by Melissa Donovan
Part 4 of 4
Digital cutting helps manufacturers from all backgrounds save on cost and time, especially when the process is brought in house. Beyond the ability to control the entire process once under one roof, a manufacturer is then given the advantage of better managing time constraints on a job.
From Out to In
In 2006, Fire by Design Inc. began as a builder and installer of custom outdoor fireplaces, fire pits, and barbecue islands. Two years later, it moved away from the assembly and installation of these products and began to focus its efforts on supplying burners, burner pans, and electronic ignition system components.
Today it specializes in manufacturing the pieces—like those mentioned and more—found in fireplaces and fire pits. It works from one location with 18 employees. These components are made out of metals like stainless steal and black steal and need to be cut and/or bent to certain shapes and sizes.
Initially, the cutting and bending of metal products was outsourced. However, it spent a lot of money doing so and other issues were also present. “There were times throughout the year when we experienced long lead times with local vendors, depending on how busy the were,” explains Bob Roman, president, Fire by Design. One of its vendors was also unable to engrave, so when products required some form of identification, Fire by Design used paper labels instead—which wasn’t ideal.
After researching several options, Roman came upon Kern Laser Systems. He looked for the ability to cut and engrave, hoping to eliminate the paper labels, cut lead times, and save money in the process on material and cutting costs.
The model now run in house is the Kern OptiFlex, which is the company’s flagship high-performance laser system. The HyperDual motion package installed on the OptiFlex sets the standard for large format laser cutting and engraving machines. This improved motion system features a rack and pinion design and powerful servo motors at each side of the laser table. Cut acceleration rates are up to three times faster with a 100 percent increase in top-end vector speed. The X-axis has also been upgraded with twin linear rails and a thicker steel reinforced belt.
Thanks to the Kern OptiFlex, paper labels are eliminated and replaced with engraved labels. In addition, the company expanded its cutting beyond just the components found in the fireplaces and fire pits.
“In the beginning, we only cut 16 gauge stainless steel, but now we are expanding into cutting other materials for our shipping department such as foam and rubber,” notes Roman. He credits this to the machine’s ease of use. Switching the cutting head is simple, allowing it to cut steel and then foam in less than ten minutes.
Combining the ease of use with the having the machine in house and accessible 24/7 really sets the company apart from the competition. “Having the laser cutter enables us to have consistently shorter lead times than our competitors and with the engraving, it gives our products a much more professional look,” he explains.
The cost savings from using the Kern OptiFlex is also apparent. Prior to purchasing the laser cutter, Fire by Design spent $300K in one year to cut and bend all its metal, offsite. With the machinery now in house, the cost has come way down and based on Roman’s financial calculations, the laser cutter as well as other machines will be paid off in less than two years.
Sky is the Limit
Thanks to the Kern OptiFlex Fire by Design can focus on adding new products to its portfolio without worrying about how long it might take to cut and bend metal and get the part back in time. The biggest advantages to going digital for this business were cost savings and quick turn times.
Similar to the other companies profiled in this four-part series, Fire by Design continues to experience great success with its in-house digital cutting device. According to Roman, the business is growing quickly and he feels “the sky is the limit.”
Read part three of this series, End-to-End Automation.
Apr2021, Industrial Print Magazine