Manufacturing

Fine Cut Technology

At Dhananjay Group, we specialize in Fine Cut Technology — an advanced sheet metal cutting process that bridges the gap between Conventional Stamping and Fine Blanking.
This innovative technology provides high-precision results at an economical cost, making it the preferred choice for automotive and industrial applications that demand accuracy, consistency, and cost efficiency.

Dhananjay Group continues to invest in advanced technologies like Fine Cut to deliver next-generation sheet metal solutions that meet the evolving needs of global customers.

Fine Cut Technology provides a superior finish, higher accuracy, and cost advantages — redefining efficiency in metal cutting and stamping.

Advantages Over Conventional Blanking

Economical Alternative to Fine Blanking: Fine Cut Technology delivers exceptional performance while keeping operation costs significantly lower than Fine Blanking — providing an ideal balance between quality and economy.
Better Yield: With optimized design, the scrap bridge is maintained at nearly 60% of the material thickness, ensuring substantial savings in material cost and improving production yield.
Lower Tool Development Cost: Tooling costs are considerably lower than those required for Fine Blanking, making Fine Cut a more viable option for cost-sensitive programs without compromising quality.
Eliminates Secondary Operations: This process minimizes or completely eliminates secondary machining processes such as drilling, reaming, straightening, shaving, hobbing, or broaching, thereby reducing production time and improving throughput.
Precise Dimensional Control & Repeatability: Fine Cut Technology ensures high accuracy and tight tolerances (70–100 microns), delivering parts with smooth, straight edges and consistent quality across high volumes.

Stamping Facility (Press Shop)

At Dhananjay Group, our state-of-the-art Stamping Facility is equipped with a comprehensive range of presses designed to meet the diverse requirements of our customers. With advanced machinery and intelligent automation systems, we ensure precision, consistency, and high productivity across all stamping operations.

Our facility is capable of handling both progressive and single-action tooling, supported by stringent quality checks at every stage. From prototype development to high-volume production, we maintain tight dimensional control, superior surface finish, and optimized material utilization, ensuring every component meets international standards of performance and reliability.

Press Machines & Capabilities

Mechanical Presses – up to 1000 Tons: Our heavy-duty mechanical presses deliver high-accuracy stamping with consistent performance for medium to large components, ensuring superior dimensional control and repeatability.
Hydraulic Presses – up to 400 Tons: Hydraulic presses enable flexibility in forming complex shapes and thicker materials with uniform pressure and excellent surface finish.
High-Speed Progressive Presses – up to 500 Tons: Designed for continuous and high-speed operations, these presses support progressive die stamping for mass production with minimal downtime and waste.
Fine Cut Blanking Press – up to 800 Tons: We specialize in precision cutting using Fine Cut Blanking presses — delivering burr-free, straight-edged components with minimal secondary operations.
Total Installed Presses – 200 Nos: With over 200 presses of varying capacities and configurations, our stamping facilities are capable of handling diverse production volumes and part complexities with ease.

Full Width Coil Auto Blanking

The Full Width Coil Auto Blanking Line at Dhananjay Group is engineered for high-efficiency, precision-driven sheet metal processing, enabling the seamless transformation of metal coils into flat blanks with exceptional dimensional accuracy and repeatability.

This fully automated line is capable of handling heavy-gauge coils up to 6mm thickness and 1300mm width, supporting a wide range of materials and applications across diverse industrial sectors. The integrated automation system ensures continuous coil feeding, precision leveling, and synchronized blanking operations, significantly reducing manual intervention and downtime.

By minimizing material wastage and ensuring uniform flatness and edge quality, the line delivers consistent, ready-to-form blanks that enhance productivity in downstream operations such as stamping, forming, and welding.

Technical Specifications

Maximum Coil Size: The line can process coils up to 6 mm in thickness and 1300 mm in width, accommodating a wide variety of materials and dimensions with precision and stability throughout operations.
Coil Load & Press Capacity: Designed for heavy-duty performance, the system supports coil loads up to 20 metric tons and operates with a 400-ton press, ensuring efficiency and reliability even for large-scale production runs.
Component Capability: The auto blanking system is ideal for producing circular or custom-shaped blanks, automotive components, industrial flanges, rings, and various structural parts with consistent accuracy and quality.
Key Operational Advantages: With high-speed continuous blanking, precision coil handling, and optimized nesting, the system minimizes material waste, enhances productivity, and improves workplace safety through reduced manual handling.

Laser Cutting Facility

At Dhananjay Group, precision begins with cutting-edge technology. Our Fiber Laser Cutting Facility is equipped with an advanced 12 KW Trumpf TruFiber source, delivering exceptional accuracy, superior edge quality, and consistent performance across a wide range of materials and thicknesses.

With an expansive bed size of 6.5 x 2.5 meters, the system offers the capability to process both small precision components and large structural parts with equal efficiency. This flexibility allows us to cater to diverse industrial requirements, from automotive and engineering applications to heavy fabrication projects.

The high-power laser ensures fast cutting speeds with minimal thermal distortion, enabling clean, burr-free edges and reduced post-processing. Integrated automation for sheet loading, unloading, and nesting optimization enhances throughput while minimizing material wastage.

Key Highlights

Power & Performance: Equipped with a 12 KW Trumpf TruFiber laser source, our system delivers exceptional cutting power, enabling precise processing of a wide range of materials including mild steel, stainless steel, aluminum, and specialized alloys.
Large Format Capability: With a spacious 6.5 x 2.5-meter bed size, the facility can handle both small precision components and large sheets, ensuring flexibility for diverse production requirements.
Precision & Efficiency: The advanced fiber technology ensures high repeatability, burr-free cutting, and minimal thermal distortion, while intelligent nesting software optimizes material utilization and minimizes waste.
High-Speed Productivity: Designed for both prototype and mass production, our laser cutting system offers superior accuracy, clean edge finishes, and high throughput — delivering complex geometries and intricate designs with speed and reliability.

Welding & Assemblies

At Dhananjay Group, we offer advanced welding and fabrication capabilities to deliver high-quality, precision assemblies that meet stringent customer requirements. Our Welding & Assembly Division is equipped with both Robotic and Manual Welding Systems, ensuring consistency, efficiency, and flexibility across diverse applications.

Robotic Welding

Our dedicated robotic welding shop is equipped with 14 state-of-the-art robotic cells, designed for high-volume, repetitive, and complex welding operations.

Advanced Welding Solutions for Precision Manufacturing

Automated Welding Systems: Our state-of-the-art robotic welding systems deliver superior weld consistency, strength, and dimensional accuracy. These systems minimize human intervention, enhance productivity, and ensure high repeatability for precision assemblies.
Precision Tooling & Fixtures: By integrating advanced tooling and fixture designs with automation, we achieve uniform bead formation, excellent weld penetration, and long-lasting joint integrity — maintaining quality across every weld operation.
Manual & SPM Welding Stations: For low- to medium-volume and customized applications, we operate Manual and Special Purpose Machine (SPM) welding stations that offer flexibility and precision in diverse manufacturing needs.
Multi-Process Welding Expertise: Our skilled welders are proficient in Spot Welding, Projection Welding, TIG Welding, and MIG Welding, enabling us to handle both intricate precision parts and large structural assemblies with consistent excellence.

CNC/VMC Machining

At Dhananjay Group, our in-house machining facility stands as a cornerstone of precision and reliability. Equipped with state-of-the-art CNC and VMC machines, we ensure exceptional dimensional accuracy, consistency, and superior surface finish across all critical components — meeting the demanding standards of modern manufacturing.

This high-performance setup enables us to seamlessly execute complex machining operations on both standalone components and integrated sheet metal parts. By maintaining full control over the machining process, we ensure faster turnaround times, reduced dependency on external vendors, and uncompromised quality at every stage of production.

Our machining facility plays a crucial role in supporting the production of child parts used in our sheet metal assemblies, along with secondary machining operations such as drilling, tapping, milling, and contouring on formed sheet components.

In-house Machining Capabilities

CNC Turning Centers: Our precision CNC turning centers are designed for producing high-accuracy rotational parts with superior surface finish and dimensional control, ensuring consistent performance across all production volumes.
Vertical Machining Centers (VMCs): Equipped for complex milling, drilling, and contouring operations, our VMCs deliver exceptional precision and repeatability, ideal for intricate components and tooling applications.
Fixture & Tool Machining Support: We offer complete in-house fixture and tool machining capabilities, supporting our own tooling development for stamping, welding, and assembly operations — enhancing efficiency and accuracy.
Close Tolerance Machining: Our machines are capable of maintaining tight tolerances for critical and functional components, ensuring every part meets the highest performance and reliability standards.

Special Processes

Expanding Mesh

Inhouse facility for Sheet Metal expanding (Thk. Range 0.3 ~ 0.8 mm

Sheet Metal Perforation

Inhouse facility for Sheet Metal Perforation (Thk. Range 0.2 ~ 0.5 mm

Embossing

Inhouse facility for Sheet Metal Embossing (Thk. Range 0.15 ~ 0.2 mm

Facilities-Surface Treatment

Fully Automatic Alkaline & Acid Zinc Plating plant:

Fully Automatic Alkaline & Acid Zinc Plating Plant: Our automated facility delivers uniform zinc coating with excellent adhesion and corrosion resistance. Supporting both alkaline and acid processes, it ensures precision, consistency, and efficiency for high-volume and specialized applications.

Manual Duplex Nickel Chrome Plating plant:

Manual Duplex Nickel Chrome Plating Plant: Our dedicated facility provides durable, high-quality duplex nickel chrome finishes with superior corrosion resistance and aesthetic appeal — ideal for specialized and high-performance components.

Fully Automatic Powder Coating plant:

Fully Automatic Powder Coating Plant: Our high-capacity automated powder coating facility delivers durable, uniform, and eco-friendly finishes. Designed for efficiency and consistency, it ensures excellent coverage and surface protection for large-scale production.

Liquid Nitriding

Liquid Nitriding: Our advanced nitriding process enhances surface hardness, wear resistance, and fatigue strength while maintaining dimensional accuracy — ideal for improving component performance and durability.