Expansive knowledge and application

At DMark® we make handmade metal parts – and masterpieces – using traditional methods blending classical metal formations with the very latest techniques to create new works across a wide range of unique projects. A merger of tradition and innovation.

Traditional sheet metal fabrication and coachwork continues to be a valuable skill for many sectors – craftsmanship that’s rare.

Know-how we’ve honed and improved across a broadening range of equipment and tools allows for great precision and customisation in our work.

We create exquisite hand-formed shapes, from the simple to the complex, from flat sheet metal – using a hammer (or other customised tools and flippers) and dolly. This typically requires intricate levelling and general panel formation, and is the process before planishing. Hand forming or panel-beating metal panels in this way takes gentle manipulation, and patient expert application of our rare and proven fabrication techniques.

Specialist tools aren’t necessarily required here. We still use hammers and dollies that must be over 50 years old, and we occasionally seek out tools that might be over a century old – certainly pre-war – as they’re proven and yet to be outdated. We use whatever is best for the project, and it’s all about the subtle application of skill, deftness and feel we’ve developed in our dedication to our craft.

Anyone with a hammer can make a dent. But accurately hammer-forming sheet metal means tapping and controlling a precise point of contact, so handling the right dolly or custom-made tool is often the DMark difference.

Shaping metal on the George Kendrick English Wheel through different anvils takes years to perfect, and requires an intimate knowledge of how metal behaves – plus a lot of patience.

The top anvil has a flat surface profile with no crown, and is the larger of the two wheels. The smaller bottom anvils usually have a slight crown, or raised profiles of varying widths.

In a regular workflow we’d only change the bottom anvil, and do so when its profile most closely matches the profile we want the panel to end up with. So as the panel is formed, we change the bottom anvils to suit as the sheet metal forms incrementally and takes shape. Sometimes this requires flattening an area of a curved panel, in which case we’d use a flat anvil (or one with a shallower crown) to work the metal gently back into a flatter profile. Between these two points of contact is where the magic happens, and how one handles and moves the panel through the two anvils is DMark’s ‘secret sauce’.

Adjustable pressure between differential anvils allows tiny changes to the metal panels as they’re wheeled, and our custom anvils allow us to manipulate sheet metal into even more complex and intricate forms, and access difficult areas.

At DMark we typically use our English Wheel to subtly stretch sheet metals to shape them in all manner of ways… but it’s not always for stretching. Sometimes we need to flatten and smooth out uneven panels, too, and we can even manipulate a panel enough to shrink areas or highlight low and high spots.

Our FJ Edwards No.9 hand-turned geared swaging tool helps us turn edges. Often, we use it to break the grain of the metal along a fold line before an edge is turned by hand, but it’s useful for a wide variety of handy formation techniques. Swaging, sometimes known as bead rolling, allows us to put swages or indentations into panels of any shape, for decorative purposes or to stiffen up sheet panelling, or both. It gives us the scope and finesse to make very subtle impressions or very deep ones.

The swaging machine also helps us make a variety of traditional metal joints, by forming steps or other profiles along an edge. This enables us to connect two or more panels with, for example, sunken lap or flanged joints.

On occasion, we’ve also made purpose-built tooling for our swaging machine, and even for our English Wheel, to create swages. Using the larger format wheeling machine might be where a panel’s shape and size prevents us from using our dedicated rotary swaging machine.

Our six-foot FJ Edwards slip rollers enable us to roll sizable metal sheets, profiles, bars and rods. For even larger panels, we sometimes use a press break from one of our trusted partners, depending on the shape we’re after.

Having made many vintage car bonnets, which often have this sort of shape, our fairly large and rare hand-operated slip rollers allow us to manipulate the roll so it’s tighter at one end than the other.

This is performed in a variety of ways – by hand, or by using a fly-press or press brake. One of the most powerful but versatile ways we’ve found to bend metals (especially thicker profiles) into consistent but non-uniform shapes, has been to use one of our two fly-press machines – often with bespoke tooling and set-ups.

If a roller or fly-press set-up is inadequate, a press-brake operation will give us accurate impressions along a linear, and often lengthy, point of contact. This can sometimes be a better way to form longer panels incrementally.

DMark sometimes applies this press-brake method with a trusted partner, to gently construct or ‘bump’ a curve or roll in a panel. It requires precisely the right tooling, plus diligence and familiarity, but it significantly reduces the likelihood of the roll arc flattening out in the middle of the panel where the tension is greatest. The key is knowing when to use which technique, and with what tool or machine.

DMark’s hand-operated FJ Edwards four-foot folding machine allows for tight, acute-angle folds that can be awkward and tricky using press brake machines. It’s also handy for other needs, thanks to the precise adjustability of the cam’s flat pressure.

We outsource some tasks to a press brake, but will perform them by hand if the project demands it (or if it enhances the end result).

We do this in a variety of ways, from using our large bandsaw, electric shears, treadle guillotine or a pair of handheld snips, to outsourcing to a laser or waterjet cutter for large or complicated sheet profiles – or even a hand-held plasma cutter for specific needs.

At DMark, we typically have our blank metal sheets laser-cut by a local firm, as it is the most accurate and efficient option. We begin this process by creating a 2D CAD file, and where necessary build in a margin with excess material removed after forming.

This is the act of pulling material together (shrinking) or opening the material up (stretching) to make returned edges curves, and to move material, transitions, edges and folds.

We can shrink and stretch in a number of ways. Using our large Eckold K800 machine, and a smaller hand-operated Eckold HF100 (with grippy or soft jaws) are the most effective ways to achieve shrinking and stretching across a wide range of gauges, but where appropriate we can still use an old-school hammer and dolly… and be surprisingly agile, subtle and accurate.

DMark mostly uses its Eckold K800 machine for dome forming, but this can also be done by hand with a hammer and our own bespoke dolly shapes. Not all jobs need domed sections, but the tooling used for doming is handy with other transitions and form combinations. We never rule out a technique or idea – we often ‘cross-pollinate’ techniques to achieve the desired shape or style. Also, creating a dome often requires more than one shrinking operation so combinations are often used.

This is the ‘dark art’ of smoothing sheet metal. Planishing is where we use a hammer, flipper (or slapper) and dolly to lift up low spots and tap down high spots in sheet metal. Planishing is the final part of panel shaping; it is done after the main formation or any welding.

It’s a fluid, honed technique we’ve used on a variety of jobs. We always do it before filing or surface finishing, and quite often when panels have been distorted by weld heat or other damage. Planishing is also a method of manipulating and shaping the metal gently to ensure it goes precisely where you want it to. We can planish large panels or very small ones, or for projects where installation access is tight, limited, or where a panel cannot be removed.

Whether subtly or fundamentally, we’re experienced in re-forming and re-working existing metalwork with our proven tools and techniques. DMark can often re-form (manoeuvre metals to the correct shape and fit) and then re-work (handle any other auxiliary processes, repairs and finishing) metals back to condition or into new forms – and even for different purposes.

This is common with car bodywork or genuine one-off antique pieces, such as the work we’ve done on Victorian-era French copper baths. Unless the metal is severely damaged or corroded, just about any metal object can be repaired, repurposed, re-worked and brought back to life. The skills we’ve demonstrated and honed over decades mean we can resurrect rare, original (or just very tired) authentic parts.

Although there are other engineering methods of tensioning, DMark is adept at ‘taking the slack out’ of stretched sheet metal panels. We achieve this with shrinking methods alongside clever techniques with a hammer and dolly, developed over years of experience and experimentation.

At DMark we regularly see long metal profiles – or weak, thin or old panels – that are misshapen through poor handling, storage or accidents. We’re skilled in various techniques for straightening effectively without compromising integrity, usability or aesthetic.

This is typically done after planishing, shaping or excess weld removal, to remove material and re-shape surfaces. More often than not we use sharp body-files to file back metal and expose surface imperfections, high points and low points, and to flatten.

Quality body-files enable very fine or very heavy metal removal, and alongside other file shapes and file-blade cut patterns, are essential tools for many of our projects.

We use this technique in nearly all of our hand-beaten forming of sheet metal. Annealing softens the material so it can be manipulated more easily. Techniques differ between metals, but for sheet aluminium we use an easy and effective (but little-known) method of annealing from Don’s apprenticeship days.

Brazing is a method of joining metals using a filler rod. Done right, the the capillary-action of the molten filler rod produces an attractive, naturally flowing, strong joint which often needs little or no filing or post-processing. It often requires careful and precise clamping before the parts can be brazed, which is why at DMark we are very conscientious with the overall pre-braze set-up, torch access and pre-fluxing.

DMark often uses soft solder to join brass in low-stress joints, as seen often on our brass DB2 brightwork products and other metals. It’s a suitable way to join metals without getting the join area too hot. It’s generally used on brass and copper, but thanks to improvements to fluxes and filler materials, we can also soft-solder other metals, such as stainless steel.

It does mean a different colour to the ‘parent’ metal, though, so this needs to be factored into some jobs, but most are subsequently plated so the colour difference is not an issue. We’ve found a great combination of a particular solder and flux that works fantastically well for us, whether with a flame or solder iron.

Used on low to medium stress joints on brass-work more often than not. Silver soldering achieves a stronger join than soft solder but is not quite as strong as a bronze/brass brazed one. Over soft-solders, a higher temperature is required – so it can affect the surrounding area more. Silver-soldered joints clean up particularly nicely though, and a capillary-action fettled joint is a beautiful thing! The filler rod is very closely colour-matched to brass unlike soft solder wires, and although there are many different melting-point rods, we tend to get away with using just one or two if (on those rare occasions) it’s necessary.

Much like our soft soldering methods, we’ve found a fine combination of silver-solder brazing rods and fluxes that cover all the jobs DMark has been involved with so far.

Oxy/acetylene welding, or gas welding, probably requires the most skill and technique of all the types of welding we offer. It’s still preferable for some tasks, such as aluminium panel welding, where it allows us to create perfectly seamless joins that match the parent material. Sometimes we use a rod; most times we do not. But for perfect colour-matching, and where a filler rod is required, we cut our own strips from the same parent metal.

We’re also experienced and capable with TIG and MIG, or even really old-school stick welding methods! Admittedly, we use them less and less now we have a brilliant hand-held laser welder…

Our two specialist metal cold-forming Eckold machines have interchangeable dies that allow for precise and powerful sheet-metal manipulation that includes shrinking and stretching, and more. Our bigger pedal-operated, air-powered K800 Kraftformer machine allows for larger panels – from flat, or already with three dimensional form – to be readily worked. While our smaller hand-operated HF100 machine is used most often for edge forming where access is limited, the K800 machine reigns supreme and we use it across many project types.

We also cold-form metal sheets, solids and profiles using our Norton 8DB 14” deep-throat, and shallow-throat No.4 fly-press machines – and often with our own custom tooling. The fly-presses allow us maximum scope when it comes to hand-operated press-type work and tooling options. Having said that, we now 3D-print job-specific tools for both the fly-presses and the K800 Kraftformer machine, which further expands DMark’s technical offering.

With methods proven over decades, and with adaptive tooling set-ups, DMark can use old tooling stock or create new apparatus particular to a customer’s need, to press louvres of all shapes and sizes in sheet metal. Preferring to use our deep-throat fly-press for most louvre forming tasks, we also maintain a smaller fly-press and even a separate rig configured using a hydraulic press, which can be used for particular configurations. Yet we tend to rely on our generously scoped, bigger fly-press for most work, as we did when producing over 970 louvres in aluminium for panelling within the Napier Railton room at the Peninsula Hotel in London.

Making it is one thing then there’s the aesthetics and what it physically feels like. At DMark we take this very seriously and are keen to discuss these aspects with clients in early project scoping. Often we have to come up with our own interpretations and techniques or even develop hybrid methods.

Talk to us about sample making – whether that’s proving manufacture, methods or finishes and surface treatments.

We apply meticulous attention to detail across all kinds of surface finishing and protection. DMark can provide or oversee plating, such as chrome or nickel, and other treatments or surface protectors, either in-house or via longstanding trusted partners. We’re adept in high-quality finishing on nearly all metals and combinations.

We confirm the type of finish clients require early on, as the process of achieving it often needs to start much earlier in a project’s build-cycle than some might think. As always, it comes down to know-how, dexterity and patience.

We provide expert polishing and brushing from coarse to smooth, and from highly reflective finishes to a variety of brushed finishes. Our two aluminium Austin Healey 3000 gearbox covers are fine examples, which we can make to order in a fine brush finish or a rich and reflective polished version.

DMark does a lot of metal finishing and scratch removal in-house. This mostly involves wet or dry linishing, burnishing and surface treatment by hand or with handheld machines, progressing through abrasive grades to achieve stunning results. When required, we can also outsource metal polishing to a trusted local specialist who has powerful stationary mops. This is usually for harder metals such as stainless steel, but we can also do this in-house using our own marginally less powerful kit!

DMark creates custom tooling and templating to support our creative manufacturing processes for customers, and for our own complex projects, plus jig design and fabrication. We tend to outsource machining and other CNC operations for metal when the need arises, but have in-house capabilities for most projects.

Our specially made tooling and adaptations – often born of problem-solving and necessity – enable a more comprehensive range of sheet-metal manipulation options.

Our recent investments allow us to digitally capture and measure small and large objects precisely with our new 3D scanner. We can also analyse complex surface geometries and use the data to design new tooling and new parts with CAD software. This paired approach also enables further evaluation and better inspection of the quality and consistency of parts we already produce – and will produce. Meanwhile, it will help us solve project fabrication, tool and fixture-making challenges, plus sizing and scaling demands, with greater accuracy and precision.

DMark can also design and create simple and complex tooling aids and parts more efficiently with our new 3D printer. This, in league with our highly versatile laser welder, will greatly expand our in-house capabilities in sheet-metal welding and tailored fabrication.

DMark was the first metal fabrication outfit in the UK to take delivery of an IPG Photonics Handheld LightWELD 1500 XC laser welder. Isn’t it amazing to think we can join metals together using light! It’s a fantastic bit of kit that gives us even greater scope and accuracy across all welded joints.

It allows us to weld very thin and surprisingly thick sheet metal gauges with an extremely localised heat band, thus dramatically reducing the heat transfer into the metal panel. This is a game changer for DMark, as dealing with the problematic effects of excess heat on surrounding metalwork can be exhaustive.

The attractiveness and accuracy of a good laser welded joint – straight or curved, the fact that we can now explore welding different metal combinations together, and more, allows DMark and its clients to think beyond what was possible yesterday.

DMark has recently invested in an engineering-grade 3D Printer, the Markforged Mark Two, which allows us to produce extremely accurate, reliable, nylon polymer based parts for presses, cold-forming dies, jigs, buck sections, hand-held drifts, various tooling, assembly fixtures, end-user products, and more parts we haven’t even thought of yet!

This new technology means we can produce parts that are on par with the strength and stiffness of aluminium, thanks to a secondary continuous reinforcement material like carbon fibre. Precise 3D dimensional accuracy and incredibly smooth surface finishes, without the need for additional post-processing, means our new in-house part-creation package keeps us at the forefront of the latest additive manufacturing developments.

Alongside DMark’s additive manufacturing investment, we’ve also added a portable hand-held 3D scanner – the Zeiss T-SCAN hawk 2 – to our in-house capability. Our new 3D scanner and accompanying software will capture geometric data from real-world objects, and very quickly and efficiently put that digital surface data into a CAD file for further processing. Our scanner and accompanying equipment is capable of capturing extremely accurate geometry from many surface types (even shiny reflective metal finishes) using the very latest blue-laser light technology.

At DMark, the reverse-engineering and re-manufacture of rare and even damaged parts has been greatly enhanced. We can now capture geometric data easily, especially complex free-flowing forms or previously tricky to measure objects, far more accurately and efficiently than ever before. We are even able to preserve historical accuracy for parts lacking drawings.

For a good while, software has been another tool to compliment all the hardware associated with metal fabrication. It will be even more so with the advances of powerful Artificial Intelligence, and the convergence of software and hardware. We’re already seeing impressive developments in the field of sheet-metal forming and fabrication, and we predict many more to come.

We use various software packages to help make extraordinary metalwork, and by working in both 2D and 3D CAD formats, it helps us in all sorts of ways. Our depth of knowledge is now expanding into software relating to 3D scan data, 3D printing, 3D modelling, surfacing and reverse-engineering tools. We strive to be at the forefront of technology, but maintain an understanding of what came before it. DMark’s treasured anvil was cast in 1882, and is as good today as it was then!

When needed, DMark can also rely on trusted colleagues and partners for their software specialisms and expertise. We often find clients, or their teams, are also more than willing to help where they can with their capabilities in this area. Quite often we’ll receive a CAD drawing when a customer first reaches out to us.