Engineering Portfolio

Field-Proven Heavy Engineering, Built in Morocco.

Explore our documented industrial achievements: custom heavy machinery, multi-axis CNC retrofits, Siemens PLC programming, and precision mechanical emergency repairs. Complete case studies and engineering methods gathered on one page.

Armasteel

Custom DesignDelivered6 months

Twin 5-Axis Welding Robots — 16-Meter Linear Travel

Complete turnkey engineering, 3D kinematic modeling, fabrication, and programming of twin 5-axis welding robots with real-time infrared seam tracking and 16-meter linear gantry travel for Armasteel.

Twin 5-axis welding robots on 16-meter linear track

Autodesk Inventor 3D CAD modeling and kinematic simulation

Mechanical structural frame fabrication and assembly

AC servo motor cabling and control cabinet integration

Automated weld seam quality testing on test bench

01 / 05

The Industrial Challenge

Armasteel required an automated welding cell capable of laying continuous, high-integrity weld beads along ultra-long structural steel girders (up to 16 meters), maintaining absolute precision across variable weld joints.

Deployed Engineering & Method

RAFI Robotiques et Machineries engineered a bespoke 5-axis robotic kinematic system mounted on an extended 16-meter rigid track. We integrated advanced infrared closed-loop sensors dynamically syncing feed rate to weld geometry in real time, accompanied by an intuitive, hardened industrial HMI.

Measurable Result

Dual synchronized robots deliver an industry-leading 16-meter operating envelope with zero manual rework. The installation dramatically multiplied plant throughput across heavy structural, naval, and automotive fabrications.

Matissar

Automation & PLCDelivered10 Days

Emergency PLC Automation Reprogramming — Spring Assembly Machine

Full sequential logic reconstruction, emergency on-site PLC reprogramming, and rapid line recommissioning for Matissar's high-speed spring assembly line.

Online PLC logic controller reprogramming

Dynamic line testing and throughput validation

01 / 02

The Industrial Challenge

Sudden catastrophic shutdown of Matissar's automated spring assembly line triggered by an accidental memory erasure of the central Programmable Logic Controller (PLC), paralyzing plant output.

Deployed Engineering & Method

Immediate on-site emergency deployment of our senior automation engineers. In-depth reverse-engineering of machine kinematics and optical sensors, complete rewriting of the PLC ladder/Grafcet architecture, reprogrammed safety interlocks, and optimized cycle times.

Measurable Result

100% production capacity restored within 10 business days. Achieved optimized cycle timing, elevated operational reliability, and delivered fully documented code backups with diagnostic architecture.

Univers Acier

Heavy Mechanical RepairDelivered12 Days

Custom Bronze Gear Machining — Scharmann Boring Mill

Complete kinematic teardown, precision reverse-engineering, and bespoke gear hobbing of high-grade phosphor bronze worm wheels for a heavy Scharmann horizontal boring mill.

Kinematic teardown and worn worm gear extraction

Phosphor bronze gear precision hobbing and metrology inspection

01 / 02

The Industrial Challenge

Critical shutdown of Univers Acier's primary heavy Scharmann boring mill caused by catastrophic tooth fracture and severe galling of the internal bronze worm drive. OEM replacement parts were obsolete with prohibitive import lead times.

Deployed Engineering & Method

Complete workshop teardown of the mechanical transmission train, high-precision metrological reverse-engineering, metallurgical selection of high-wear-resistant phosphor bronze alloy, precision CNC gear hobbing, and reassembly with micrometric backlash adjustment.

Measurable Result

Flawless recommissioning achieved in 12 days. Whisper-quiet power transmission with zero residual backlash, restoring original boring concentricity and extended component lifecycle.

Belhou Frères

Heavy Mechanical RepairDelivered10 Days

CNC Press Brake Recalibration & Guillotine Shear Realignment

Comprehensive geometric and electronic recalibration of a CNC press brake, paired with precision grinding and clearance adjustment of industrial guillotine shear blades.

CNC parameter restoration and backgauge datum calibration

Ram parallelism verification and hydraulic balancing

Loaded test bending and angular tolerance verification

01 / 03

The Industrial Challenge

Line stoppage on Belhou Frères' CNC press brake caused by backgauge servo misalignment and critical dulling of guillotine shear blades, resulting in sheet metal burring and dimensional inaccuracies.

Deployed Engineering & Method

Full diagnostic audit and precision recalibration of kinematic and electronic backgauge axes. Disassembly, high-precision surface grinding, blade honing, and micrometric blade gap calibration across the entire cutting bed.

Measurable Result

Full operational restoration delivered in 10 days. Certified angular bending accuracy and pristine, burr-free shear cuts across sheet metal and heavy plate thicknesses.

Mif Maroc

CNC RetrofitDelivered10 Days

Electronic Overhaul & Complete CNC Retrofit of Plasma Table

Comprehensive electronic modernization, installation of a modern compact CNC controller, and rapid 10-day recommissioning of an industrial CNC plasma cutting table for Mif Maroc.

Modern compact CNC controller integration

In-depth electronic PCB diagnostics and testing

Shielded servo cabling and multi-axis synchronization

CNC plasma test cutting on structural steel plate

01 / 04

The Industrial Challenge

Following a critical motherboard failure and complete system lockup, Mif Maroc faced severe delivery bottlenecks. Aging electronics, brittle wiring harnesses, and worn servo drives threatened prolonged shutdown.

Deployed Engineering & Method

Complete removal of outdated control architecture and integration of a high-performance compact CNC controller. Installed new digital AC servo drives, replaced industrial shielded cabling, added high-sensitivity arc voltage torch height control (THC), and recalibrated X/Y/Z axes.

Measurable Result

Restored micrometric cutting precision, optimized traverse feeds across thin gauge sheet and heavy structural plate, and resumed full production within 10 days under a 2-year warranty.

Longofer

Heavy Mechanical RepairDelivered14 Days

Siemens Sinumerik 840D Diagnosis & Commissioning — Twin CNC Lathe

Restoration of corrupted Siemens Sinumerik 840D system software, reconfiguration of Simodrive 611 modular servo drives, and kinematic unjamming of the Z-axis on a twin CNC lathe.

Siemens Sinumerik 840D diagnostic link and system recovery

Power distribution cabinet and Simodrive 611 modular drive inspection

Z-axis closed-loop position and velocity recalibration

01 / 03

The Industrial Challenge

Longofer's heavy Gemine twin CNC lathe suffered a total lockout due to an unyielding mechanical/servo lock on the Z-axis, compounded by corrupted Siemens Sinumerik 840D system files and lost drive parameter tables.

Deployed Engineering & Method

CNC specialists executed a full bit-level restoration of the Siemens system software image, rebuilt machine parameter maps, unjammed mechanical ballscrew assemblies, and recalibrated closed-loop velocity and position parameters across Siemens Simodrive 611 drives.

Measurable Result

100% digital bus communication and kinematics restored. Smooth, chatter-free turning operations resumed within 14 days with zero loss of factory axis resolution.

Industrie Métallurgique

Automation & PLCDelivered10 Days

Safety PLC Replacement & Total Control Modernization — Adira Press Brake

Replacement of failed safety logic controller, complete custom automation rewriting, and system recalibration following a severe power surge on an Adira CNC press brake.

Electrical system audit and safety relay failure diagnosis

Optoelectronic safety light curtain validation and test bends

01 / 02

The Industrial Challenge

A major electrical surge destroyed the safety module and corrupted the firmware and calibration registers on an Adira CNC hydraulic press brake, halting plant operations.

Deployed Engineering & Method

Emergency on-site intervention: installation of a Category 4 fail-safe industrial safety PLC, custom programming of redundant safety routines (optical light curtains, emergency dual valves), and full restoration of OEM hydraulic pressure curves.

Measurable Result

Returned to active duty in 10 days. Certified maximum-level operator safety compliance and repeatable zero-deflection bending accuracy.

Ilpea Galvarplast

Custom DesignIn ProgressFinal CAD Phase

Precision Cutting & Perforation Prototype Station (1500 mm)

Turnkey mechanical engineering, 3D CAD modeling, and tooling development of a custom manual station for angular cutting and precision perforation of extruded profiles up to 1500 mm.

3D CAD rendering of custom cutting and punching workstation

The Industrial Challenge

Ilpea Galvarplast required a dedicated, highly ergonomic manual workstation capable of processing continuous polymer/metal extrusions up to 1500 mm with flexible angle cuts and repetitive punch perforation without material deformation.

Deployed Engineering & Method

Comprehensive mechanical architecture developed in Autodesk Inventor featuring adjustable micrometric stops, toggle clamp fixtures, and rapid-change hardened die punches. Rapid engineering iterations refined in version 2.1 incorporating direct shopfloor feedback.

Measurable Result

Final 3D engineering package and kinematic validation approved by client. Manufacturing and precision machining underway at RAFI facilities.

Univers Acier

CNC RetrofitIn ProgressActive Commissioning

Modernization & CNC Retrofit of Three Heavy Machines

Comprehensive mechanical overhaul, guideway scraping, and electronic retrofitting of a large CNC horizontal lathe and two heavy cylindrical grinders powered by RAFI's Made-in-Morocco CNC controller.

The Industrial Challenge

Three foundational machine tools (a heavy-duty CNC lathe and two high-precision cylindrical grinders) stood idle due to complete electronic obsolescence and unserviceable proprietary OEM controls.

Deployed Engineering & Method

Precision mechanical rebuild, guideway regrinding, ballscrew replacements, modern synchronous AC servo retrofits, and integration of RAFI's proprietary Moroccan-engineered CNC control architecture.

Measurable Result

Assembly and on-site cabinet wiring currently in active commissioning. Project provides sustainable second-life capability to 3 strategic assets with guaranteed local lifetime support.