Even the simplest shape requires great skills, lots of work energy and resources. Matteo Gerbi strongly believe in sustaining our local manufacturers and in designing sustainable products; but in the end the real sustainability is to take care of the product itself by fully appreciating the quality and the passion behind it.

This is the reason why Matteo Gerbi has decided to show the production sequences of his design, through pictures and brief descriptions, so you could be able to enjoy the work and the passion behind Ray Shelf the revolutionary bookshelf.

Ray Shelf is entirely made in UK

THE MAKING OF RAY SHELF IN PICTURES

STEP 1A – CNC Punching

The components of Ray Shelf are cut from a steel metal sheet using a hardened steel punch. The manufacturing process is called CNC Punching and the machines are controlled directly from files created by CAM software

STEP 1B – CNC Punching

As you can see from the picture below, the cuts are very precise. The sections are removed from the metal sheet.

STEP 2A – Press Braking

The sections are now bent. This forming technology is called Press Braking and is manually operated. The metal is bent along a single axis between a punch and die. This technique is used only for the rectangular and triangular Ray Shelf’s supports.

STEP 2B – Press Braking

The picture shows the product after the press braking.

STEP 3A – Bending

For the circular and elliptical Ray Shelf supports, a wheel forming process is used in order to produce accurate sheet metal curved.

STEP 3B – Bending

The picture shows the metal sheet after the bending.

STEP 4A – Welding

All the sections are now welded together. In the picture you can see how this job requires a great precision and expert knowledge of the equipment.

STEP 4B – Welding

The support takes its final shape.

STEP 5 – Cleaning

Imperfections such as welding scales are removed from the edges.

STEP 6A – Powder Coating

The supports are now ready for powder coating. Firstly, the support has to be clean from all oil, grime and lubrication greases. Then, the powder is applied using an electrostatic gun.

STEP 6B – Powder Coating

The supports are now ready for curing (see picture below). The supports are placed in an oven for 20-30 min at 200 LC. During this process the powder begins to melt, flows out, and it reacts chemically to form a higher molecular weight.

Finish

Ray Shelf is now ready.

RS - HOW IT IS MADE

MODULAR SHELVING SYSTEM