ISSUE 115 MARCH 2025
THE LASER USER
WORKING TOGETHER PROVIDES SOLUTIONS
Cableboss first approached GF Laser (GFL) in March 2024 regarding the potential to mass produce a powder-coated metal bracket to support the running of cables in ceiling voids and
walls.They had already produced the part in plastic but also wanted to bring to market a metal version for the commercial sector that met strict building regulations.
GFL’s first job was to analyse the part to see whether it could be laser cut and folded, at volume, utilising existing tooling. In addition, the part was also checked to make sure that there would not be any issues with powder coating. Once the estimating team had undertaken the necessary feasibility checks, pricing was put forward to supply in batches of up to 5,000 units. The team also suggested to Cableboss that the part could be produced more cost-effectively by cutting the part using pre-galvanised mild steel, which would alleviate the need and subsequent cost for powder coating.
Cableboss liked the idea of using a pre- galvanised part, so engaged GFL to produce some samples for approval, with a view to placing an order for an initial 1000 units. These samples were quickly made and approved and gave confidence to Cableboss to place the initial order for the 1000 parts. GFL also agreed to provide a fulfilment service which meant that parts could be shipped directly to Cableboss customers, again reducing transport costs.
Whilst these parts sold quickly and generated a lot of interest in the building industry, the team at Cableboss were keen to improve the product and one of the ideas was to put small lips on the apertures, which would remove the requirement for rubber grommets for added cable protection. Whilst this wasn’t something GFL could easily do, their sister company Moseley Brothers’ core offering was tool making, so the project was handed over to them.
The client’s customers expressed concerns about possible damage caused when cables were passed through the holes and being dragged along the material’s edge. This often necessitated cutting and installing grommets, which increased installation time. After a productive discussion, a prototype design was envisaged that incorporated a safety edge around each of the cable apertures. GFL used in- house simulation techniques to present forming data to the client and a newly proposed laser-cut blank profile to the GFL team.
Once the concept had been presented and approved, GFL proceeded with tool design, which was completed internally at Moseley Brothers. Keeping costs low for the client was essential, as they needed to gauge feedback from their existing customer base with a small sample batch of parts before committing to changes in their packaging and marketing strategy. The future potential of this product was
also considered, ensuring the tool could easily be adapted for larger production quantities.
Tool design was reviewed internally at Moseley Brothers by the technical team, material was sourced, and drawings were issued to begin manufacture. GFL used its CNC millers, 3D CAM software, and toolmaker expertise to keep lead time to a minimum.
Once manufacture was complete, GF Laser supplied the new laser cut and folded parts to trial the prototype tool in one of Moseley Brothers’ in-house presses. The results were promising, though the edge formed slightly higher than anticipated. Thanks to the collaboration between our two companies, a new shape was quickly generated, and parts were cut, folded, and trialed within the same working day, thus completing the development and try-out process with minimal delay. Cableboss received the parts and offered very positive feedback.
Contact: Simon Tregillus
simon.tregillus@
gflaser.co.uk https://gflaser.co.uk/
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