As precision cold forming and machining specialists we understand the need for production equipment such as laser, plasma and welding systems, to perform reliably for extended periods while consistently delivering sub-micron levels of accuracy and repeatability.

So when we are asked to design and manufacture components for engineering systems we have the first-hand knowledge and experience to develop innovative solutions that capitalise on the latest materials and production techniques.


For example, we’ve worked closely with customers to develop a new generation of plasma nozzles that work longer, more reliably and with greater precision than ever before.  Similarly, we’ve developed and supply fully assembled and tested ball-lock systems for shaft control, which enhance the performance and operating characteristics of slitter and rewinding systems.

Cold-formed plasma


Our cold-formed plasma and laser consumables give a significant improvement in cut quality over conventional machined nozzles. Feed rates can be increased by up to 10% and still achieve improved cut quality. These advantages are a direct result of the mirror finish and curved internal nozzle profile.


Plasma Consumables

Dawson Shanahan works with leading global plasma OEMs, supplying them with high quality cold-formed plasma consumables. Laser marking and packaging is provided to customer requirements, and we also offer a design and development capability to reduce waste.


Generally speaking, machined nozzles have an internal surface finish of around 1µm. Our cold formed nozzles have a surface finish of around 0.1µm. This gives better, less turbulent gas flow resulting in the improved cut quality and speed.


There is a marked improvement in cut quality and this together with increased feed rate offers the end user a significant cost saving through reduced machining time and reduced clean-up.


YAG Laser Nozzles

YAG laser technology and optical fibre delivery systems are creating new laser application areas. As a result the laser’s significance as a flexible tool for manufacturing is growing rapidly.


YAG laser technology has a price advantage over more complex five-axis CO2 laser based gantry systems for three-dimensional part cutting.


YAG nozzles are traditionally very difficult and expensive to manufacture due to the very long tapered bore.


After extensive R&D, Dawson Shanahan produces COLD FORMED YAG nozzles up to 75mm long and we are confident that this length can be increased with further development.


CO2/YAG Cold Formed Laser Nozzles benefits:

  • improved cut quality
  • increased feed rates
  • significant cost savings
  • reduced machining time
  • reduced clean up


Laser Mirror Blanks

Laser Mirror Blanks also benefit from manufacturing by cold forming. Lower cost is achieved as well as uniform grain size, and most importantly the deformation in the process reduces the problems caused by porous or defective flaws in the parent material.

We have designed and developed our own unique ball-lock systems for shaft control, which enhance the performance and operating characteristics of slitting and rewinding systems.

Our tested and proven mechanisms ensure precise control of web tension, minimise dust from cardboard cores and enable packaging systems to operate for extended periods at fast speeds. We can manufacture and assemble ball lock mechanisms in house, cutting the cost of sourcing and assembling your own components.


We work to the highest ISO quality standards, partnering with your design and production teams to select the best materials, and maximise component performance and operating life at optimum cost. Additionally, we can manufacture, assemble and test full systems or sub-systems, delivering a complete, ready to install solution for OEMs or end users.


To learn more about our expertise in the packaging sector please contact our sales team on +44 (0)1938 551700 or contact us via our online form.

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