Process/Production
Process & Production
We are manufacturer with a strong know-how in several production processes.
4 production centers, located in China and Germany.
A know how that supports you on each production step
At Luxe we take pride in being able to manage every single step of the full development process. From R&D, mould design, prototype development, certification and testing to batch manufacturing.
Surface Treatment
Parts and components from Luxe are available with a very complete range of surface treatments which are outsourced to our local and trusted partners.
Currently we offer:
- Electroplating of chromium, nickel, zinc-nickel, cadmium, copper, zinc, silver, tin-zinc and zinc-iron.
- Conversion films such as anodizing, passivating and phosphating
- Electropolishing
- Painting and powdercoating
- PTFE coated & PTFE lining
Gasket & Rubber Parts
Professional seal manufacturing
Sealing is a major feature of most of our products. Customers rightfully demand excellent and long-lasting sealing performance in their applications which are not rarely.
For rubber and sealing material we cooperate with renowned international supplier.
FDA certification for some materials.
PTFE & PFA Coated
The PTFE and PFA coating ensures optimum chemical resistance.
In general, this process is used on materials such as stainless steel and steel. We can apply this know-how to rigid tubes, machined fittings, valves, … Do not hesitate to let us know your needs; our engineers can study the feasibility of your request.
CNC - Precision Machining
Precision machining is the process of removing material to obtain a required shape or surface which cannot be achieved via other production methods such as casting. To do this fast and with consistent quality, CNC machines (computer numerical control) are generally used for large production batches.
Assisted by CAD-CAM (computer aided design – computer aided manufacturing) software, the design to machined part turnaround time can be kept very short and first-time right.
At Luxe, all of our parts and product follow this process. It provides fast results and consistent quality.
Capacity and capability of Luxe Precision Machining:
- Software: CAD-CAM programs, ProE and UG
- Machining of steel, stainless steel, aluminium and copper alloys.
- 300 CNC stations
- Maximum size of diameter 750mm, length 1000mm and 100kg in weight.
- Roughness up to Ra 0.2
- Size tolerance up to 0.005mm
- Expert workers dedicated
Gravity Casting
In the process of gravity casting, a molten aluminium alloy is poured into a die and fills the cavity only by the force of gravity. Via controlling process parameters and the use of well-placed feeder and risers a solid cast shape can be made witha perfect structural integrity.
Combined with heat treatment and shot blasting, a hard, high strength, good looking and machinable casting can be obtained.
Capacity and capability of Luxe gravity casting:
- Annual capacity of 2.3 million pieces
- Materials as per ASTM, SAE, AISI, ACI, DIN, EN, ISO and GB standards
- Fully automatic manipulators
- Quick, high accuracy and repeatability.
- In-house tooling and mold workshop
- 10 gravity cast stations
Expert workers dedicated
Die casting
Die casting is a process whereby a molten alloy, usually aluminium or zinc based, is injected into the cavities of a metal die.
Capacity and capability of Luxe die casting:
- Annual capacity of 3 million pieces
- Materials as per ASTM, SAE, AISI, ACI, DIN, EN, ISO and GB standards
- We can cast zinc and aluminium alloys
- Fully automatic manipulators
- Quick, high accuracy and repeatability.
- In-house tooling and mold workshop
- 5 sets of zinc alloy die casting equipment
- 5 sets of aluminium alloy die casting equipment
- Expert workers dedicated
Forging
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Forging is the technique whereby a force is applied to a blank metal object to cause a plastic deformation. The force required is high and therefore special machines are used.
The physical deformations of the metal during the forging process reorganises the internal material structure in such a way that excellent mechanical properties can be achieved.
Our Storz coupling are an example and they have proven to be extremely strong, durable and reliable.Capacity and capability of Luxe forging:
- Annual capacity over 2 million pieces
- Materials as per ASTM, SAE, AISI, ACI, DIN, EN, ISO and GB standards
- Fully automatic manipulators
Quick, high accuracy and repeatability. - In-house tooling and mold workshop
- 10 forging stations
- Expert workers dedicated
Investment casting
Investment casting is a casting technique that starts with the molding of a wax model that is identical in size and shape to the required cast product. A process of dipping and drying follows to produce a hard heat-resistant ceramic outer layer on top of this wax model. When this layer has reached its required thickness, it is heated to melt and remove the wax on the inside. The result is a disposable hard ceramic shell which can be used to cast metal alloys.
Advantages of investment casting:
- The lifetime of the mold is extremely long as the molds are not much affected by the wax molding process.
- Complex shapes and smooth surfaces can be cast. This reduces the amount of secondary operations required.
- A wide variety of alloys are suitable for this process.
- High degree of casting accuracy and thin wall sections are possible, reducing the overall weight of the part.
Capacity and capability of Luxe investment casting:
- Annual capacity of 1800T
- Materials as per ASTM, SAE, AISI, ACI, DIN, EN, ISO and GB standards
- We can cast more than 100 different kinds of black and non-ferrous alloys and as well fulfil special demands of customers.
- Near net shape castings with complex sizes and shapes with a dimensional tolerance of ±0.1mm , minimizing the need for secondary processes.
- In-house tooling and mold workshop
- 4 investment cast stations
- 8 sets of wax injection stations
Metal Powder Sintering
In the metal sintering process a powder is pressure compacted into a die followed by heating until the powder particles are fused together and form a strong bond.
The key difference with casting is that during the sintering process the material temperature does not reach the threshold where solid turns into liquid. It is therefore ideal for materials with a high melting point.Materials available for sintering:
| Material category | Materials | Applications |
| Fe-based alloys | Fe-2Ni, Fe-8Ni | Automotive, tools |
| Stainless steel | 316L, 17-4PH, 310, 420, 440C | Medical equipment, watch components |
| Hard alloy | WC-Co | Cutting tools, watch components |
| Ceramic | AI203, ZrO2, SiO2 | Electronics and watch components |
| Heavy alloy | W-Ni-Fe, W-Ni-Cu, W-Cu | Military and communication equipment |
| Titanium alloy | Ti, Ti-6AI-4V | Military and medical components |
| Magnetic material | Military and medical equipment | |
| Tool steel | 42CrMp4, M2 | Tools |
| Copper alloy | – | Materials for heat and electric conduction |
