PRECISION
ASSEMBLED
COMPONENTS.

At Frank Dudley Limited (FDL), we don’t just manufacture high-quality metal pressings—we provide complete, production-ready solutions. Our dedicated assembly and secondary operation departments transform raw stampings into complex, multi-part components, saving you valuable time, logistics coordination, and streamlining your supply chain.

Whether your project requires high-volume automated integration or precision hand-built assembly, FDL has the infrastructure and technical expertise to deliver.

Get a quote for welded assemblies

ASSEMBLY EXPERTISE

COMPLETE ASSEMBLY
SERVICES

ASSEMBLY SERVICES

We offer a comprehensive suite of secondary and assembly operations tailored to meet the strict tolerances of industries like automotive, commercial vehicles, and defence:

Precision Machining & Countersinking

We provide precise post-press machining to achieve tolerances that stamping alone cannot match. Our countersinking services ensure fasteners sit perfectly flush, preserving both structural integrity and surface aerodynamics.

Drilling, Tapping & Reaming

Offering clean, accurately threaded holes for secure mechanical fastenings.

Mechanical Fastening & Bushing

Expert insertion of bushes, pins, clips, and specialized hardware to create fully functioning mechanical hinges or pivot points.

Spin Riveting & Assembly of Fixings

Highly accurate riveting and fixing solutions for permanent, vibration-resistant structural bonds.

Hand-Built & Semi-Automated Assembly

Flexible cells capable of handling everything from intricate, multi-stage hand assemblies to high-volume production runs.

Value-Added Packing

Complete component preparation, kitting, and custom protective packaging, meaning your products arrive ready for immediate integration into your production lines.

Whether you need a straightforward sub-assembly or a complex multi-component build, our experienced teams are equipped to deliver to your exact requirements.

FLEXIBLE ASSEMBLY SOLUTIONS
FOR EVERY APPLICATION

Our assembly services are built around flexibility. We work with in-house pressings alongside a wide range of outsourced parts, carefully procured and quality-checked by our experienced teams – giving you a complete, turnkey assembly service through a single trusted partner.

We source and assemble a comprehensive range of outsourced components including forgings, machined parts, castings, fasteners, springs, bushes, laser-cut blanks and manipulated tubes. Every assembled component can be finished to your specification from a comprehensive range of surface treatments, platings and paint options.

Our teams also have extensive expertise in sourcing from specialist suppliers, ensuring every outsourced part meets the same quality standards as our in-house pressings.

Multiple joining techniques including spot, projection, robotic welding and riveting.

Full component sourcing and procurement from approved specialist suppliers.

Flexible volumes from small batch prototypes to high volume production with complete finishing services.

PROVEN METHOD

HOW OUR ASSEMBLY
PROCESS WORKS

From initial enquiry to regular production supply, every welded assembly project follows a clear and structured process.

Initial review and feasibility

Sharing drawings, volumes and requirements to confirm technical and commercial fit.

Tooling design and optimisation

Engineering the right tooling approach to meet quality, cost and lead-time targets.

Samples, qualification and approval

Producing trial parts, supporting PPAP and refining the process where needed.

Series production and ongoing optimisation

Running stable production with continuous monitoring and improvement.

See our full step-by-step process

CASE STUDIES

ASSEMBLY
PROJECTS
IN ACTION

Proven results from real
customer projects using our
pressing expertise.

READY TO DISCUSS
ASSEMBLY REQUIREMENTS?

Submit your assembly project details below, or call our team on 0121 452 8500. We’ll provide expert guidance and a competitive quote for your assembled components.