Making it happen

RA specialises in the production of vehicle exhaust systems, components and powertrain systems, however, its expertise extends to all areas of vehicle engineering.

  • Project Management
  • Component and System Validation Testing
  • Tool and Attribute Gauge Design and Manufacture
  • Manufacture and Assembly
  • Process Optimisation
  • Quality PPAP / APQP
  • COP / SPC

RA works closely with its supply chain to ensure everyone understands the requirements and objectives for high quality, cost effective supply for our customers. Only TS16949 or ISO9001 accredited suppliers are approved for component supply.

Prototyping

Fast, reliable, right first time.

Supported by the Advanced Engineering team based at the Innovation Centre, RA designs and manufactures its own prototype tools and parts in support of concept development and early stage DV testing.

With a dedicated and experienced prototyping fabrication team, supported by state of the art manufacturing and measurement equipment, anything is possible.

Two 3D multi-material printers enable parts to be produced within hours of Customer sign-off.

Tool Making

Streamlined tool making processes

RA uses its in-house developed CAD toolbox to design manufacturing tools, assembly tools and attribute gauges for a wide range of products. This enables its customers to benefit with cost effective, process efficient, and fast turnaround production solutions.

  • Manufacturing tools
  • Component assembly jigs, fixtures & attribute gauges
  • Press Tools
  • Precision alignment fixtures
  • Carbon fibre lay-up tools
  • Carbon fibre cutting jigs
  • Electrical / electronic test
  • COP / SPC gauges

Manufacturing

Production Part Manufacturing

Investment of more than £2M in the latest CNC plant and machinery over the past three years has resulted in a level of quality, and capability un-rivalled in the UK.  Working with the machine manufacturers, the RA production team has developed machine and tooling specifications to meet its own requirements and achieve new levels of performance.

The following highlights just some of RA’s current plant list and capability.

Tube Manipulation And End Forming

Crippa 100HE full electric CNC multi-stack boost tube bending machine (2018)

  • Max tube diameter 100mm (stainless steel and Titanium)
  • RA Custom tooling suite
  • Min bend radius 1D
  • Min clamp length 1D (with 1D bend radius)
  • Adaptive spring-back compensation

Crippa 980LE full electric CNC multi-stack boost tube bending machine (2015)

  • Max tube diameter 80mm (stainless steel and Titanium)
  • RA Custom tooling suite
  • Min bend radius 1D
  • Min clamp length 1D (with 1D bend radius)

Faro Platinum laser scanner & V-tube software (2016)

  • 6ft machine with laser scanning head
  • First off / last off verification of bend tube
  • Cut-off length measurement and verification linked to Mille Miglia saw

Mille Miglia DTR-70E cut-off saw (2017)

  • Extended range <80 mm capacity shearing saw
  • 5 second total cycle time including loading / unloading
  • Removes requirement for 90% of cut-off fixtures

Adige SC425 rising saw (2018)

  • <145mm diameter cutting capacity
  • RA custom 180 deg rotary table for custom fixtures
  • Extended clamping ram for increased height capacity

Avamatic AV85T double headed end forming machine x3 (2015-2018)

  • Double headed expanding / reducing function
  • <100mm diameter
  • RA custom tooling for special features

KMT TS1 torca slotting machine (2016)

  • Double / Single slotting capability
  • <100mm OD capacity
  • Capable of multiple profiles

Vixen Agiwash AG1200 custom 900 x 1200 x900mm (2015)

One of the most important pieces of equipment in the factory.  Everything is thoroughly cleaned before welding.  Ensures perfect welds and helps keep the factory and workforce safe and clean.

Exhaust Component & Sub-assembly Manufacturing

Nosstec (Luna) 8344 CNC rolling machine (2016)

  • Max 2.0mm stainless steel and Titanium
  • Max 740mm body length

KMT CNC double ended hydraulic horizontal internal “stuffing” machine (2016)

  • Single or double ended operation
  • Max body length 750mm
  • Force monitoring for COP

Kemper sound insulated weld bays with full Kemper extraction & filtration – Stainless Steel (2015-2018)

  • 2m x 1.5m sub assembly bay x3
  • 5m x 5m sub assembly bay x 2
  • 5m x 5m final assembly bay x 3
  • 4m x 3m final assembly bays x 6

Welding plant (2015 – 2018)

  • Jackle ino MIG / MAG weld plant x20
  • Jackle pro TIG water cooled weld plant x 10
  • Model PF181 Projection and spot welding machine by Sureweld

Titanium Exhaust System and Component Manufacturing

A dedicated, highly skilled team manufacture lightweight exhaust systems and components within a state of the art facility at its March House site.

This clean environment produces high quality high temperature Titanium product for the world’s leading vehicle manufacturers.  The process of welding titanium requires spotlessly clean and dry parent material and filler wire to be combined in an inert argon environment.

EZIOT 7.25kW De-gassing Oven

  • 2000 x 1200 x 900mm capacity

Glovebox™ Final assembly Welding Chamber (x2) 2017-2018

  • RA Custom chamber designed by Glovebox™
  • Welding Chamber size 1600 (W) x 1000 (D) x 1100 (H)
  • Ante-chamber size 1200 (W) x 600 (D) x 450 (H)
  • RA Custom Oxygen level control with warm-up and standby mode for maximum efficiency
  • Oxygen level alarm (visible and audible)

Jacomex™ GP Sub-assembly Welding Chamber 2017

  • Jacomex chamber with extended anti-chamber
  • Welding Chamber size 800 x 1200 x 800mm
  • Anti-chamber size diameter 400 x 1200mm
  • Oxygen level alarm (visible and audible)

Vehicle Component / System Assembly

Electronics Assembly

  • Bespoke Component testing equipment
  • Electronic system build
  • Electronic system testing

System / Kit Assembly

Vehicle system build and test is carried out at both March House and Egerton close sites

  • Intake systems
  • Fuel systems
  • Exhaust system
  • Powertrain Tuning kits

Exhaust Finisher / Trim manufacture

  • Steel
  • Titanium
  • Carbon fibre
  • Multi-material
  • Carbon ceramic

Production and Process control

Quality is embedded within our company philosophy. A key part of ensuring RA delivers consistent high quality product, is ensuring our production processes run consistently and with repeatability. Both preventative and output measurement techniques are used throughout the process to ensure continuity and consistency of supply.

  • Strategic material & component sourcing
  • Traceability to source and in process
  • Poka yoke mechanisms
  • Standard operating procedures (SOPs)
  • PFMEA / Control Plans
  • Attribute gauges
  • COP / SPC gauges

Health and Safety

The RA welding team use Speedglass with Adflo or Optrel respiratory protective equipment. Along with Kemper weld bay extraction this minimizes weld fumes throughout the factory, and helps to ensure a clean working environment for all.

All extraction and filtration systems are covered by a routine maintenance program. LEV checks are conducted at the legislative intervals.

RA has on site bulk argon and mixed gas storage tanks, eliminating the need to move heavy individual gas bottles and allowing gas to be piped directly where it’s needed in each weld bay.

All work in progress (WIP) is moved around the production facility safely and securely in custom designed and built trolleys.