PRECISION METAL COMPONENTS
Engineered Accuracy for Demanding Applications
At Rex Consolidated, our Precision Components division delivers high-accuracy, close-tolerance parts engineered for performance, reliability, and repeatability. Manufactured using advanced CNC machining, turning, and milling technologies, our components serve critical functions across automotive, electrical, industrial machinery, and instrumentation applications. From small-volume prototypes to large-scale production runs, we offer end-to-end solutions tailored to our clients’ exacting specifications. Each part undergoes rigorous quality control to ensure dimensional integrity and functional excellence.
MANUFACTURING CAPABILITIES
STAMPING
Our stamping capabilities deliver high-precision metal components with consistent quality and repeatability. Using progressive and compound dies, we produce a wide range of parts for automotive, electrical, and industrial applications. With in-house tool design and maintenance, we ensure fast turnaround and cost efficiency. From prototypes to mass production, we maintain strict dimensional accuracy and surface finish standards. Our stamping shop is equipped to handle ferrous and non-ferrous materials.
Key Capabilities:
- High-speed stamping presses up to 200T
- Progressive, compound, and blanking dies
- Tolerance control as low as ±0.05 mm
- Materials: CRCA, stainless steel, brass, aluminum
- Surface finishes: deburring, plating, powder coating
Tool and Die development
Rex Consolidated provides comprehensive tool and die development support for the reliable manufacture of precision metal components. From initial component assessment and process planning to tool design, development, trial production and final validation, each solution is engineered to achieve dimensional accuracy, production efficiency and consistent repeatability.
Our capabilities include progressive dies, compound dies, blanking and forming tools, bending tools, punching tools, machining fixtures, inspection gauges and customized production tooling. Tool designs are developed according to component geometry, material properties, production volume, tolerance requirements and expected tool life.
Through controlled trials and continuous refinement, we optimize material utilization, cycle time, component quality and overall manufacturing cost. Regular tool inspection, preventive maintenance and repair support help maintain stable performance throughout the production lifecycle.
Key Capabilities
- Progressive, compound, blanking and forming dies
- Punching, bending and drawing tools
- Jigs, fixtures and inspection gauges
- Tool design based on drawings, samples or 3D models
- Prototype tooling and production trials
- Tool validation and dimensional inspection
- Tool modification, repair and preventive maintenance
- Process optimization for high-volume production
- Customer-specific tooling and documentation support
MACHINING
MACHINING
Rex Consolidated offers precision CNC machining services for complex components requiring tight tolerances and intricate geometries. We specialize in turning, milling, and drilling of ferrous and non-ferrous materials to meet diverse industrial needs. Our team supports both prototype development and high-volume production. Each part undergoes quality checks at multiple stages to ensure flawless performance. With strong technical expertise and process control, we deliver reliable, cost-effective machining solutions.
Key Capabilities:
- CNC turning and vertical milling centers
- Tolerance capability up to ±10 microns
- Machining of mild steel, stainless steel, aluminum, brass
- Batch flexibility: from 10 pcs to 100,000+
- In-process and final QC using precision instruments
SPINNING
MACHINING
Rex Consolidated provides high-precision metal spinning services for the production of symmetrical, hollow components across automotive, lighting, HVAC, and industrial sectors. Our process involves forming flat metal discs into cylindrical or conical shapes by rotating them at high speed and shaping them with precision tooling. Spinning offers strength, material efficiency, and flexibility in design — ideal for both prototyping and high-volume applications. With a focus on dimensional accuracy and surface finish, our team ensures consistent results in every batch.
Key Capabilities:
- Conventional and CNC-controlled metal spinning
- Suitable for aluminum, mild steel, stainless steel, and copper
- Component diameters up to 600 mm
- High repeatability with minimal material waste
- Surface finish customization and post-processing options available
SURFACE TREATMENT
Rex Consolidated offers advanced coating solutions designed to enhance the durability, corrosion resistance, and aesthetic value of metal components for automotive, industrial, and heavy-duty applications. Our coating processes provide a protective barrier against wear, moisture, and environmental stress, ensuring long-lasting performance in demanding conditions. By combining precision application techniques with stringent quality checks, we deliver consistent, high-quality finishes that meet international standards.
Key Capabilities:
✔ Electro-galvanizing and hot-dip galvanizing for superior corrosion protection
✔ Powder coating and liquid coating for customized surface finishes
✔ Zinc, nickel, and phosphate coatings for enhanced strength and wear resistance
✔ Coating thickness control as per customer and OEM specifications
✔ Post-coating inspection and testing for adhesion, durability, and uniformity
Metal Sintering
Rex Consolidated offers advanced sintering solutions designed to enhance the strength, density, and structural integrity of metal components for automotive, industrial, and heavy-duty applications. Our sintering processes enable the production of high-precision parts with controlled porosity, excellent mechanical properties, and consistent dimensional accuracy. By combining optimized temperature control with stringent quality checks, we deliver reliable, high-performance components that meet international standards.
Key Capabilities:
✔ Controlled atmosphere sintering for improved material properties and oxidation resistance
✔ Precision temperature profiling to ensure uniform densification and structural consistency
✔ Capability to process ferrous and non-ferrous powder metal components
✔ Dimensional control and minimal distortion during sintering
✔ Post-sintering inspection and testing for density, strength, and structural integrity
Casting
LASER CUTTING
HOT FORGING
Rex Consolidated offers comprehensive casting solutions for producing complex, durable, and dimensionally accurate metal components for automotive, industrial, and heavy-duty applications. Our capabilities include aluminium pressure die casting, investment casting, and sand casting, enabling us to manufacture components across a wide range of sizes, materials, geometries, and production volumes. By combining controlled casting processes with stringent quality inspections, we deliver reliable, high-performance components with excellent surface finish, structural integrity, and consistent dimensional accuracy.
Key Capabilities: ✔ Aluminium pressure die casting for lightweight, high-precision components with complex geometries ✔ Investment casting for intricate parts requiring close tolerances and superior surface finish ✔ Sand casting for medium-to-large components and flexible production quantities ✔ Capability to cast aluminium, steel, stainless steel, cast iron, and other alloys ✔ Secondary operations including machining, heat treatment, surface finishing, and assembly ✔ Comprehensive inspection and testing for dimensions, material composition, strength, and casting integrity
HOT FORGING
LASER CUTTING
HOT FORGING
Rex Consolidated offers comprehensive hot forging solutions for producing strong, durable, and structurally reliable metal components for automotive, industrial, agricultural, and heavy-duty applications. Our hot forging process enables the manufacture of complex components across a wide range of sizes, materials, geometries, and production volumes. By combining controlled heating, precision die forging, heat treatment, and stringent quality inspections, we deliver high-performance components with improved grain flow, excellent mechanical strength, superior fatigue resistance, and consistent dimensional accuracy.
Key Capabilities: ✔ Open-die and closed-die hot forging for complex and heavy-duty components ✔ Capability to forge carbon steel, alloy steel, stainless steel, and other suitable alloys ✔ Production of crankshafts, connecting rods, flanges, yokes, gear blanks, and customised forged components ✔ Controlled heating and forging parameters for improved grain flow and structural integrity ✔ Secondary operations including trimming, heat treatment, shot blasting, machining, and surface finishing ✔ Comprehensive inspection and testing for dimensions, material composition, hardness, strength, and forging integrity
LASER CUTTING
LASER CUTTING
LASER CUTTING
Rex Consolidated offers comprehensive laser cutting solutions for producing precise, complex, and consistently accurate metal components for automotive, industrial, agricultural, and heavy-duty applications. Our advanced CNC laser cutting capabilities enable the processing of sheets, plates, tubes, and structural profiles across a wide range of materials, thicknesses, geometries, and production volumes. By combining precision cutting technology, optimised process parameters, and stringent quality inspections, we deliver components with clean edges, minimal distortion, excellent repeatability, and reduced material wastage.
Key Capabilities: ✔ CNC fibre-laser cutting for sheets, plates, tubes, and structural profiles ✔ Capability to process carbon steel, stainless steel, aluminium, and other suitable metals ✔ Production of brackets, flanges, mounting plates, enclosures, profiles, and customised components ✔ Complex contours, slots, holes, and intricate geometries with high dimensional accuracy ✔ Optimised nesting to improve material utilisation and reduce production waste ✔ Secondary operations including bending, welding, machining, deburring, surface finishing, and assembly ✔ Comprehensive inspection for dimensions, cut quality, edge condition, and conformity to customer drawings
MATERIALS PROCESSED
Rex Consolidated works with a diverse range of ferrous and non-ferrous metals to manufacture precision components for automotive, electrical, industrial and general engineering applications. Our manufacturing processes are selected according to each material’s mechanical properties, dimensional requirements, surface-finish expectations and operating environment. We can also accommodate customer-specified grades and materials based on technical drawings and application requirements.
Carbon and Mild Steel
CRCA, HR steel, low-carbon steel, free-cutting steel and alloy steel for stamped, machined, formed and load-bearing components.
Stainless Steel
Grades including SS 201, SS 304, SS 316 and SS 409 for applications requiring corrosion resistance, strength, hygiene or elevated-temperature performance.
Aluminium and Aluminium Alloys
Lightweight, corrosion-resistant materials suitable for precision-machined, spun and formed components.
Brass
Free-cutting, lead-free and application-specific brass grades for inserts, bushings, fittings, fasteners, electrical terminals and precision-turned components.
Copper and Copper Alloys
High-conductivity materials used for electrical, thermal and specialized industrial components.
Spring Steel
High-strength grades for clips, retainers, clamps, spring components and applications requiring controlled flexibility and fatigue resistance.
Powder Metals
Ferrous and non-ferrous metal powders used to manufacture sintered components with controlled density, dimensional consistency and application-specific mechanical properties.
Custom Material Requirements
Materials can be selected and sourced according to customer drawings, international standards and specific mechanical, chemical, corrosion-resistance or temperature requirements. Material certificates and traceability documentation can be provided where required.
Surface Coating Capabilities AT OUR NEW PLANT
Advanced Surface Finishing Solutions for Enhanced Protection
At Rex Consolidated, we offer a comprehensive range of surface coating solutions designed to enhance the durability, corrosion resistance, and appearance of our products. By combining precision manufacturing with advanced finishing technologies, we ensure that every component performs reliably in demanding automotive, commercial vehicle, industrial, and agricultural applications.
Our coating processes are selected based on the specific application, environmental conditions, and customer requirements, providing long-lasting protection against corrosion, abrasion, moisture, chemicals, and harsh operating environments.
Our Coating Capabilities
We offer a wide range of protective surface finishes, including:
- Powder Coating – Provides a durable, attractive finish with excellent resistance to corrosion, impact, and weathering.
- PU (Polyurethane) Coating – Offers outstanding abrasion resistance, flexibility, and protection against chemicals and environmental exposure.
- Liquid Coating – Suitable for components requiring customized colours, finishes, or application-specific performance characteristics.
- HR Coating – High-temperature resistant coating designed for components exposed to elevated operating temperatures.
- CED (Cathodic Electro Deposition) Coating – Delivers uniform coating coverage, including complex geometries, with exceptional corrosion resistance and excellent paint adhesion.
- Manganese Phosphate Coating – Provides enhanced wear resistance, anti-galling properties, improved lubrication retention, and an excellent base for subsequent coatings or painting.
Quality You Can Depend On
Every coated component undergoes a controlled finishing process and thorough quality inspection to ensure consistent coating coverage, excellent adhesion, uniform appearance, and long-term durability. Our processes are designed to meet the stringent quality expectations of OEMs, Tier-1 suppliers, and global aftermarket customers.
Custom Finishing Solutions
Recognizing that every application has unique performance requirements, Rex Consolidated offers customized surface finishing solutions tailored to customer specifications. We can accommodate special coating systems, colour requirements, gloss levels, corrosion protection standards, and application-specific performance criteria to meet the needs of a wide range of industries.
Whether supplying standard products or fully customized components, our advanced coating capabilities ensure that every Invicta product delivers superior protection, reliability, and lasting performance in the most demanding service environments.
Brass COMPONENTS
Precision Brass Engineering by Rex Consolidated
Rex Consolidated is a global leader in the manufacturing of high-quality, precision-engineered brass components. With over four decades of expertise in metallurgy and CNC machining, we provide critical hardware and industrial solutions that power the automotive, electrical, plumbing, and aerospace sectors.
Our brass division is built on a foundation of technical excellence and material innovation. By utilizing premium-grade brass alloys and state-of-the-art automated technology, we ensure that every component offers superior corrosion resistance, high thermal conductivity, and the tightest tolerances required for modern industrial applications
Why Partner with Rex Consolidated for brass components?
- Advanced Machining Capabilities: Our facility in Faridabad is equipped with multi-spindle automats and high-precision CNC/VMC machines, capable of handling complex geometries with a tolerance of up to ±10 microns.
- Quality & Compliance: As an ISO 9001:2015 certified company, our quality assurance team performs rigorous checks—including thread gauging, salt spray testing, and spectroscopic material analysis—to guarantee 100% defect-free products.
- Material Versatility: We work with a wide range of brass grades (including Free Cutting Brass, Lead-Free Brass, and Naval Brass) to meet specific environmental and mechanical requirements.
- Customization at Scale: Whether you require small-batch prototypes or high-volume OEM production, we offer end-to-end support from design and tool development to final surface finishing (Nickel, Chrome, or Tin plating).
- Global Export Footprint: With a robust logistics network, we successfully serve Tier-1 OEMs and distributors across North America, Europe, and Asia, ensuring timely delivery and competitive pricing.