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Easy 60% time savings in laser welding mailboxes
Lastek launched a super-efficient technique for joining thin sheet metal with Fanuci's handheld laser welding device.

Easy 60% time savings in laser welding letterboxes

SemperFi belongs to the Devos Group. A household name in subcontracting in West-Flanders, but also far beyond. That the company has made it this far, has everything to do with the clear vision of the managers to always strive for the best possible quality with the highest possible efficiency. The recent investment in a Fanuci handheld laser welding machine, distributed by Lastek, proves this once again. SemperFi can now weld its letterboxes 60% faster.

With SemperFi, Managing Director Lieven Devos realized his dream of putting his own ready-made product on the market. With the same eye for detail and customer focus for which the company is now known.

"It started with mailboxes, but in the meantime we also produce garden tables. The common thread is always the same: we start from a relatively simple design, but strive for the best possible quality and finish. Does the customer not like the models we have? Then, thanks to our machinery, we can go to great lengths to make his specific wishes a reality," says Bert Depauw. "That way we can make the mailbox a real business card. After all, it's the first thing you see."

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Bert Depauw: "The time savings we're making with handheld laser welding is phenomenal."

View of workshop: made in Belgium

A concept that is clearly catching on. Last year alone, 600 went over the counter. Semper Fi now has its own showroom, where customers can discover the possibilities of its own products. Depauw: "These stand side by side with a number of other brands from suppliers who impose the same conditions on their products as we do. Quality comes first, which is why we offer a ten-year warranty." 

Remarkably, the showroom overlooks the workshop behind it. "The bulk of the sheet metal work is done three kilometers away. This is where all the components are assembled, welded and then ground. We want to show our customers that their products are made here, and not shipped from China. In addition, it gives us the ability to respond quickly to customer inquiries. We want him to feel like king here."

Lastek launched super-efficient technology

Until recently, the welding shop consisted of two departments: one for semi-automatic welding and one for TIG welding. But when Depauw saw what could be done with a handheld laser welding machine from Fanuci during a demo by Lastek, he was immediately convinced of its potential. 

"As a company, we are always looking out for new technology that can help us produce more efficiently and therefore at more competitive prices. Especially for letterboxes, where the thickness of the sheet material is relatively limited, this could save us a huge amount of time. Because the weld is easily made, but especially because much less post-treatment is required. Because of the low heat generation, the weld looks handsome and hardly any grinding is involved."

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Safety first. Everyone who does laser welding uses proper safety glasses.

Testing in practice

Less welding time, less welding fumes, and fewer grinding hours. Immediately sold, right? "We did not proceed overnight. We got to use the device to see if it could add value in our production." 

Two thresholds still held Depauw back: the weight of the hose package and the (still) limited possibilities in thicker material. "We go up to 8 mm thick here, so on paper the device runs into its limits. But in practice, the results still turned out to be puffy." Then again, to optimize weight, Lastek provided wire feed via an elevator arm. "The gun gives a somewhat less flexible impression, but it turned out to be mainly a matter of learning to work with it and getting used to it."

The less, the better

Depauw does not hear anyone on his team grumbling when they have to use the Fanuci device for their pieces. 

"Just because there is so much less grinding involved. Everyone here finishes their pieces themselves. The less they have to grind, the better. The time savings we get with handheld laser welding is phenomenal. We did the test on our most popular mailbox model, the Syntax. By the time I had the mailbox fully welded up, it had just done one side with TIG welding. Count on at least 60% faster work. In the past, it would have taken us a week to restock. Now we do it in a day. Besides, the unit has only been in use here for a few months. We are still experimenting with the settings to get the best results. We are certainly not at the end of its capabilities yet and will explore how we can also use it in supply as an added value."

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To optimize weight, Lastek provided wire feed via an elevator arm.

Safety first

Still, Fanuci is already proving himself to be a very welcome addition to its own products. Although customers cannot marvel at its tricks. "Laser light has to be handled very carefully for safety reasons. We followed all of Lastek's recommendations to make an enclosed cabin for the device. Anyone who wants to go inside has to put on safety glasses. Those are the ground rules. We also installed an extraction system. The health and safety of our employees always comes first."    

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