Technical analysis of turbos in development

Technical analysis of turbos for development. Reverse engineering.

The whole manufacturing process of our new components starts at Melett’s headquarters in the UK.

As part of a process to ensure new Melett parts are developed correctly, our in-house engineers undertake rigorous technical analysis of turbos from existing OEM ranges. This includes an in-depth design analysis and detailed failure diagnosis so that the new Melett parts incorporate, where possible, improvements to the original component design.

As new turbos are identified for development, the Engineering team undertake full technical analysis of turbos from several original samples. They thoroughly analyse dimensions, surface finishes, tolerances, and materials to gain a deep understanding of the whole assembly.

With vast experience in turbocharger parts and turbo repair, the Melett Technical team speak fluent ‘Turbo’, and can provide expert advice and support to customers across a large range of technical repair issues.

Development requests:

think-iconRemember: You can request the development of components through our website by clicking the ‘Request Development’ button on any turbo build sheet when you are logged in.

  • To help us identify which development requests are a priority, for each request you submit, please provide as much information as possible;
  • Development requests are thoroughly reviewed and help build a database, which forms the foundation of our development programme;
  • They also give the Technical team a better insight into the aftermarket requirements and allow us to prioritise the most popular requests.

Continuous investment in our in-house Engineering team and Technical departments, and in our own manufacturing facility, has enabled us to significantly speed up the development process. This increased capacity, along with crucial customer feedback, has allowed us to dramatically increase the number of new products being developed; a trend that is set to increase further in the future.

We regularly release products on our New Product Bulletins. If you do not receive the Bulletins, please contact [email protected] to be added to our mailing list.

Strong Engineering Principles

All Melett parts are engineered in the UK by Melett’s in-house team of highly skilled engineers. With over 100 years combined experience, our engineering team offer a wealth of technical knowledge and expertise, as well as a thorough understanding of turbo components and how they are used in the marketplace.

With the emphasis on accuracy and attention to detail, Melett engineers incorporate 3D measurement capability, down to a repeatable accuracy of 2 microns, along with state of the art 3D modelling software to create engineering drawings for manufacture. The team follow stringent internal processes to fully assess the performance of parts and the possible reasons for their failure, reinforcing Melett as the industry experts for quality replacement turbocharger parts.

Strict Quality Control Processes

At Melett, we operate a Quality Management System which complies with the requirements of ISO 9001:2015 for the design, manufacture and supply of replacement turbocharger parts to the independent aftermarket. From initial analysis through to the finished product, we incorporate the highest level of inspection throughout every stage of production, and carry out the final quality inspection of every component in our UK facility to ensure material, dimensions and surface finishes are to specification, before they are packaged in a genuine Melett box.

What does ‘Melett Quality’ mean?

  • Our customers can use Melett replacement turbo parts without concerns about fitting or warranties;
  • Turbo repairers need to focus on the job in hand – repairing a turbo, not worry about the quality of the parts they are using and whether they will do their job;
  • Melett quality gives turbo repairers peace of mind and trust that if they are using our parts they can rest assured they will produce a quality repair;
  • Where turbos have failed through known design issues in the market, where possible, Melett replacement turbo parts have this failure designed out, again helping to reduce warranties.

Highest Quality Manufacturing Standards

Significant investment in our own manufacturing and core production facilities, gives us 100% control of the complete production process, whilst maintaining the highest quality manufacturing standards.

The Melett Manufacturing Facility incorporates the latest machinery and technology, including casting tooling, welding machines and the latest Japanese CNC controlled equipment with onboard CMM. With a wealth of experience in component production and quality control, the production team offers a thorough understanding of the full manufacturing process.

At Melett, we also work with fully certified ISO/TS16949 quality manufacturers, who adhere to the same strict quality control principles and have a great deal of experience in the manufacture of high precision parts for existing OEM turbocharger companies.

Dedicated UK Core Production Facility

Continued investment in the latest technology and highly skilled technicians, has allowed us to maintain tight control over all stages of core production, whilst offering customers complete traceability of every component part. Our dedicated UK Core Production Facility, incorporates a parts wash room, extensive core building workshop, balancing area using the same high speed VSR machines as the OE’s and packaging department.

Every Melett core assembly is etched with a unique serial number, ensuring all Melett products are fully traceable to the UK, whilst giving customers piece of mind that their order is genuine Melett parts.