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Unit I: Vasai Phata Production Floor

Precision Shearing & Blanking

Sheet Metal Shearing, Blanking and Cutting Division: CNC, Hydraulic, Manual and Light-Gauge Across 10 Machines

CapabilitiesSpecificationsQuality ProtocolIndustries ServedRelated Services

Expertise and Experience

Aero Enterprises Unit I Vasai Phata operates a 10-machine shearing, cutting, drilling, and surface finishing division that handles every blank preparation and secondary operation requirement in a single production floor. The shearing line runs three distinct machine types: a CNC shearing machine for precision programmed blank production, a manual hydraulic shearing machine for heavy-gauge and structural blank cutting, and a manual mechanical shearing machine for standard batch blank preparation. Two kachi light-gauge sheet cutting machines handle thin sheet and strip shearing below 1.5mm where standard shearing blade clearance would produce excessive edge deformation. Four drill tapping machines handle hole drilling and thread tapping on fabricated components. One surface grinding machine handles flatness correction, weld flush grinding, and surface finish preparation on components requiring tight flatness tolerance before assembly or coating. All shearing, cutting, drilling, and grinding operations at Unit I feed directly into the stamping press floor, CNC press brake, welding bays, and 7-tank powder coat line on the same production floor without inter-vendor transport or batch handoff.

Why Our Process Wins

An inaccurate blank is not a shearing problem. It is a compounding error that travels through every downstream process the blank passes through. A blank that is 0.3mm oversized on one edge produces a bend that is 0.3mm out of position, a hole pattern that is 0.3mm off nominal after stamping, and an assembly that fails fit-check at the client end. At Aero Enterprises Unit I, blade gap calibration per material grade and thickness is performed before every production run on the CNC and hydraulic shearing machines. Squareness is verified by diagonal measurement on first-off blanks before batch shearing is approved. Grain direction is maintained throughout the blanking sequence for components that will undergo subsequent bending or deep drawing, because shearing against grain direction on CR IS 513 DDQ grade increases the risk of edge cracking at bend radii on severe draw operations. These are not optional quality checks. They are the production standard that ensures the blank entering the press is the correct blank, not an approximation of it.

CNC Shearing Machine
1 x CNC Shearing with NC Back Gauge
Manual Hydraulic Shearing
1 x Manual Hydraulic Shearing Machine
Manual Mechanical Shearing
1 x Manual Mechanical Shearing Machine
Kachi Light-Gauge Cutting
2 x Kachi Machines for Thin Sheet below 1.5mm
Drill Tapping Machines
4 x Drill Tapping Units, M3 to M16 Standard Range
Surface Grinding
1 x Surface Grinding Machine
Total Machines
10 Machines: Shearing, Cutting, Drilling, Tapping, Grinding
Max Shearing Width
2500mm
Max MS Thickness
6.0mm (Hydraulic Shearing)
Max SS Thickness
4.0mm
Parallelism Tolerance
±0.2mm
Material Capability
MS HR IS 2062, CR IS 513, GI IS 277, SS 304, SS 316, Aluminium, Brass, Copper
Thin Gauge Capability
Below 1.5mm via Kachi Light-Gauge Cutting Machines

Machinery at Unit I Vasai Phata

1 x CNC Shearing Machine (NC Back Gauge), 1 x Manual Hydraulic Shearing Machine, 1 x Manual Mechanical Shearing Machine, 2 x Kachi Light-Gauge Sheet Cutting Machines, 4 x Drill Tapping Machines (M3-M16), 1 x Surface Grinding Machine. Total 10 machines at Unit I Vasai Phata. Integrated with Fiber Laser, Power Press Floor, CNC Press Brake, Welding, and 7-Tank Powder Coat Line.

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Core Capabilities

CNC Shearing: Precision programmed blank production on the CNC shearing machine with NC back gauge positioning for consistent blank length and width across high-volume batch runs. CNC back gauge control eliminates the manual measurement and repositioning between cuts that introduces cumulative dimensional error in large batches. Correct for precision blanks feeding CNC press brake programs and progressive die stamping operations where blank dimension tolerance directly affects formed component accuracy.
Manual Hydraulic Shearing: Heavy-gauge and structural blank cutting on the manual hydraulic shearing machine for HR IS 2062 and thick CR IS 513 up to 6mm MS and 4mm SS. Hydraulic blade drive provides consistent cutting force across the full 2500mm blade length regardless of material thickness variation within the specified range. Correct for structural frame blanks, base plate cutting, and large-format blanks where CNC back gauge programming is not required.
Manual Mechanical Shearing: Standard batch blank preparation on the manual mechanical shearing machine for medium-gauge material where production throughput is the priority and CNC programming setup time is not justified by blank geometry simplicity.
Kachi Light-Gauge Sheet Cutting: Two kachi machines handle thin sheet and strip shearing below 1.5mm where standard hydraulic shearing blade clearance set for heavier gauges would produce excessive edge rollover, burr, and deformation on thin material. Correct for CR IS 513 thin strip, shim material, light-gauge GI, and decorative SS sheet where edge condition quality on thin gauge is a downstream process requirement.
Drill Tapping Operations: Four drill tapping machines at Unit I handle hole drilling and thread tapping on fabricated sheet metal components and structural assemblies. Tapped holes in sheet metal components eliminate the need for loose nut fastener systems, reducing assembly time and component count for clients producing modular assemblies. Standard tap sizes from M3 to M16 are within the operational range of the drill tapping machines at Unit I.
Surface Grinding: One surface grinding machine at Unit I handles flatness correction on components with thermal distortion from welding, weld bead flush grinding on visible joint faces, and surface finish preparation on components requiring tight flatness tolerance or specific surface roughness before assembly or powder coat application. Surface grinding on weld joints before powder coat eliminates the weld crown profile that creates thin coating spots and potential coating adhesion failure at the joint.
Strip Shearing for Coil-Fed Press Operations: Coil stock from Unit II Dhumal Nagar is slit to the required strip width at Unit I before feeding into progressive die stamping operations. Strip width accuracy directly affects blank developed length and hole pattern position in progressive die operations. Strip width tolerance is held to plus or minus 0.2mm on the shearing line to ensure consistent blank geometry across the full coil length.
Grain Direction Control for Bending and Deep Drawing Blanks: Blanks destined for subsequent bending or deep drawing operations are sheared with grain direction orientation maintained relative to the primary bend line or draw axis. Shearing across grain direction on CR IS 513 DQ and DDQ grade increases edge cracking risk at bend radii on tight-radius bends and at draw punch contact zones on deep draw operations. Grain direction is marked or documented on blanks for DDQ deep draw operations at Unit I.

Verification Protocol

Blade gap calibration per material grade and thickness before every production run on the CNC and hydraulic shearing machines. Incorrect blade gap for the material being sheared produces rollover on the entry face and excessive burr on the exit face. Both conditions create downstream problems: rollover affects blank flatness and die fit in stamping, burr affects powder coat edge adhesion and creates laceration risk for assembly operators.

First-off diagonal measurement for squareness verification before batch shearing is approved. Diagonal measurement across the blank corners confirms that the sheared blank is square within the tolerance required for the downstream process. A blank that is out of square by more than 0.3mm will produce a bent component that is out of parallelism by the same amount after forming.

Blank dimension verification on first-off using calibrated steel rule and digital calipers against the required blank length and width. Batch shearing is not approved until first-off dimensions are confirmed within plus or minus 0.2mm parallelism tolerance.

Grain direction verification on blanks destined for DDQ deep draw and tight-radius bending operations. Blanks oriented against grain direction on CR IS 513 DQ and DDQ grades are identified and re-sheared to the correct orientation before entering the press floor.

Surface scratch prevention audit on SS 304 and SS 316 blanks. Stainless steel surfaces are protected with PVC film during shearing and handling to prevent blade contact marks and handling scratches on cosmetic surfaces. Film is removed only immediately before the downstream process that requires bare metal surface access.

Drill tapping thread verification using calibrated Go/No-Go gauges on tapped holes across batch samples. Thread form and depth are verified before the component proceeds to assembly or dispatch. Undersized or damaged threads identified at this stage are corrected before assembly, not after.

Surface grinding flatness verification using a precision straight edge and feeler gauge on ground components to confirm flatness within the tolerance required for the downstream assembly or coating operation.

Source Material at Unit II

HR Coil and SheetCR Coil and SheetGI Sheet and CoilSS Coil and SheetPO SheetFull Catalog

36 Years of Fabrication Experience

ISO 9001:2015 certified. JSW and TATA primary mill partner. Serving LED lighting, tracker OEM, automotive, furniture, and stationery sectors.

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Unit I Capability

Machinery Deployment: 1 x CNC Shearing Machine (NC Back Gauge), 1 x Manual Hydraulic Shearing Machine, 1 x Manual Mechanical Shearing Machine, 2 x Kachi Light-Gauge Sheet Cutting Machines, 4 x Drill Tapping Machines (M3-M16), 1 x Surface Grinding Machine. Total 10 machines at Unit I Vasai Phata. Integrated with Fiber Laser, Power Press Floor, CNC Press Brake, Welding, and 7-Tank Powder Coat Line.. Managed within our primary production hub in Vasai Phata.

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Vertical Integration

Industrial Applications

LED Lighting Manufacturers: Housing panel blanks, bracket strip blanks, driver compartment body blanks, and mounting plate blanks sheared to precision dimensions for direct feed into laser cutting, stamping, and CNC bending operations at Unit I.Tracker OEMs: Structural plate blanks, mounting bracket blanks, slotted adjustment plate blanks, and channel section blanks for solar tracker frame fabrication requiring consistent blank dimension accuracy across high-volume production batches.Automotive OEMs: Precision chassis bracket blanks, body panel blanks, and reinforcement plate blanks in CR IS 513 DQ and DDQ grade with grain direction controlled shearing for subsequent deep draw and tight-radius bending operations.Furniture Manufacturers: Panel blanks, frame section blanks, hardware component strip blanks, and wall unit component blanks for modular office and industrial furniture fabrication requiring consistent blank squareness and flatness.Stationery Manufacturers: Precision thin-gauge strip and component blanks sheared on kachi machines for stationery mechanism and hardware assembly operations requiring tight edge condition and dimensional accuracy on small-format blanks.Sheet Metal Component and Parts Clients: Custom cut-to-size blanks, structural plate cutting, strip preparation for coil-fed press operations, and general blank supply across all material grades for fabrication clients across the Mumbai, Thane, and Palghar industrial belt.
All Sector Capabilities

Industries We Serve

LED Lighting Tracker OEMs Automotive OEMs Furniture Manufacturers Stationery Manufacturers Industrial Fabrication

Mill-Certified Steel Supply at Unit II Dhumal Nagar

HR Coil and SheetCR Coil and SheetGI Sheet and CoilSS Coil and SheetPO SheetSecondary CR SheetSecondary HR SheetSecondary GI SheetSecondary SS Sheet
Technical Deep-Dive

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Aero Enterprises Production Infrastructure

20 Power Presses · 3000W Fiber Laser · 7-Tank Powder Coat · ISO 9001:2015

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Consolidate your sourcing and fabrication with a single partner. JSW and TATA certified steel at Unit II. Full fabrication sequence at Unit I. No subcontracting.

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Mill Test Certificates (MTC) Available Upon Request