Preguntas Frecuentes


Consulte a continuación algunas de las preguntas más frecuentes. Si necesita más información, llámenos o envíenos un correo electrónico.

Why is a quick setup time for a machine so important?

Many small volume production projects are requested for special Helices therefore it is of vital importance to process these orders effectively and as efficiently as practicable. This means being able to predict the blank cut for a perfect fit at the outset so there are no trial and error requirements, this means being able to get the machine set-up and into production quickly. We have replaced other modern machines that were sold with pre-programmed settings, which have in the longer-term proved to be little more than a gimmick with time wasted dialling in the exact settings for production. Helix Flight machines allow the operators to set up for a job in under 5 minutes. This includes swapping-out tooling (if required), and dialling in any adjustments due to the choice of material's spring back. This is the case even when a job is being completed for the very first time.

How many forming plates are usually supplied?

Helix Flight supply a set of forming plates to meet our client’s forming requirements. This depends upon the choice of a right or left hand flight requirement, and also the pitch range that a client prefers. We have supplied differing clients with 2 forming plates, and other clients with over a dozen. Our small diameter machines are typically provided with 6 forming plates, with both left and right hand options. Our medium diameter machines are typically supplied with 6 forming plates, also with both left and right hand options. Larger intermediate diameter machines can have up to 12 left and right hand forming plate options. These quantities vary and is flexible being subject to each individual client's needs and purpose for the manufacture of the Flights. The advantage of Helix Flight’s system is that it provides the smallest, most practical number of forming plates for the job in-hand as described by the client. Each forming plate has a range of pitch capabilities and a wide range of diameter capacities. Often the next job is able to be completed without changing the tooling, this makes the production of small Flight orders highly-efficient due to the time and therefore cost savings.

Being based in the USA what options are available to accurately diagnose a potential operating fault?

One of our primary goals in building highly-durable machines is that in the rare event of a break down we can give support globally from our base in New Zealand. This is particularly important for companies that work within strict time constraints during production. Fortunately, we've gained in excess of 20 years of experiential experience in building long-lasting machines well-before we advanced into manufacturing the innovative and reliable HF1 Series machines. All of our machines are registered online using our advanced diagnostics system, this allows us the convenience to directly assist with any diagnostics required when a problem arises in an emergency situation. In support of this statement, we only use world-leading branded parts which are reliably accessible worldwide, and should be available within your nearest city. Additionally, in the rare event that a problem occurs, we keep in stock a wide-range of manufactured parts for overnight airfreight too.

How safe are your machines for the operator?

Our machines are designed to comply with UL and CE marked safety requirements. Forming speeds are limited for the jaws of the machine to avoid operator injuries. When we started our design process, we examined 30 years of safety incidents and have mostly eliminated the causes of these incidents via our design and machine operations. We don’t have foot pedals which were the main cause of serious harm injuries. All machines are designed for a single operator and the hydraulic oil runs at a safe temperature to avoid burns. The list of safety features are extensive, and we are replacing a growing number of both old and modern machines due to safety issues.

During Covid outbreaks, can we request a live demo of your machines?

We can arrange a full demonstration of our technology at any time. Please contact Helix Flight through our contact page.

What is the typical ROI on Helix Flight Forming machines?

The ROI on a machine is complex and subject to numerous variables and so careful evaluation is recommended. It often involves considerations for the costs of the blanks, and the costs incurred to form the helices in their different sizes, versus the cost to buy-in formed helices. When following the simple equation above, we often see justification for a machine pay-back within 1-3 years.

Nevertheless, other considerations are equally important for making a shrewd investment in a Helix Flight machine, including:

  1. Savings are made in the stock of formed helices to meet quick delivery times.
  2. Savings made in having to rent stock is not required.
  3. Improved margins with the ability to provide an overnight turnaround for
    R&M work.
  4. A rain-making effect, with in-house sectional helices helping to attract larger projects.
  5. Diversification into new, niche markets.
  6. The cost-savings achieved by having an in-house sectional helix forming service, which  avoids third party down-time for repairs as they randomly occur.
  7. Having exclusive technology that adds to increased business value and in turn,
    any potential opportunity for a future sale of the business.

All of the above are important relevant to the ROI for your machine, on top of the basic costs of production versus market pricing per helix formed.

Do we need to keep replacing the tooling components of Helix Flight machines?

Helix Flight has several grades of tooling which is dependent upon the client’s needs. We have STANDARD grade forming plates which are very quick to refurbish and 600HBW which are our most robust and durable forming plates. These forming plates will naturally wear out over time, subject to frequency of work cycles, and helix manufacturing volumes.

We have manufactured machines that are now 8 years old with all the original tooling, and others that have transferred to 600HBW to minimise refurbishing needs.

Helix Flight is always pleased to work with clients to provide the most suitable tooling for their immediate needs, and are keen to ensure the lowest whole-of-life cost per helix manufactured.

What are the approximate costs to maintain a Helix Flight machine?

The maintenance costs for Helix Flight machines are genuinely minimal.

Typically there is a cost for replacing oil filters subject to work cycles and machine hours. Every few years the replacement of hydraulic oil and amortisation of the forming plates is required. On a recent ROI analysis for clients, we have shown that these costs are on average less than <1% of the capital cost of the machine per year.

What sort of operational life can be expected from a Helix Flight machine?

Helix Flight machines are designed to have an expected service life of 1 million mild carbon steel (250 MPa yield strength) helices or 25 years.

Machine parts such as the PLC have been specifically selected to ensure a 25 year life. One of the key benefits of our advanced online diagnostics system is our ability to upgrade the machine operating systems as new developments go live. Most machines that we have supplied over the years have had at least one operating system upgrade, which has added new features and a range of future-proof capabilities.

I am an OEM and have no experience in Helix flight forming; so, approximately how long does it take to train operational staff?

This question is really at the heart of our original goal for Helix Flight’s technology. We now have numerous examples of leading companies through commissioning, training, and actively up to and including production usually well within 2-3 days. Especially when we consider that not all companies have gained any previous experience in the process of forming helices.

We are now achieving the same time-frames with our new commissioning, safety induction, and training video modules. We support this with Zoom call assistance too. We have achieved this even when several of the companies we have installed machines with have limited, or no, English language abilities spoken in-house.

The huge advantage of our new video modules is that if a staff member changes, we are easily able to ensure new staff are swiftly up and running with the correct training from day one.

Another advantage is that we are frequently adding new video modules, as new techniques are developed for technical challenges. Operators then have the the ability to watch videos as repeat refreshers which we have seen is very much appreciated before they commence a new or highly technical project in forming a Helix.

How reliable is the Blank Cut Design Manager (BCDM) Software for accurately predicting blank cuts at the first attempt?

The Helix Flight BCDM software is in continuous development and improvement; however, the vital function of predicting the amount of stretch during forming from accurate blanks is absolutely assured. Users are predicting blanks from 50mm (2") in diameter to 6,000mm (236") diameter, from 25mm (1") in pitch to 7,200mm (283") in pitch, and in thicknesses from 1mm to 50mm. These accurate predictions are also across a range of material grades.

We work interactively with our machine owners to investigate, develop and trial new features. All of our existing machine owners have direct access to the latest BCDM software programme.

What is the HS or NCM number for the export of Helix Flight's machines?

The HS or NCM number for Helix Flight Forming machines is 8462.2900

What tariff or duties apply to Helix Flight sectional forming machines?

Helix Flight machines are exported from NZ which has a multitude of free trade agreements around the world. This can mean little or no government tariffs or duties between these countries. Although it is important that our clients check with either our company for the specific details for a particular machine, or their own customs brokers to ensure that they have the current information on inbound duties or tariffs for their country of operation.

What are the vital requirements for our company premises to install a Helix Flight Forming Machine to ensure its smooth operation?

The main requirements include an Ethernet connection, three phase power supply, a clean concrete floor of adequate strength related to the weight of the machine.

We build our machines to meet your local power supply requirements.

Medium diameter and larger machines will need a dedicated lifting aid, such as a pivot arm gantry and a two speed electric hoist.

Intermediate diameter and large diameter machines may need a special recess in the floor for the most efficient and practical set-up for ease of operation.

Are Helix Flight machine owners showing increased growth and profitability in their businesses since adopting the Helix Flight forming technology?

A testimony to this is when our clients need an additional Helix Flight machine to continue their growth. A reflection of our greatest success happens when we are able to enjoy the swift growth of a client company after the adoption of our technology.

We are honestly delighted to be able to confirm that we have a growing number of companies with multiple machines on their premises; with a growing number looking to invest in their second and third machines in the near future.

Can Helix Flight machines cold form abrasion resistant materials such as Hardox 500 HB, AR400, or Creusabro 8000, and other similar abrasion resistant materials?

Helix Flight is now the global leader in cold forming helices from these types of abrasion resistant materials.

Can Helix Flight Forming Machines make tapered perimeter helices in a final cut form?

Yes. This is a key advantage of our technology. The Helix Flight technology used to make tapered perimeter helices in a final cut form avoids the need for the multiple processes of other systems that use cut-away false pieces; and also makes substantial cost savings incurred by extended time delays that happen with other less efficient systems.

Do Helix Flight have machines readily available and in stock?

We are currently building stock machines; however, these are often sold before full completion due to the heavy and increasing demand for Helix Flight technology.

Please contact us (see options below) to discuss the availability and timely supply of any specific model of machine that you are considering for your needs.

Call Daniel direct: +64 21 999 099  
E-Mail:  [email protected]  or:  [email protected]
Main Office: +64 9 232 7805 
Or, complete the form on the page of this website that shows the machine you're interested in: www.helixflight.com



Do Helix Flight have forming plates in stock and available for immediate despatch?

Yes, we do. We always aim to keep a full range of forming plates in stock and ready for despatch by air or sea subject to freight and shipping schedules. Although, this is related to the immediate work demands of other orders that we have underway; or machines that are in the complex completion stages of being despatched, which will usually take priority.

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