True Form Helix Manufacturing...

Machines...

Helix Flight Manufacturing Machines Limited (Helix Flight), specialise in making machines that produce True Form Sectional Helices (industrially known as "Flights"). Helix Flight are now renowned for introducing this global innovation to a niche, highly-specialist sector of machine manufacturing.

Helix Screw "Flights" are used across many applications, such as Augers, Screw Conveyors, Agitators, Marine Anchors, Screw Piles, Screw Presses, Turbines and a multitude of other practical, commonly used Screw-Flighted products.

With over 20+ years of expertise in the Flighting industry and with an extensive global presence, our world-leading and Award-Wining technology offers versatile, State-of-the-Art machines, to produce sectional helices with different specifications ranging from 2 inches (50.8mm) up to 157 inches (4,000mm) Outer Diameter (OD).

Helix Flight provides inclusive training with our user-friendly design software, this helps to ensure the quick and effective uptake of the production process to safely, and swiftly, manufacture precision Helix Flights which are reliably accurate for the numerous applications associated with the many industries that use them around the globe. Our market-leading technology delivers long-term, defensible, competitive advantages in Sectional Helix Flight manufacturing.

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Safety...

Safety...

The highest Safety. Eliminating many of the primary causes of injury that were identified by an industry incident survey which covered the last 30 years.

Training...

Training...

This only takes 2 days for commissioning the machine, a full safety induction and comprehensive operator training to completion within 3 days.

Speed...

Speed...

Taking as little as 25 seconds per Helix formed for straightforward items.

True Form...

True Form...

True Form helices ensure that the flange is always perpendicular (90 degrees) to the shaft, keeping the internal edge parallel to the shaft, this ensures an accurate fit-up to the shaft for a perfect job.

Adjustability...

Adjustability...

Ultra-adjust-ability and flexibility are the primary features of all Helix Flight machines. Each machine is manufactured to offer a broad range of options in the production of a formed helix, each with an extremely wide range of sizes and differing specifications. Also, the machines are designed for a swift set-up between jobs, and features that adjust within seconds to allow for the variable changes experienced with the different types of Steel, Hardox and Abrasive Resistant material blanks.

Whole-of-Life Machine Costs...

Whole-of-Life Machine Costs...

The expected service life of a Helix Flight machine is 25 years, or 1,000,000 Helices manufactured, with planned low-maintenance.

NO high tensile raised blades which mark helices and compromise safety

NO helix grab kinks and no risk of pitch and fit-up issues due to post forming stress release problems

NO tags and cut-aways required for forming tapered, notched, or legged, helices

NO time-wasting manual set-up adjustments, and NO throw-away items while dialling-in on precise settings

NO Shims or Packers required for forming Abrasion Resistant materials

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60

Machines

47

Countries

6

Continents

1822368

Sectional Helices produced on Helix Flight Machines

We are having great successes with the Helix Flight Forming Machine press in our firm, it really is a Rolls Royce of a machine and testament to your engineering expertise and experience in forming highly accurate Flights. Today, we pressed our largest diameter flight and it came out perfectly, and ...

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Sectional and Helicoid Flight Manufacturer

"Thank you for your generous offer, we have already confirmed, so this mail is for information only following our application. The machine we bought has after 2 years of intensive work, still performs well and accurately. No doubts that I am very satisfied by Helix Flight's standards of machine ...

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Sectional and Helicoid Flight Manufacturer

Waste Recycling Equipment Manufacturer

We really appreciate the guidance and instruction from the videos supplied and for all the remote support that the Helix Flight team has provided, and the consistent professionalism.

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Waste Recycling Equipment Manufacturer

Ken Stebner – Director of Special Projects, North America

“We are pleased with the simplicity, flexibility and reliability of the HF1 as it continues to produce perfect pitch and helix to pipe fit-ups. As industry becomes increasingly familiar with screw piles, our sophisticated clients are requiring true pitch helices as part of their specifications. ...

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Ken Stebner – Director of Special Projects, North America

Screw Piling and Auger Manufacturing Company

In recent years, it was decided to introduce HF1MD to handle increased size to meet auger production enquiries of a large helix to the machine. HF1MD was digitised, numerically controlled and has been superbly improved. HF1MD had become easy to set-up for our intense operations. The stick position ...

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Screw Piling and Auger Manufacturing Company

Commercial and Industrial Engineering suppliers

We commissioned an HF1 MD VX flight forming machine from Helix Flight to replace our ageing conventional flight press. The improvements in productivity were instant in both quality and speed of pressing time. Our operators and support staff were given only one days training on the new machine, ...

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Commercial and Industrial Engineering suppliers

    Blank Calculation and Profile-Cutting

    Blank Calculation and Profile-Cutting

    There are two important steps in the operation of forming a Sectional Helix: The first is to cut a flat disk (a "blank") of required material thickness from a sheet of metal. Helices stretch when forming, so it is of critical importance to have accurate blanks cut out of flat plate. When formed into a 3D Helix it must meet the finished product specification. Helix Flight’s ‘Blank Cut Design Manager’ (BCDM) software predicts the precise blank size in seconds by entering the required finished Helix specifications.

    Cutting blanks is usually completed by either a laser, a plasma or a water-jet profile-cutting machine. The important aspect of this operation is to calculate the size of the blank, which when formed into a Sectional Helix must have an accurate finished size and pitch.

    There are many variables that may affect how a helix stretches while forming. These complex variables include D,d,P,T and G, and also the Pitch to Inner Diameter (ID) ratio, Flange to Diameter ratio as another example. Our BCDM software predicts blanks accurately from 50mm in Diameter, and 25mm in pitch; to - 4,000mm in diameter and 4,800mm in pitch, and up to 50mm in plate thickness.

    Once generated, the profiles of the blanks can be downloaded in a simplified .dxf format to send to the profile-cutting machines for nesting and subsequent profile-cutting to the required quantities. Our BCDM software has many auxiliary features to accommodate more specialist Helix blank designs with special features such as tapered perimeters, cone shafts, notches, legs, teeth positions, cant angles and many more options.

    Please click on the "Play" icon above to watch the video ^

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    Forming Sectional Helices...

    We don't just sell and supply machines!

    The second part of the overall equation in producing a Sectional Helix involves forming the blank into the Helix through the use of our innovative technology.

    These State-of-the-Art, safe to operate machines, make the process swift, simple, safe, and seamless for the operator. It involves a swift machine set-up with tools, then straight onto the production part of forming the Sectional Helix and checking the perfect fit-up on the shaft that is being used for the project application.

    Any fine adjustments can now be made just as swiftly and simply, and takes only a few more seconds to manage to adapt for the specific steel grade that is being used on the day. There should be no throw-away items due to the BCDM software providing the correct blank cut from the outset; plus, the ability of the machine to flexibly adjust the pitch up or down with amazing precision to meet the exact specifications of the job in-hand. This also ensures that an accurate fit-up is not only flush to the shaft, but is also aligned to meet each of the Helix's jointing edges, making a perfect seal where required.

    Helix Flight provide a complete solution, with our BCDM software providing the precise prediction through mathematical formulas to present the blank for forming in our machines. Also, the range and variety of material options that can be processed, left and right-hand forming plates ...And; of course, the ultimate Helix Flight Forming Machine from the range available (and continually expanding) to continuously and consistently produces accurate True Form Helices.

    We are always pleased to discuss your requirements, and are bound to have the perfect solution to give your business the competitive edge with our world-leading technology, and the excellence in standards of finish that we stand by for all our customers, together with our ongoing support across all elements of customer service and online back-up.

    We form genuine, partner relationships with our customers ...for the entire Sale & Licensing agreement of the machine!

    We don't just sell and supply machines!

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