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Bespoke fabrication for custom aluminium panels

C&C Fabrications was presented with a unique and challenging project, involving the production of aluminium panels with diamond-shaped cutouts, designed to hide unsightly roller shutters. The panels, numbering over 300, varied in length and width, and required CNC press brake folding to accommodate different wall fixing brackets. This project was commissioned by Waverley, on behalf of a client with very specific aesthetic and functional requirements.

Objectives and challenges

The primary objective of the project was to create aluminium panels with a consistent and visually appealing diamond lattice pattern to fit precisely within the varying dimensions specified by the client. The challenges included:

  1. Geometry customisation – Ensuring that the diamond patterns were to a consistent standard across different panel sizes required meticulous tweaking of borders and geometries.
  2. Equipment limitations – Some panels exceeded the capacity of C&C Fabrications’ laser cutting machines, requiring a creative approach to develop alternative production methods.
  1. Tight deadlines – The project had to be completed in phases, with batches delivered every two weeks, to meet the rapid pace of construction and changing on-site dimensions.

Solution and implementation

To address these challenges, C&C Fabrications employed a multi-faceted approach:

Firstly we focussed on 3D modelling and design where a 3D model was designed in a lattice style, stretching the diamond geometry to suit each panel’s specific dimensions. This model was then converted into 2D fabrication drawings, which were reviewed and approved by Waverley before production.

We then tackled the challenge of panels exceeding the laser machine’s capacity through innovative manufacturing, producing the panels in two halves and then joining them seamlessly, with added bracing for support. This approach allowed for quicker turnaround times compared with outsourcing.

And finally, we utilised powder coating for the panels, which were powder coated in three different RAL colours, providing a durable and aesthetically pleasing finish.

The project was executed in batch phases, with panels supplied in batches every two weeks. This strategy ensured that the fast-paced project remained on schedule and could adapt to any changes in dimensions as the scaffold was removed from each building level.

Outcome

Despite the complexity and the tight deadlines, the project was completed successfully over a period of six months. The collaboration between C&C Fabrications and the project manager was crucial in managing the workflow and ensuring timely delivery. The client was pleased with the quality and structural integrity of the panels, which met all their requirements and contributed to the overall success of the construction project. Project Manager Lloyd Palmer was pleased with the outcome and said “The project certainly went well. I have no complaints about C&C and the quality of the product you produced was 10/10”

To partner with C&C for an upcoming project, don’t hesitate to get in touch with our team.