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Behind the scenes of manufacturing the New Micro Tuffboxes – Part One

Last month saw us launch our new range of Micro sized Tuffboxes, aimed at the on-the-go portable toolbox security market. As like all the other Tuffboxes, the Mircos are manufactured in Britain at our Oldham factory so we have gone behind the scenes to look at how the little Tuffboxes came to life…

Stage One – Design

Our own in-house CAD engineers programmed the Micro Tuffbox, based on its big brothers. The CAD designers made small adjustments due to its smaller proportions. The toolbox still utilises the same handles and base design, to allow existing accessories to fit including fork feet and the lockdown chains.

Stage One - Design

Stage Two – Cutting

We take a piece of 1.5mm thick steel and cut it on our Trumpf TruLaser 3030 machine.

Stage Two - Cutting

Stage Three – Forming

The cut pieces are then bent on our Trumpf press brake machines to form the toolboxes structure and lids.

Stage Three - Forming

Stage Four – Welding

All the cut and formed pieces are taken to the welding department to weld and join together to become the main base unit and lid.

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The following photos detail the various steps of the handle inlet before, during and after welding to the main side panel.

Stage Four - Welding

Stage Four - Welding

Stage Four - Welding

Stage Four - Welding

Then the side panel, with the handle now attached, is welded onto the main body of the Tuffbox toolbox. Firstly the welder tack welds it in place…

Stage Four - Welding

Stage Four - Welding

…and then uses a process called MIG welding to join the pieces together.

Stage Four - Welding

Stage Four - Welding

Stage Five – Finishing

The finished welded pieces are then taken to the finishing and grinding team who grind and polish off the weld marks to create a clean smooth base for the powder coating stage.

Stage Five - Finishing

Stage Five - Finishing

We’ll continue with our how it’s made feature next week detailing the powder coating and assembly stages of making a Tuffbox.