built in the Eastern Cape. Nelson Man-
dela Bay stadium was the last of five
new stadiums to start construction.

T
he stadium has
an eye-catching,
unique roof-struc-
ture and a spectacu-
lar view, overlooking the
North End Lake. It consists
of six levels on the western

side and five levels on the southern, eastern and

northern sides. The roof is made up of a series of
white petals making it look like a flower hence its
nickname “The Sunflower”. The stadium boasts 23
private boxes, 150 VIP suites, 60 business suites, a
sports and clothing shop, gymnasium, lecture room
and function as well as two conference rooms which
are able to accommodate 200 people
Ground was broken in January 2007 and the stadium
construction was handled by a consortium made
up of Grinaker-LTA, Interbeton and Birdair. On 8
July 2008 it was announced that the stadium had
been removed from the list of stadiums for the 2009
FIFA Confederations Cup as it was believed that it
would not be ready on time. Surprisingly, however,
it became the first newly-built 2010 stadium to be
completed and handed over.
Coating selection
The stadium is situated in a C5 marine environ-
ment. The painting scope of work was to touch up
the shop-applied primer and intermediate coat and
apply one full coat of polysiloxane to approximately
2000 tons of steel.
Coating selection was based not only on the re-
quirement for resistance to the corrosive marine
environment but also to the aesthetic and archi-
tectural requirements. The specified coating was
an International Paints system, using Interzinc 52
primer, intermediate coat of Interguard 475 and a

 Advanced Materials Today Jul/Aug 2010

 CORROSION

final coat of Interfine 878, which is a

polysiloxane with a life expectancy of
30 years.
Spills and splashes
The stadium required a very high
standard of cosmetic appearance and
aesthetics were a key requirement. The
coating system offers high performance,
high solids finish, an extended lifetime,
superior gloss and colour retention and
significant improved resistance to yel-
lowing and chalking. The tough and
hard wearing finish coat exhibits good
flexibility and abrasion resistance and it
offers protection against spills, splashes
of a range of chemicals such as acids,
alkalis, solvents and salt solutions.
Coating the steel roof in situ presented
several interesting challenges! In order
to meet the client’s aesthetic require-
ments the coating could not be brush
applied as anticipated but needed to be
sprayed. Typical South African ingenu-
ity came into play as local painting
contractor, Bulldog Projects perfected
a sustainable technique of spray ap-
plication which allowed painting while
suspended on ropes in the renowned
Windy City conditions.
No incidents
The total roof area painted was 50 000
square metres requiring 4 740 litres of
paint. Overspray unfortunately resulted
in the additional painting of approxi-
mately 45 000 seats and 238 vehicles
– although these were all successfully
and timeously restored!
Working on the structure without a
safety incident was an achievement in
its own right and credit must be given
to the site management and the highly
skilled access rope crews, who spent
25 000 man hours working at heights
in high winds.
It was indeed gratifying to have a small
South African company, Bulldog Projects
commended by American roofing sub-
contractor Birdair, Inc as a professional
organisation, experts in their field, who
continually met the project technical and
delivery constraints associated with this
extremely complex roof structure.
Another case where South Africa has
left a positive impression – just like
the Positive impression left by the new
Nelson Mandela Bay Stadium.
Isinyithi Cathodic Protection (Pty) Ltd, Tel:
(011) 465-1807, Fax: (011) 467-0458, Email:
pipeline@isinyithi.co.za

Advanced Materials Today Jul/Aug 2010 

 Tindrum 10/084
DO YOUR
FORKLIFTS
MEET THE
RIGHT
CRITERION?
If you’re thinking forklift trucks, you’re thinking TCM.
And if you’re thinking TCM, you’re thinking Criterion.
Criterion Equipment is proud to be the sole distributor of TCM forklift trucks in
Southern Africa. With over 30 years experience and a highly competent
network of branches, dealers and agencies throughout the region,
Criterion will meet all your material handling needs.

HIGHEST RESALE VALUE

Renown for its durability and simplicity, the comprehensive TCM forklift truck
range has proved itself across the globe. Commanding the highest resale value
in the industry bears testimony in itself. Moreover, TCM products with
Criterion backing have earned a reputation for being very user and
service friendly, minimising downtime and optimising productivity.

SERVICE FRIENDLY
From the IC engine range, heavy duty trucks and container
handlers, to the vast array of electric models, Criterion
has exactly the right TCM for your specific need.
Click on www.criterion.co.za for more
information on the TCM range, as
well as the various options of
how to acquire your TCM
product – or simply
give us a call.

Criterion Equipment
1 Wrench Road, Isando,
Johannesburg, South Africa
Tel: 011 966 9700
Fax: 011 966 9736
E-mail: info@criterion.co.za
Web: www.criterion.co.za

Criterion Equipment (Pty) Ltd is a wholly-owned subsidiary of Invicta Holdings Limited

10 Advanced Materials Today Jul/Aug 2010

 STOCKISTS AND SERVICE CENTRES

Steel Wherever,
Whenever
Steel stockist, BSI Steel, continues making inroads into the steel supply business in southern Africa with its
accurate and timely stocking and distribution business.

T
he company’s footprint continues to grow “Our core focus is carbon (mild) steel in all its vari-
and the recent acquisition of competitor, ous forms. This covers the full flat product range,
Staalbeer, is proof of their buoyancy in a long products including structural steel, tubing,
suppressed market. cold formed sections, roofing & most other related
Chief executive of the company’s South African products. To maintain the service levels that are
Merchants division, Ross Teichmann, attributes the Our core focus is carbon (mild) steel in all its various
growth of the company to its readiness to deliver
forms
what their customers want where and when they
need it. This is not always an easy feat when one
considers the vast amount of different products
available in the market.
Right supply
“BSI Steel moves hundreds of tonnes of steel
around the sub-continent every day. The success
of the business is due largely to the fact that we
have effective supply chains that ensure the steel
is delivered on time to its destination.

BSi has four distinct operations within

the group:
• Merchants – stock holders who offer “just-
in-time” service out of the various branches.
• Bulk sales local – bulk sales into the South
African market.
• Bulk sales export – bulk sales into the Southern
African countries.
• Processing – primary steel processing as well
as a roofing division.

Branches
• Gauteng: 1 branch and the group’s
main processing and
distribution centre.
• Pietermaritzburg: 1 branch
• Zambia: 2 branches (Kitwe &
Lusaka)
• The DRC: 2 branches
(Lubumbashi & Kolwezi)
• Zimbabwe: 2 branches (Harare &
Bulawayo)
• Mozambique: 1 branch in Maputo
• Mauritius: 1 office

Advanced Materials Today Jul/Aug 2010 11

STOCKISTS AND SERVICE CENTRES

expected from us, we avoid veturing too far from
our core offering,” Ross explains.
Although the company does supply some stainless
steel products and other specialised steel, this is on
a fairly limited basis for the time being. Likewise,
unlike other stockists, the company has chosen to
limit its supply to unworked products and not to
get involved in establishing service centres that
add further value to the steel.
Great future
“BSI Steel is a highly diversified business that
provides customers with options in terms of steel
supply. While we offer a just in time service to
those that need it, we also offer bulk sales to those
large production facilities that have a predictable
requirement. We have a wide network of branches
and traders in Southern Africa and will continue
to expand on this as and when the opportunity
arises.

BSI Steel has processing capabilities

that operate out of our Gauteng
(Kliprivier) facility

“While we do offer “1st stage” processing to our

customers, we are always mindful of the fact that
to establish a fully fledged service centre, there is
While it does not limit itself, the company does have a range of products that are the risk of eventually competing with your customer
core to the group base. This is something that BSi Steel will avoid.
“It has always been our intention to offer fair value
Recent developments and exceptional service to the market and we
• On the 1st March 2010 BSi opened a branch in Maputo (Mozam- remain committed to continued improvement in
bique). This is in line with its strategy in other countries in Africa, this regard,” adds Ross.
where it serves the market through stockists as well as bulk sales.
• On 1st May 2010, BSi Steel celebrated its 25th year of servic-
ing the steel industry. William Battershill started Discount Steel on
1st May 1985. He rented a small house on the KZN Varsity farm.
Initially, his target market was the farming community, where he
focused on B Grade tubing. It wasn’t long before William expanded
his range to accommodate light industry in the Pietermaritzburg and
Durban markets.
• Roofing Division. BSi recently commissioned three roofing lines.
The division now offers corrugated iron (8.5 and 10.5mm), IBR
profile and widespan profile.
• The company also commissioned a new cut to length line. It
installed an internationally acclaimed Schnutz leveler that increases
its processing capabilities substantially. The processing range of
this machine is 0.8mm to 6mm thickness and 2000mm maximum Ross Teichmann
width.
• June 2010. BSi Steel acquires the privately owned Staalbeer.
This acquisition complements the business in many ways and adds
to the diverse trading style.

12 Advanced Materials Today Jul/Aug 2010

STOCKISTS AND SERVICE CENTRES

BSI Steel is an Altx listed South African based or-

ganisation, with strong ties to the southern African
markets. Its primary product range is made up of mild
(carbon) steel in all its different forms. Its strength
lies in its diverse product range, as well as differing
trading styles. Not only does it have established
branches in southern Africa, but it also trades into
other markets where it does not have an established
branch network.
It also has established trading relationships with
clients in Namibia, Malawi, Botswana, Tanzania
and Kenya.

Its strength lies in its diverse product range,

as well as differing trading styles

Logistics
“ In addition to us running our own fleet of trucks
to service our just-in-time customers, we also have
years of experience in handling the logistical require-
ments needed to service the sub-Saharan markets,”
adds Ross.
While it does not limit itself, the company does have
a range of products that are core to the group. These
include flat products – hot and cold rolled, galva-
nized, plate, aluzinc, colour coated. Sections – light,
medium & heavy mill (angles, flats, squares, rounds,
channels, beams), tubing – hot rolled structural and
cold formed sections – lipped channels and angles
and open channels.
“BSI Steel has processing capabilities that operate
out of our Gauteng (Kliprivier) facility. This facility
provides an essential service to the sales divisions
in their quest for customer satisfaction through com-
petitive pricing, service and quality. It is continually
expanding its processing facility in order to be the
best in the game,” concludes Ross.
BSI Steel, Ross Teichmann, Tel: (011) 861 7600, Fax: (011)
861 7611, Web: www.bsisteel.co.za

Advanced Materials Today Jul/Aug 2010 13

14 Advanced Materials Today Jul/Aug 2010
 WELDING

Real World Training

Welder training has entered the space-age with the acquisition of virtual welding machines for the newly
established Austrian Welding Academy in Isando.

T
he “virtual reality” ma-
chines overcome many of
the problems associated
with real-world training,
such as wastage and high cost
of materials with the advantages
of obtaining immediate feedback
of quality of weld or mistakes
made.
“Training welders in the real world
is a time consuming and costly
exercise that requires specialised
and knowledgeable trainers to
examine welding results, provide
feedback to learners and rectify
problems.
“Virtual welding provides instant
feedback and results. It is particu-
larly valuable for training novices
or for conveying new techniques,”
says Tom Rice of the Austrian
Welding Academy.
Upskilling the industry
The academy was set up by
Böhler Uddeholm Africa recently
to provide skills training for weld-
ers from beginner to advanced
level. The computerised welding Virtual welding provides
machines form part of the training curricula and instant feedback and results
are used in the orientation learning phases. Once
the trainee has mastered the welding exercises on people how to weld specialised ex-
the virtual training station they hone their skills pensive materials. It saves a fortune
using real materials and the appropriate welding and contributes to more affordable
equipment. training fees,” he says.
Böhler Uddeholm’s worldwide partner, the Austrian South Africa’s Austrian Welding
welding equipment supplier, Fronius, supplied the Academy follows similar centres
machines for the academy. It is a world-leader in set up around the world to improve
the supply of welding equipment for industry and the skills of welders. The academies
developed the virtual reality machines in response make use of highly skilled and ex-
to calls for more cost-effective and less wasteful perienced welders and technologists
training practices. who impart world-class techniques
to learners.
In addition the developers saw an opportunity to
provide instant and useful feedback to trainers The academy also makes use of
with accurate results available at the click of a the latest equipment in order to
button. put learners in real-world situa-
tions using machinery that is most
According to Tom the “virtual reality” training sta-
likely to be encountered in the
tion is particularly appropriate for the local market
workplace.
where it can, if need be, be transported to different
locations to give on-site training. Tom Rice, Austrian Welding Academy,
Tel: (011) 571 2390, Email: tom.r@
“It is quick and effective and is useful when training bohler.co.za

Advanced Materials Today Jul/Aug 2010 15

16 Advanced Materials Today Jul/Aug 2010
 Official magazine of
the NTIP
Until now our tool, die and mould
makers (TDM) had a rough time
trying to stay up-to-date with
developments and happenings
in their industry.
Not any more, as Advanced
Materials Today takes up the
reins on behalf of the National
Tooling Initiative Programme
(NTIP) to act as its official
mouthpiece and to keep the
industry informed.
TDM Today is a new section in our
magazine that is dedicated solely
to TDM. It will update readers
on the latest NTIP initiatives,
training and skills development,
as well as bringing up-to-date
local and international news to
the desktops of decision makers
within the industry.
There will be a focus on best
practices and each issue will
profile a local TDM related com-
pany that upholds world-class
manufacturing practices. Even
more features will be brought
into the section as it expands
in months to come.
The announce of the magazine
as the official magazine of the
NTIP comes as a result of its
focus on manufacturing within
the metal working and other
advanced materials industries
and because of its broad reach
to an appropriate readership.
From this issue, all members
and prospective members of the
NTIP will receive a complimen-
tary Advanced Materials Today
magazine in their post boxes on
a bi-monthly basis.
The partnership is attracting
widespread compliments and
considerable interest has already
been shown from industrial
advertisers wishing to reach
this important segment of the
market. We look forward to being
of service to the industry.
Tooling Around
The activities of the Tool-making Association of SA (TASA) have been stead-
ily escalating over the past 4 years through the establishment of the National
Tooling Initiative Programme (NTI) aimed at the rehabilitation and growth of
this critical manufacturing industry support sector.
A
s a sub-sector to the manufacturing
sector, it is well hidden from the
public eye and worldwide, this sector,
as a standalone sector represents
only a fraction of the turnover of the manu-
facturing sectors, making it less important
in terms of development support.
Few however are familiar with the effect
tooling can have on the cost of producing a
product. Tooling can represent as much as
15% of the initial cost invested to bringing
a new product to market.
Competitive manufacturing
Between 30 and 50% of a product’s Life
Cycle Cost (LCC) can be attributable to tool-
ing performance. Competitive manufacturing
is thus heavily reliant on a strong tooling
sector support.
TASA recently attended the ISTMA (Inter-
national Specialised Tooling and Machining
Association) World Conference in Windsor,
Canada, held in June 2010. TASA is affiliated
to ISTMA via the European chapter – ISTMA
Europe, where it is in the company of all the
top European tool-making countries such as
Germany, Portugal, Spain, Italy and others.
At the world conference, the three main
groupings of the worldwide tooling fraternity,
ie, ISTMA-Americas, ISTMA-Europe and
ISTMA-Asia, get together to share trends,
technology developments and strategy.
Some interesting observations came from
the conference.
Standings
In 2009, the worldwide tooling consumption
amounted to 65 billion Euros. The European
contribution to this turnover stands at 14
billion Euros for the same period. The peak
turnover of South African tooling consumption
(largely depended on automotive industry
model launches) is estimated at R6 billion
(4% of EU and 1% of global turnover).
The European tooling industry’s focus going
Advanced Materials Today Jul/Aug 2010
forward will be on
focus (specialisa-
tion), lean manu-
facturing, innova-
tion, technology
convergence, sup-
ply chain develop-
ment, financial
performance and
added value sup-
Dirk van Dyk
ply.
Transfer to a knowledge based
sector
The EU will be investing billions of Euros
into strengthening its manufacturing capac-
ity through the Manufuture programme.
ISTMA Europe has succeeded in positioning
the tooling industry to participate in this
investment through the European Tooling
Platform to run under Manufuture.
Tooling consumption amounted
to 65 billion Euros
This structure will serve as the governance
structure, through which the roadmap for
investment into the tooling sector will be
developed.
South Africa, through the National Tooling
Initiative Programme has taken a bold step
in following suit, to develop and strengthen
its tooling sector. TASA has, similar to the
EU, created the INTSIMBI structure to act
as the governance structure through which
the NTI roadmap for the industry is being
developed and executed.
Through its NTI programme, TASA is at the
forefront of using the Manufuture model
to position the tooling sector to improve
its service to the local manufacturing
industry.
National Tooling Initiative, Dirk van Dyk, Tel:
(012) 643 9360, Email: dirkvd@ntipweb.co.za,
Web: www.ntipweb.co.za
17
18 Advanced Materials Today Jul/Aug 2010

Tools
For The
Trade
Exploding populations and global
competitive plastic related markets
around the world rely on smart
manufacturing to meet high volume
demand for quality items.
Microspray irrigation
Bevan checks a mould before spark erosion taks place
I
n South Africa it is no different and here we have
companies like Conver-Tek that manufactures
world-class tools, dies and moulds to rigorous
demands of plastic manufacturers in selected
precise industries.
Only the highest quality steel is used
According to Bevan Davis, managing director of
Conver-Tek, the quality of the design, cooling, steels
used and manufacture of the actual moulds to be
used, has an enormous bearing on the quality, cost,
output, and life of the product and mould.
“That is why it is critical to make use of only the
best designs, tool steels, cutting tools and toolroom
machinery in their manufacture,” says Bevan.
TDM COMPANY PROFILE
Specialised needs
He explains that modern tool and die making is
specialised and in many instances complex with
many interrelated requirements for specialised
plastic engineered products.
“For example, a tool may be required for quality high
speed injection moulding of engineering polymers
that must last through the entire life-cycle of a
product (sometimes +10 years), while maximising
speed, quality, critical sizing, no runner wastage
and minimising costs, machine downtime, repairs
to tools and production scrap.
“In order to achieve this one needs to understand
the product requirements, plastic materials needed,
production, manufacturing process and engineer
tools in such a way that they deliver beyond the
expectations of the client. We have tools that have
delivered ± 100,000,000 units that still produce
to the original tight spec and quality. The long term
cost of the tooling into the product is a fraction of
a cent versus the ongoing hidden added production
costs of non performing “cheap” tools.
Best-of-breed
Conver-tek upholds the motto “what you put in, is
what you get out, and there is no such phenomena
as a cheap quality tool” and Bevan is a firm believer
in this principal. The company makes use of only
the highest quality tool steel from its long-time
supplier, Böhler Uddeholm.
“Depending on production requirements and
expected tool life we use some tough high spec
steels to build our tools. These steels are difficult
to machine in the precise detail with standard
cutting tools. Here we make use of CNC Chamille
spark erosion technology with delicate electrodes
for precision detail. This of course increases the
Advanced Materials Today Jul/Aug 2010 19
TDM COMPANY PROFILE

“There is a good reason why we use the machines

we do. They have been found to deliver the best
performance for this type of work internationally
and are up to the rigours of working the kind of
materials that we do,” Bevan says.
The company’s machine shop makes use of Haas
and Deckel CNC milling machines, Victor CNC
lathes and CNC Chamille spark erosion equipment.
Most of the cutting tools, on the other hand, are
provided by Sandvik.

Bevan shows the newly developed anti-tamper water meters built and designed
in-house by Convertek
We have tools that have delivered ± 100,000,000 units
costs of the tools”.
“We invested heavily in recognised machine tools
that are up to the precision toolmaking task and
make use of the highest quality cutting tools and
spark eroding equipment to build our tools.
Concept to completion
Gone are the days of crafting tools, dies and moulds
over an extended period of time. Modern TDM is
in itself becoming a highly technical production
process nowadays. Customer demand calls for
ergonomic design, rapid product development from
concept, to prototype and end-product to compete
with Chinese and Eastern opposition toolmaking
companies.
Every aspect of tool, die and mould making requires
expertise and it all begins with a fit for use precise
design. This is achieved with the assistance of 3D
modelling and CAD / CAM software. All parameters
need to be taken into consideration and, when
the final drawings are presented, will be taken to
rapid prototype level. The exact dimensions and
functions of the product can be provided using
rapid prototyping.
“We have recently grown a detailed scaled model
for a new racing car. It has been fully tested in the
wind tunnel at Wits to finalise the design. Tools
are now being cut for this racing car to be raced
at Le Mans next year. The aerodynamic design was
fully tested using rapid prototyping technology,”
Bevan adds.
From there it goes into the manufacturing process
using the captured approved CAD design data and
it is machined to specification at the machine shop.
After vigorous quality checks the tool, or mould will
be delivered after it has been jointly commissioned
by Conver-Tek’s staff and the customer to ensure it
performs to the designed spec.

Aftersales
“We will supply all the production parameters to
the client to ensure that the tool is properly utilized
to ensure it performs optimally,” Bevan says.
Conver-Tek’s efforts have not gone unnoticed. It
was recently recognised as an outstanding local
firm by the University of Aachen in conjunction
with the University of Stellenbosch, who undertook
benchmarking studies of South African tool, die and
mouldmakers against their European compatriots
on behalf of the National Tooling Initiative (NTI)
recently. “We like the rest of Europe will have to
compete against the Chinese and need to adjust
our performance to compete for the same slice of
cake. Our quality and performance is our selling
edge.”

20 Advanced Materials Today Jul/Aug 2010

 TDM COMPANY PROFILE

More than meets the eye

There is more to Conver-Tek than manufacturing
and supplying tools, die and moulds. The company
is, in fact, its own best client, as its other core
business is plastic injection moulding of products
for the water and engineering plastics sectors. The
company has worked specifically in the armaments,
medical, water, motor, electronics, pump and pool
industries.
Although the divisions were started simultaneously
and complement each other, they maintain a high
degree of independence. Experience gained in the
injection moulding production lines often transpires
to improvement and optimisation of services to
customers on the tool, die and injection moulding
side of things.

Innovation station
Conver-Tek is seen by many as an innovation house.
Many of the products produced on the plastic and
tooling side have stood the test of time and some
have even changed our lives.
“We were one of the inventors of the original micro Tools at the disposal of the tool and die maker
irrigation system and produced both the tooling for
their manufacture and the end products ourselves.
Although it has been licensed, copied and produced
elsewhere in the world it still makes use of our
original concepts and materials.
“We further developed the first plastic water meters
for Meinecke in Germany that withstand 80 Bar
burst pressure. This was considered as impossible
by the engineers at the time.
“The company also originally developed and pro-
duced the tooling and production for the legendary
Kreepy Krauly pool cleaner for over 20 years that
revolutionised the way pools are cleaned around
the world,” says Bevan proudly.

Modern TDM is in itself becoming a

highly technical production process
nowadays

What’s next
And the innovation doesn’t stop there. Conver-Tek
has produced many other “world first” plastic de-
velopment innovations, most recently the company
was awarded the contract to design and produce
tamper-proof all polymer water meters in housings
for metropolitan municipalities in South Africa. The
meter boxes and fittings are patented innovations of
the company and world-wide interest has already
been expressed in them.
A plastic car muffler system and a plastic solar geyser
with P.V. power and combined water heating are
in the pipeline and are being shown to interested
concerns globally. A few new technologies in the
challenging water industry to resolve ongoing prob-
lems are in an advanced stage of development.
“In order to compete in a global competitive market-
Kreepy krauly
place dominated by countries with huge manufactur-
ing infrastructures we have had to keep innovating
and producing better quality products locally than
can be found anywhere else in the world in order
to stay ahead of the pack,” concludes Bevan.
Bevan is currently Chairman of TASA Gauteng and
a director of the NTI. The main purpose of these
functions is to uplift and develop the toolmaking
industry which has been written about in the intro-
duction to this TDM section of the magazine.
Conver-Tek, Bevan Davies, Tel: (011) 827 2460, Fax: (011)
827 2498, Email: bevan@convertek.co.za, Web: www.
convertek.co.za

Advanced Materials Today Jul/Aug 2010 21

TDM NEWS

Grow Your Customer

Base
From comparisons of South Africa’s tool, die and mould (TDM) making market vs European and South
American countries, it is clear that our industry is too dependent on too few customers.

A
ccording to a benchmarking study under- urgent plans to broaden their customer bases, even
taken for the National Tooling Initiative if that means looking abroad for new additional
(NTI) by Aachen University and the Uni- business.
versity of Stellenbosch this situation can
The success of the Fifa World Cup may serve as just
cause a price squeeze. In many instances the all
the introduction South African businesses need.
too powerful customer gets to dictate pricing with
the threat of taking business elsewhere. Findings
Key findings of the benchmark are that SA has by
The situation is clearly not a healthy one far a smaller customer structure, we have no real
The situation is clearly not a healthy one and com- ‘movement’ in customer structures, there is no
pany owners and managers should put in place pooling of skills among toolmakers and no joined
projects of toolmakers for customers. Rather, there is
mistrust and fighting
for customers.
One of the key sug-
gestions made by
Aachen University
scientists, as a re-
sult of the findings,
was that the country
should develop clus-
tering activities with
pooled resources and
skills to serve key
sectors.
Official
mouthpiece
Key to the success of
such clusters would
be the establishment
of communication
platforms to reduce
mistrust, and hence
the agreement by
the NTI to appoint
“Advanced Materials
Today” as the official
mouthpiece of the
initiative.
Aachen University:
www.rwth-aachen.de
University of Stel-
lenbosch: www.sun.
ac.za

The accompanying graphs illustrate our position against the European and South American
companies

22 Advanced Materials Today Jul/Aug 2010

 EXCLUSIVE AGENTS FOR
E

CNC MACHINES
16 Nguni Drive, Longmeadow West, Modderfontein
PO Box 931, Bedfordview, 2008, South Africa
Tel: 011 608-0088 • Fax: 011 608-0148
E-mail: info@hitech.co.za

www.hitech.co.za

Advanced Materials Today Jul/Aug 2010 23

TDM NEWS

See it in 3D sible for revitalising the

Advance Design So- TDM sector in Gauteng in
lutions was recently its broadest sense. This role
appointed as premier includes assisting tooling
reseller for IronCAD, companies to be globally
a leading provider of competitive in terms of
3D design produc- quality, cost and delivery,
tivity solutions for a process that will require
industrial applica- the conducting of bench-
tions. marking exercises with
successful countries such
Advance Design So-
as China and Germany.
lutions is a division
of Puremission Engi- “The GTI is a support
neering that has of- function to the NTIP and
fered design services its activities. Therefore my
to various industries role as GTI CEO is to assist
throughout South the TDM sector to achieve
Africa. While work- its maximum potential in
ing with their clients, the Gauteng area,” says
Advance Design So- Henk.
lutions observed a He will assist SMME’s
need from engineers and BEE companies to
for a 3D design so- effectively compete in the
lution that offered tooling industry. He will
freedom to design also be tasked with creating
and modify products Advance Design Solutions observed a need from engineers for the support mechanisms
a 3D design solution
during analysis and to enable the toolmaking
validations stages of the development cycle. The industry to recapitalise and use the appropriate
IronCAD design solutions offered a perfect solution technologies to be competitive.
for these customers with its innovative design ap-
Henk is no stranger to the tooling industry. Be-
proach and short learning curve.
fore taking the
“Within our design services operation, we have ob- reigns as CEO of
served a need for designers to have a solution that GTI, he was CEO
is easy to learn and use that could take the three of the Western
dimensional concept in the designer’s mind and Cape tooling ini-
bring them to reality for advance interrogation. tiative. He holds
“Being new to IronCAD ourselves, within a day of a Masters degree
use, we were able to be up and running in IronCAD in Industrial and
productively, meeting the demanding needs of our Mechanical En-
customers. It was a natural progression to offer this gineering from
solution to allow our customers the ability to be the University of
equally innovative in their design concepts and to Stellenbosch and
give them the ability to produce production-ready has 20 years ex-
products” says Sam Du Plessis, general manager perience in the
of Advance Design Solutions. manufacturing
industry in the
Advance Design Solutions, Tel: (011) 326 2040, ads@
fields of design, Henk Snyman
ironcad.co.za, Web: www.ironcad.co.za
procurement and
manufacturing.
Dirk van Dyk, NTIP CEO, says with a fully functioning
tooling initiative in the Gauteng region, members
of the Tooling Association of South Africa (TASA)
New Gauteng leader can feel confident that they have an association
In its drive to revitalise the tool, die and mould that is constructively protecting and promoting
making (TDM) sector in Gauteng, a move aimed at their interests. “With his deep understanding of
bringing the manufacturing sector to competitive the tooling industry and what we are trying to
levels, the National Tooling Initiative Programme achieve, Henk is the ideal candidate to drive this
(NTIP) has appointed Henk Snyman as CEO of the initiative,” he says.
Gauteng Tooling Initiative (GTI).
National Tooling Initiative, Dirk van Dyk, Tel: (012) 643
As the newly elected GTI CEO, Henk will be respon- 9360, Email: dirkvd@ntipweb.co.za

24 Advanced Materials Today Jul/Aug 2010

 TECHNOLOGY

Future of Casting
Casting and forging measuring can be labori-
ous and time consuming in the field unless
new technologies are embraced and used.
Optical measuring systems are at the fore-
front of new technologies in the industry and
can save time and effort, while returning
accurate information.
the object which are recorded by two cameras. The
computer automatically calculates the 3D coordinates
for each camera pixel of the scanned surfaces with
very high precision and resolution.
Each individual measurement takes approximately
1-2 seconds and is automatically transformed to a
common object coordinate system using previously

O
ne of the latest innovations
comes from optical mea-
suring specialists, GOM,
in Germany with the
introduction of the Atos 3D Digitiser.
Using advanced camera technology in
casting applications, the Atos allows
full field measuring and fast validation
of the object’s complete and complex
surface rather than collecting a few
points with a probe and leaving large
unknown areas.
Local supplier
Aurelio Grech-Cumbo, CEO of RGC
Engineering, the sole-distributor in
South Africa, says the technology is
based on the principle of triangulation
and projects different patterns onto Measurement of a Pattern Plate with the GOM ATOS System

ATOS Inspection Software: Typical measuring report

Advanced Materials Today Jul/Aug 2010 25

TECHNOLOGY

applied reference points. During measurement, the

software checks online for system calibration, sen-
sor movement or any ambient changes that might
affect the measurement.
Data on the move
The Atos 3D optical digitizer is mobile and can
simply be transported to an object, so that heavy
casts, tools and models can be easily inspected right
away on-site in foundries, tool- and die- shops. Due
to its design, the sensor head is built to perform in
harsh and adverse production environments.
As a non contact optical measuring device, Atos
is also ideal to check sensitive sand cores before
the casting process.
The measuring volume can be adapted to specific
measuring tasks and object sizes within a few
Atos System with GOM touch probe
minutes by interchangeable lens sets. Due to this
flexibility, the Atos system is able to measure ob-
jects of various sizes, from filigree injection-molding
components to a complete aircraft. Turntables,
robots or multiple axis motion units are available
for automated measurement of multiple parts.
Software
A software suite called Atos Inspection Software is
available with the unit and provides a number of
functions essential for the casting industry. In ad-
dition to full field 3D shape and dimension analysis
against CAD, the software allows calculation of
material thickness in order to check material allow-
ance for further processing. It is possible to control
size and position of basic primitives and also virtual
calipers. Inspection sections with tolerance bands
are available as well as classical 2D dimension-
ing tools. The Atos reference point system allows

The computer automatically calculates

the 3D coordinates for each camera
Touch probe for smaller measuring volume pixel of the scanned surfaces

moreover checking of parting surfaces

for offset, fitting and proper closing of
mould halves.
For documentation and further processing
the Atos Inspection Software includes
enhanced reporting and documenta-
tion functions and interfaces in order
to generate standard or customised
3D measuring reports or traditional
tables with CMM points. Results and
deviations can be exported to various
formats such as Excel, HTML, Word,
etc. For recurring measuring tasks the
software evaluation can be automated
using macros and scripting language.
GOM also provides a free Atos 3D Viewer
and such measuring results can be eas-
ily shared with customers or colleagues
from other departments.
Non-contact measuring of sand cores with Atos

26 Advanced Materials Today Jul/Aug 2010

TECHNOLOGY

Touching and probing

In the past, evaluation of optically hidden surfaces
such as water jackets, cooling holes, deep pockets
and deep cylinders, had to be measured on classical
CMMs, a process which is very time-consuming due
to necessary fixing and alignment of the parts.
The GOM touch probe as an add-on to the Atos
3D Digitizer helps to overcome this obstacle. The
handheld touch probe enables the user to switch
between 3D full-field measurement and online
tactile probing of specific single points. A time-
consuming modification or rebuild of the sensor
setup is not necessary.
The GOM touch probe is a calibrated set of point
markers which are optically tracked by the Atos
3D Digitizing system measuring the online 3D
coordinate of the calibrated probe tip.

The modular concept of the GOM Touch

Probe allows an adaption for many
different applications

A live inspection of points and primitives is avail-

able. Tactile probing of geometries such as planes,
spheres, cylinders and cones as well as circular,
slotted and rectangular holes and borderline seg-
ments is also possible. The touch probe allows
fast point based probing against CAD to determine
deviations to reference data also in difficult to ac-
cess areas.
Lightweight
The touch probe allows effortless measurement
over long periods and for larger measuring projects.
A constant rigid mounting of the part such as on
CMM´s is not necessary. Due to the dynamic ref-
erencing either part or sensor can be freely moved
to find comfortable positions. The Atos software
allows various alignment strategies at any time,
while the mechanical and cable-free probe can be
operated via a remote control.
An audio-feedback signalises probed points and
elements to guarantee a safe workflow and dif-
ferent touch probe sizes are available for small to
large objects.
The modular concept of the GOM touch probe al-
lows an adaption for many different applications
via fast interchange of probe heads and extenders.
In addition the user can create customised touch
probes for specific tasks.
RGC Engineering, Aurelio Grech-Cumbo, Tel: (011) 887
0800, Fax: (011) 887 7833, Email: aurelio.grech-cumbo@
rgcengineering.co.za

Log onto www.promech.co.za to read

back issues of
“Advanced Materials Today”

Advanced Materials Today Jul/Aug 2010 27

JOINING

Nuts About Fasteners

A dedicated team of fastener enthusiasts are ensuring that our is a major feat and supplying the correct quantities
manufacturing industry has the latest and best fasteners avail- and products at the right time is a challenge that
able to them, sourced from all corners of the globe. has been perfected over the years.

I
Challenging convention
t seems that no matter how well designed an It is the more specialised jobs that really get the
item is or how strong the materials used are, blood of the BMG team pumping. It provides them
if it needs jointing, the chances with the challenges that keep the job stimulat-
are that a potential ing. As newer, better and stronger materials
weak point will ex- are developed, fastener technology
ist unless the right needs to be adapted or exist-
solution is found. ing technologies tested and
The job of the fas- specified to match the new
teners division at materials.
Bearing Man Group Fasteners that
(BMG) is to seek out require optimal
technologies that performance
are appropriate for in extreme
different industries NordLock
temperatures,
and applications and abrasive en-
to bring them to our shores. vironments or
As a result BMG has agencies from the world’s leading that are subject
manufacturers of fasteners. These include Nord-Lock to corrosion from
bolt securing systems, Huck range of fasteners as exposure to chem-
well as locally developed lockbolts and Thome + ical processes require
Schwind spe- specialist knowledge.
ciality fasten- According to Darryl Campbell, BMG Fastener
ers for critical general manager, no other fasteners are better
or extreme ap- for such applications as the range available from
plications. Thome + Schwind.
Runs like These are manufactured in standard, stainless
clockwork steels and high nickel alloys for extreme and critical
At the main applications. This is the pinnacle of fastener evolu-
warehouse in tion and each component is machined to precise
City Deep, Jo- specifications and can be manufactured to meet
hannesburg, demanding requirements.
the opera-
tion runs like If it needs jointing, the chances are that
a retail fast a potential weak point will exist
moving goods
store with a
Although the use of these fasteners in everyday
massive range
applications would be overkill, it is in applications
of fasten-
such as shipbuilding, petrochemical, process and
ers stocked
nuclear technology that these fasteners have found
and shipped
a niche. Although usually too expensive for mass-
around the
produced goods the Thome + Schwind fasteners
clock to
are tailor made for tightly engineered goods and
destinations
structures.
where they
are needed. Ever tight
Keeping track In a similar way the use of Nord-Lock securing
of the hun- systems has found a niche in the South African
dreds of differ- market. The Nord-Lock’s proven wedge-locking
ent items, in method uses tension rather than friction to secure
different sizes a bolted joint. This system has proven itself effec-
Darryl Campbell, BMG Fastners general manager and materials tive in semi-permanent applications or where joints

28 Advanced Materials Today Jul/Aug 2010


need to be tight under any conditions and the user
prefers having the option of opening the joint in
future. Unlike welded joints the Nord-Lock can be
released and reused.
The Nord-Lock system is available in a variety of
different materials and sizes for any application
where a tight, lasting joint is required. Like the
Thome + Schwind systems the Nord-Lock system
is pricier than conventional locking systems, but
users can rest assured the joint will not loosen
under tough conditions.
Structural integrity
A product that has been a mainstay of BMG’s
line-up is the Lock Bolt. This product is useful in
applications that require high strength permanent
fasteners. These are commonly used in construction
projects or for the joining of heavy gauge steel. It is
a permanent solution that will not work loose even
during extreme vibration and thanks to the company’s
specially developed semi-automated tools provides
a fast and effective means of joining.
Lock bolts have been used in landmark applica-
tions around the world where structural steel has
been joined on site in a similar way for decades.
Its simple yet effective design has ensured that it
remains the most popular permanent bolt in use
around the world today.
Due to demand from the local market, BMG itself
has developed an effective lockbolt and tooling
solution that is available at a considerably lower
price to suit local needs. In applications where
cost considerations are important the locally
manufactured lockbolts are proving to be popular
and demand is high.
Global best
“We have our roots firmly in South African soil,
but rather than only supporting local suppliers,
have made a decision to stock the best offerings
from around the world that conform to strict qual-
ity codes and standards. We made this decision
Lock bolts
JOINING
in the interest of our customers and only local
products that can match international standards
are stocked,” says Darryl.
He adds that it is the company’s focus that has
earned it a reputation for quality and reliability of
supply and has resulted in engineers specifying
its products in a number of high profile contracts
through the years. One of the more recent contracts
is the Gautrain Rapid Rail Link project.
Customers will be far more prepared for the boom than
they were for the recession
“We feel that we earned bragging rights on this,
as it is a high-profile project that requires strict
quality and reliable supply. We supplied all the
integral requirements for the project with our Huck
Fit systems,” says Darryl.
In an instance like this where human lives are
at stake and consistent quality is required it is
refreshing to know that BMG’s fastener specialists
have carefully studied the requirements and sup-
plied their client with a solution that is up to the
demands that will be placed on it.
2010 recession discretion
Supplying the 100 branches around the country
is a smooth operation that runs like clockwork.
But, 2009 was a tough year for most and BMG
fasteners felt the effect of the slow-down in the
manufacturing industry. Darryl’s outlook for the year
ahead is bullish post the Soccer World Cup.
“We are ready for the year ahead and feel cus-
tomers will be far more prepared for the boom
than they were for the recession. We anticipate
that most decision making in the country will
start-up again now that the World Cup
month is over and business should
improve dramatically.
“The other big move this year will
be away from Cadmium Plating
because it is considered to be
carcinogenic. Also, we will move
away from Hexavelent to Trivalent
Chrome in electroplating of fasteners
to ensure we reduce workers to exposure to
possible side effects,” concludes Darryl.
BMG, Darryl Campbell, Tel: (031) 576 6262, Fax:
(031) 576 6525, Email: darrylc@bmgworld.net, Web:
www.bmgworld.net
Advanced Materials Today Jul/Aug 2010 29
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 MANUFACTURING

Chop, Chop Scissors

The world’s best hairdressers regard their scissors as an extension of themselves without which
they are doomed to be lesser mortals with the ability of your average side-of-the-road barber.

D
rop or damage their scissors in any way sors smashes its way through the hair strand and
and you are likely to feel the cold blades leaves a splintered end that will deteriorate with
in places other than through your hair. time and lead to the dreaded “split end” that turn
What few people outside of the trade perfect coifs into bad and unsightly hairdos. Like
know is that good cutting scissors
add flair and accuracy and when
you are at the top of you game with
little to differentiate yourself from
the competition, it is vital that your
cutting tools are up to the job.

They can cost anything

between a thousand Rand up
to R25 000 per pair
Made in Japan
Good hairdressing scissors are made
in a number of factories around the
world, but few inspire as much history
and custom as those from Japan. They
can cost anything between a thousand
Rand up to R25 000 per pair and
embody the highest levels of blade
craftsmanship known to man.
A crafted pair from the Land of the
Rising Sun could probably slice an
apple into quarters in mid air with a
couple of wooshes of a skilled arm.
The reason the Japanese scissors are
highly regarded is that the blades
are made in the same way as the
legendary Samurai sword, which
possesses arguably the best blade
produced by man.
Samurai way
Blade making was once the noblest of
crafts and blacksmiths would spend
days, weeks even months crafting
swords. It was intensely spiritual
and on delivery a bond was forged
between the blade and the owner as
a matter of deep belief.
Beyond the mystics was the fact
that if the sword failed in battle and
didn’t deliver decisive cuts, the owner
would perish. Thankfully, the same
fate does not meet a bad hairdresser
with a blunt pair of scissors.
But, any good hairdresser will tell
you that a blunt or misaligned scis-

Advanced Materials Today Jul/Aug 2010 31

MANUFACTURING

Cutting test
The process usually reveals itself through a
noticeable grain, much like a wood grain, on
the blade. However, this is not standalone proof of
the quality of the steel nor skill of the craftsman.
For this purpose suppliers back up claims with
scientific data and proof. They also offer lengthy
guarantees and after sales service in case some-
thing goes wrong.
In ancient times it was harder to satisfy the enqui-
ries of the fearsome Samurai who had to be shown
actual cutting results. These included cutting tests
performed on bamboo trunks and other objects.
The results were then inscribed under the
handle. Results measured the cutting effect
of a single stroke and the number of bamboo
trunks cut down.
But top warriors and their leaders needed more. For
this reason the best swords were often tested on
prisoners and the results also inscribed under the
handle. One stroke may have accounted for three
necks or two torsos or a number of limbs. Anyone
who owns an ancient and authentic Samurai sword
can therefore verify the effectiveness of their sword
on human flesh.

the mystical sword, the scissors blade should cut

cleanly through the strand leaving no jagged bits
or rips.

Good hairdressing scissors are made in a number of

factories around the world

Steel tempering
Just like the Samurai swordsmiths, scissors makers
craft their blades by alternating hard brittle steel
with soft malleable steel. This is heated up and
beaten flat, many times over until the craftsman
is happy that the right temper is achieved. Once
forming is completed, the leading edge of the
blade is heat treated, tempered and honed
to a razor sharp edge.

32 Advanced Materials Today Jul/Aug 2010

MANUFACTURING

• A hairdressing scissor’s price is determined by the

the amount of man-hours spent making it.
• Quality scissors can take up to 90 days to
manufacture
• The cutting edge is fine and can last month
before they need to be resharpened
• Scissors need regular services for rebalancing,
sharpening and alignment
• Scissors have a cutting edge and cutting surface
on each side of the blade
• The first requirement for Japanese scissors makers
is to have a “sharp eye and steady hand”

Salon quality
Top salons know that the Samurai way is upheld
by the likes of companies such as Hikari, who has
a distributor in South Africa, as well as Matsuzaki,
distributed through Final Touch, a sister company of
the well-known Carlton Hair studio and these salons
are prepared to pay top-dollar for these scissors.

To this day, some of the best known scissors still

originate from Japan, although the cold precision
blades produced in Germany and other countries
compete technically, they do not hold the same
weight of history.
When next you have your hair cut remember that
the blades of many of the top scissor brands are not
sommer like the ones you buy at the local hardware
— they are legitimate tools of the trade.
Carlton Hair International, Nadia, Tel: (011) 646 2420, Web:
www.carltonhair.com, . Hikari, Paul Missenden, Tel: (011)
326 2643, Web: www.hikari.co.za

Advanced Materials Today Jul/Aug 2010 33

Industry News
40 years of screwing The 100 employee company has grown its turnover over the
Local fastener manufac- past two to three years by around 30 percent. Key to this
turer, Tel-Screw Products, growth has been the move to more modern, and versatile,
recently celebrated its 40th machine tools, especially the multi-axis machines from
birthday and 10 000 th line Yamazaki Mazak.
item held on its shelves. In addition, it has invested heavily in some of the most
Through the years, the com- up-to-date manufacturing technology. Key to its growth has
pany has become known for been the move to more modern, and versatile, machine tools,
its ability and willingness especially the multi-axis machines from Yamazaki Mazak.
to manufacture or source “We bought our first Mazak about four years ago,” says Paul
any product in any quantity Barber, Supercraft’s sales director.
for its clients and coined
the phrase “ we will make
any quantity, except half of
anything.”
The business started in
Germanton on the outskirts
of Johannesburg 40 years
ago and at the time spe-
cial fasteners were mostly Ronnie Teleng of Tel-Screw
imported. “Our original Products
staff consisted of a total
workforce of four people,
and since the move to Boksburg in 1984 has grown to 140
people, led by a team of fully qualified artisans,” says Ron-
nie Teleng, managing director of Tel-Screw.
“Many of our products are marketed overseas and across our The installation of two Mazak Variaxis multi-surface, simultaneous five-
borders through the bolt and nut merchants that we supply. axis machining centres has improved productivity and reduced work in
We also sell directly to clients in the mining, building and progress at Supercraft
motor industries.
He adds that the potential to take time out of jobs, both
“Our strong feature has always been the specified fastener that
through reduced set-up and also higher machine performance
no-one else carries or will manufacture and we are prepared
was a necessity.
to make any quantity required in a short delivery time.
“We manufacture some very complex parts,” says Nigel Prior,
“For special breakdowns, we are able to offer a 24-hour turn-
Supercraft’s manufacturing engineer. “With our previous ma-
around time, depending on the component,” adds Ronnie.
chine capacity these would take up to six set-ups to complete.
Tel-Screw is also equipped to do all types of bending and With the Variaxis we achieve this in two, and with the twin
forming and is capable of undertaking cold heading, hot pallet arrangement we can run first and second operations
forging, thread rolling, screw cutting, hot bending, cold back-to-back. This improved our service of supplying fast
bending auto machining and NC machining. It has full tool track deliveries to our aerospace customers.”
room facilities for milling, welding and guillotining. Yamazaki Mazak UK, Web: www.mazak.eu. Hi-Tech Machine Tools,
Tel-Screw Products, Ronnie Teleng, Tel: (011) 898 3200, Email: info@ Peter Killian, Tel: (011) 608 0088, Fax: (011) 608 0148, Email: info@
telscrew.co.za, Web: www.telscrew.co.za hitech.co.za, Web: www.hitech.co.za

Supercraft into orbit Giant recycled soccer ball

The Aluminium Federation of SA, in partnership with Hula-
British aerospace company, Supercraft has enhanced its
min, KMG and other stakeholders launched a Guinness
airframe manufacturing ability with the addition of three
World record recycling project at Brightwater Commons in
multi-axis machining centres from Yamazaki Mazak UK.
Randburg.
Founded in 1982 as an aerospace fabrication company,
The project took three months to complete and included
Supercraft has developed over the years into a full-service
the collection of tonnes of used aluminium foil for recycling.
manufacturer for machining and fabricating high precision
Thirty schools took part in the collection of foil, which was
aerospace components, adding treatments such as welding
deposited into a 2.5 m diameter aluminium soccer ball.
and painting, before building these parts into recognisable
airframe assemblies. KMG undertook the mammoth task of supplying the alu-

34 Advanced Materials Today Jul/Aug 2010

 Industry News
to 292 000N and 104 600N respectively, with screw di-
ameters of 40 to 63mm. An additional circulation of balls
doubles the ball count and thus increases the load capacity
as compared to the standard version. This high performance
nut, in conjunction with multithread precision screws with
pitches of 20, 25 and 40mm, reaches travel speeds of up
to 150m/min. The rotation-symmetric design allows both
the screw and the nut to be driven. Bosch Rexroth provides
the ready-to-install ball screw assemblies cut to size with
machined ends.
The service life of double-threaded nuts with standard seals
is up to eight-times longer than that of the single-threaded
nut. Machine manufacturers can thus scale axis rigidity and
performance for identical mechanical construction simply by
exchanging the nuts.
Tectra Automation, Greg Calder, Tel:(011) 971 9400, Fax: (011) 971
Work in progress at KMG’s Isando Works
9440, Email: greg.calder@tectra.co.za

minium and precise laying out, laser cutting facets from

flat 1.5mm aluminium sheet and bending connections to
36 degrees so that the pieces connected together like Lego
for final welding.
The common soccer ball made from a combination of hexa-
gons and pentagons is a truncated isosahedron. Cut and drilled
KMG Steel service centres are one of South Africa’s largest Local distributor of capital equipment, First Cut, has equipped
suppliers of steel, stainless steel and aluminium and has Delmas-based steel fabrication and construction company
branches nationwide. B&T Steel with a Kaltenbach cutting and drilling line, a
KMG, Melody Barber, Tel: (011) 929 5000, Fax: (011) 929 5062,
Web: www.kmg.co.za

New nut
A new 2-start FED-E-B double-threaded flanged single nut
that enables machine tool manufacturers to considerably
improve the load capacity of ball screw assemblies while
maintaining identical dimensions has been introduced into
the market.
The new nut achieves static and dynamic capacities of up

The newly introduced 2-start FED-E-B double-threaded flanged single nut

Advanced Materials Today Jul/Aug 2010 35

Industry News
capital equipment installation and investment which was
crucial to increasing B&T Steel’s production.
B&T Steel has been in operation for over 15 years, offering
innovative steel solutions, through the manufacturing and
erection of high-quality steel structures.
functions for turning and milling machines in a central control
cabinet assembly that is fully compatible with the MTX CNC
family from Bosch Rexroth with intelligent IndraDrive servo
drives, the new IndraMotion MTX micro achieves accuracies
down to the nanometre.

“The Kaltenbach cutting and drilling line supplied to B&T Specifications correspond to the typical requirements of
Steel by First Cut now facilitates a fully automated steel compact machine tools. The IndraMotion MTX micro is ideal
production process for the company,” says Andrew Poole, for automating up to four feed drives for turning or milling
director of First Cut. machines as a CNC controller with integrated PLC.

“The installation of the Kaltenbach capital equipment assists
B&T Steel in processing up to 700 tonnes of steel a month,”
adds Robert Fourie, product manager at First Cut.
B&T Steel’s technical director Norman van Vuuren adds that
the choice to purchase the Kaltenbach drilling and cutting
line has effectively moved B&T Steel’s business into a new
dimension in which it is strategically well-positioned to
develop a presence in numerous industries.
“B&T Steel has set very high targets for future growth, and
therefore invested in new equipment to improve our capacity
and customer service going forward,” says Norman.
First Cut, Andrew Poole, Tel: (011) 614 1112, Email: andrewp@
firstcut.co.za
A high-performance 32-bit processor in the central control
cabinet assembly of the system provides for short CNC and
PLC cycle times and enables production accuracies down
to nanometres, while ensuring high productivity. The I/O
interface with modular expansion capability integrates 24V
DC auxiliary sensors and actuators into the automation setup
despite the lack of additional coupling relays.
A user panel offers a variety of standard functions that also
make it possible to commission and optimise without a
programming unit. The IndraMotion MTX micro is currently
one of the most compact system solutions for turning and
milling machines on the market and has already proven it-
self in several recently developed machine tools and is now
available locally through Tectra Automation.
Tectra Automation, Georg Venter, Tel: (011) 971 9400, Fax: (011) 971
9440, Email: georg.venter@tectra.co.za

Compact CNC controller

Tectra Automation, the sole distributor of Bosch Rexroth
pneumatic products in southern Africa, has introduced the
company’s new harmonised IndraMotion MTX control plat-
Under pressure
form to the South African market.
The Pressure Vessel Manufacturers Association (PVMA) has
This innovative controller presents all hardware and software changed its name to the Pressure Equipment Manufactur-
ers Association (PEMA) in
response to changing market
conditions.
Newly elected PEMA chair-
man, Peter Viljoen, says
that this is not just a name
change but a fundamental
re-launch. “It is the revamp-
ing of the philosophy of the
organisation to make it more
relevant to its members and
the industry as a whole.
“The PVMA has always been
affiliated to both SEIFSA and
SASSDA but when SASSDA
made a policy decision to
shed many of its affiliated
organisations, including the
PVMA, we used the oppor-
tunity to have a good look at
what we were doing.
“The name change was the
first and most obvious ac-
tion as the organisation had
A high-performance 32-bit processor in the central control cabinet assembly of the system provides for short to align itself with the new
CNC and PLC cycle times Pressure Equipment Regula-

36 Advanced Materials Today Jul/Aug 2010

Industry News
tions (PER), which now to be replaced due to problems caused by operating in the
involves all pressure harsh environment, while the fourth system, an existing
equipment, including Prosafe solution, was still performing well.
accessories, and not just “This is one of the largest systems of its kind that has been
pressure vessels. installed in southern Africa, from the number of keys used
“There are other fun- to the actual size of the installation,” says Roy.
damental changes. For “Improved safety and durability were the two main require-
example, we have ex- ments of the system.
panded membership to
incorporate the gamut “The system itself eliminates the need for a lot of keys that
of industries in the can be misplaced or misused. The keys are manufactured
value chain including from 316L grade stainless steel, are specially coded, and
users of pressurised can only be manufactured by Rockwell Automation to help
equipment,” says Peter. ensure the safety integrity of each system. The system can be
“Also, we are dedicat- configured as mechanical or electro-mechanical, depending
ing ourselves to help on the customer’s requirements. In the case of the smelter,
Peter Viljoen uplift the entire pres- a combination of both methods was used which allows for
sure equipment industry the monitoring of individual keys and integration into the
through education and training initiatives directed mainly at existing control system.
skills development.” Rockwell Automation, Adrian van Wyk, Tel: (011) 654 9700, Email:
He adds that a strong and cohesive industry association is avanwyk@ra.rockwell.com
critical in the promotion of the industry to both local and
foreign companies wishing to do business with its members.
“I am pleased to say that PEMA will quickly be in a position
to do just that.”
PEMA, Tel: Peter Viljoen, Cell: 082563.8207, Email: peter@stain-
less.co.za

Trapped key system installed
Rockwell Automation has designed and delivered a trapped
key interlocking system for a chrome smelter in Steelpoort
in the Mpumalanga Province.
The Allen-Bradley Guardmaster Prosafe system is being em-
ployed across the smelter’s four furnaces to improve safety
Prosafe trapped key
interlocking switches
Gaining momentum
Afrimold 2010, a trade exhibition for mould-making, tool-
ing, design and application development, is gearing up for
a successful debut event at the Sandton Convention Centre,
Johannesburg from 16 – 18 Aug 2010. Show times are 16
and 17 August 10h00 to 19h00 and 18 August 10h00 to
18h00.
Afrimold, aims to create a platform to highlight mould-making
and tooling and to enhance product development throughout
the African continent as well as advancing business, tech-
nology and design.
Prestigious exhibitors who have already secured their places
at the inaugural event include 3D Solids, Retecon and Bohler
Uddeholm Africa.
Margie Oosterlaak, Marketing Manager at 3D Solids says
the company is very excited to be participating in this first
event in Africa. “We are part of the Stratsys Group which
traditionally participates in both euromold and amerimold.
This show will give us the chance to demonstrate our 3D
printers for prototyping to our direct target market on the
African continent.”
“Our product is such that it needs to be seen for customers
and prospects to appreciate the true value of our system
and afrimold provides us with the ideal platform for
exposure to our specialised target market. We have had
interest from Namibia and look forward to enhancing our
interaction with them at the exhibition,” she concludes.
A high level conference program is planned to run concur-
rently with the afrimold exhibition which will address tooling
technologies from design through manufacture and conver-

Advanced Materials Today Jul/Aug 2010 37

Industry News
sion and include all the manufacturing disciplines such as
plastics, metal forming and foundry (low pressure, high
pressure and sand casting.)
In addition, specific industries will be targeted including
automotive, consumer, medical, building and defense.
Afrimold South Africa , Ron MacLarty, Cell: (072) 353 6699, E-mail:
ron@afrimold.com, www.afrimold.com
Plastics innovations at K 2010
Few industries have been hit as heavily by the 2009 economic
crisis as the construction sector. Sales of pipes, profiles and
boards have fallen dramatically and plastics processers and
machine manufacturers have experienced a significant drop
in business.
By the time of K 2010, the world’s leading trade fair for the
plastics industry taking place in Düsseldorf from 27 October
to 3 November, manufacturers of pipes, profiles, boards and
insulating materials are hoping for a revival of business.
Organisers say the current market situation is difficult to
assess although it looks as if the crisis bottomed out in mid-
2009 and the market then stabilised at a low level. If the
US market is taken as an indicator, a study published by the
Freedonia Group market research institute (Cleveland, Ohio,
USA) at the beginning of 2010 gives cause for hope.
Plastics companies from around the world will gather at the
show from 27 October to 3 November at K 2010 in Düssel-
dorf. The world’s leading trade fair for the plastics industry
will be presenting a complete overview of the production of
plastic pipes, profiles, boards and insulating materials for
use in the construction industry.
www.k-online.de
38 Advanced Materials Today Jul/Aug 2010
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