CNC plasma tube and pipe cutting automation is changing the way our industry looks at industrial handrail production. Traditionally, railings are particularly time-consuming to fabricate and process because the work requires a high level of accuracy and attention to detail. Fortunately, advanced tube plasma cutting machines and structural steel processing automation can speed timelines for handrail production while saving labor costs.
For example, at Southern Metal Fabricators (SMF), we use state-of-the-art automation like the Bend-Tech Dragon A400 for faster CNC plasma tube cutting. We can achieve dead-on accurate, plasma-cut handrails that assemble perfectly.
Combined with over 3 decades of custom metal fabrication expertise, SMF can accelerate handrail production and structural steel project timelines by:
- Improving cutting quality while speeding production timelines.
- Increasing accuracy with plasma-cut handrails that assemble perfectly.
- Accelerating materials processing to get products out the door faster.
In this blog, we will look at five ways CNC plasma tube and pipe cutting automation can reduce your timelines for handrail production while adding more value to your production projects.
1: Get Longer Material Cutting Options With CNC Plasma Tube Automation
With the Bend-Tech Dragon A400, SMF offers more options for material cutting, including the ability to cut material up to 24 feet long, with pass-through via the chuck for round, square, and rectangle material.
Cutting long materials often requires a series of adjustments and alignments when using conventional methods. These repeated setups can introduce errors, compromise material quality, and significantly increase production time. With the pass-through chuck design of CNC plasma tube cutting automation, materials can be fed seamlessly through the machine. This allows for continuous cutting of tubes and pipes of substantial lengths.
This design eliminates the need for manual repositioning, ensuring that cuts remain consistent from start to finish. Whether the material is round, square, or rectangular, the Dragon A400 delivers precise cuts in a single setup, reducing downtime and labor costs.
2: CNC Plasma Tube and Pipe Cutting Delivers More Material Value
The versatility of CNC plasma cutting automation extends beyond just cutting long materials. As we noted above, the Dragon A400’s chuck system accommodates a wide range of material profiles, including round, square, and rectangular tubes. It also cuts a wide variety of materials, including stainless and galvanized steel, aluminum, black pipe, chrome alloy, or any electrically conductive metal.
This adaptability is crucial for handrail production, as different projects often require varying tube or pipe shapes and dimensions, which may require different types of materials. For example, industrial handrails might prioritize functionality and durability, often using square or rectangular tubing for additional strength. On the other hand, architectural handrails might require a sleeker aesthetic, achieved using round tubing with custom-cut designs. The Dragon A400 handles these demands effortlessly, offering consistent results regardless of material type or shape.
3: Get More Material Thickness Options for Tube and Pipe Cutting
The Dragon A400 can cut any thickness from 1/32 inch to 5/8 inch in pipes, tubes, channels, or angles. The ability to cut a wide range of material thicknesses is a game-changer for diverse handrail production projects, including metal fabrication and structural steel processing.
This flexibility ensures that the right materials can be used for every project, from lightweight architectural railings to heavy-duty industrial handrails. This benefits the production process for a wide variety of production applications, including:
- Lightweight Applications: In architectural or residential projects, thinner materials (such as 1/32 inch) are often used to achieve sleek, modern designs. These materials are easier to handle, less expensive, and provide a polished appearance.
- Heavy-Duty Applications: In industrial or infrastructure projects, thicker materials (such as 5/8 inch) are essential to meet stringent strength and durability requirements, ensuring the safety and longevity of the handrails in high-stress environments.
4: Get More Cutting Options for Different Shapes and Sizes
Another benefit of CNC plasma tube cutting automation is its flexible size cutting. With SMF’s Dragon A400, options include round .75 to 6 inches, square 1 to 4 inches, rectangle 1 inch to 4 inches, angle and channel 1 inch to 4 inches, and hypotenuse options.
Handrails aren’t one-size-fits-all, and projects often demand a mix of materials with different shapes and dimensions. The Dragon A400 can process the following with incredible accuracy:
- Round Tubes: Sizes from 0.75 inches to 6 inches are ideal for creating smooth, rounded handrails commonly used in architectural designs, staircases, and safety barriers.
- Square Tubes: Sizes from 1 inch to 4 inches provide excellent structural integrity, making them perfect for industrial settings where strength and durability are key.
- Rectangular Tubes: Ranging from 1 inch to 4 inches, these are a go-to choice for designs requiring a sleek, modern aesthetic with added stability.
- Angles and Channels: With sizes from 1 inch to 4 inches, these profiles allow for the integration of brackets, supports, and decorative elements in railing systems.
- Hypotenuse Cuts: The machine’s ability to perform precise angled cuts simplifies the creation of complex joints and transitions, essential for custom and challenging designs.
This adaptability reduces the need for multiple machines, streamlining production workflows and cutting handrail production costs.
5: Reduce Lag Time and Increase Safety With Material Coolant System
SMF has invested in optional advanced systems with the Dragon A400, including a material coolant system (MCS). For cutting aluminum, stainless steel, or tubing with a small outer diameter (OD), the coolant system offers benefits such as:
- Enhanced Cut Quality: The coolant helps to cool the cutting area, minimizing heat-affected zones and resulting in cleaner, more precise cuts with less distortion.
- Improved Edge Finish: The coolant flow helps to flush away debris and chips, leading to a smoother and more consistent edge finish.
- Reduced Slag and Fumes: By lowering the cutting temperature, the MCS minimizes the formation of slag on the cut edge and reduces the amount of harmful fumes produced during the process.
- Increased Options for Challenging Materials: Materials like aluminum and stainless steel can be cut more efficiently with a coolant system due to their higher heat conductivity.
- Extended Torch Life: Proper cooling with an MCS can lengthen the lifespan of the plasma cutting torch by reducing heat stress on its components.
- Faster Production and Higher Quality: By enabling faster cutting speeds and minimizing rework due to poor cut quality, an MCS increases overall efficiency for processing industrial handrails and other types of railing production.
How a Metal Fabrication Partner Can Use Automation to Simplify and Accelerate Handrail Production
The above examples are just a few of the ways CNC plasma tube and pipe cutting automation can save time, labor, and production costs normally associated with handrail production. And it simplifies many of the traditional complexities surrounding the production of industrial staircases, ladders, railings, and other industrial access systems.
With a wide range of in-house automation and over 30 years of custom metal fabrication expertise, Southern Metal Fabricators can find new ways to simplify your handrail production.
Give us a chance to say, “Yes, we can do that!” by outsourcing your handrail processing or other industrial access project to Southern Metal Fabricators. Visit our metal fabrication capabilities page to learn more or contact us today.
