When the project enters the workshop: digitalization of metal fabrication with TopSolid'Steel

In the metal fabrication sector, the digitization of processes is not merely a technological evolution but a concrete tool for managing complexity, timelines, and variability. In this context, G.S.G. Metal has chosen to adopt TopSolid'Steel, launching a technological partnership with TopSolid that is set to profoundly impact the management, optimization, and total control of design and production activities.

From workshop to company: a structured evolution

The history of G.S.G. Metal, a Lombardy-based metal fabrication company headquartered in Villa di Chiavenna (Sondrio), began in 1997 as a small, family-run artisan workshop. Over the years, the company has rapidly evolved into a highly organized structure, progressively expanding its expertise and initial areas of operation. Starting with light metal fabrication, the company has broadened its scope to include civil engineering projects and precast concrete, developing a comprehensive operational model capable of covering the entire cycle, from in-house design to the fabrication of formwork.

With a staff of about 14 people and revenue of approximately 2.5 million euros, G.S.G. Metal now has a strong commercial presence concentrated primarily in Italy, while maintaining a significant and strategic export share to Switzerland. Current projects range from structures for private staircases to fire protection systems, as well as complex civil engineering projects and collaborative designs with architects for custom-made furnishings.

Led by Gil Ghiggi - son of founder Sergio - the company positions itself in the market as a true hybrid enterprise. This dual identity allows G.S.G. Metal to combine the maximum flexibility typical of the artisan world with the efficiency and rigor of an industrial organization, while maintaining a high capacity for custom-made solutions in a market context marked by fluctuating raw material costs and design complexity.

The digital choice: moving beyond 2D design

The technological turning point came in 2023, when management decided to move beyond the traditional approach based on two-dimensional drawings and transition to integrated, parametric 3D design. The strategic choice fell on TopSolid, the vertical CAD solution developed by the French software company TopSolid and specifically designed for the metal fabrication industry.
Thanks to dedicated libraries and industry-specific commands, the engineering department was able to drastically simplify the modeling of complex structures such as staircases, guardrails, and industrial frames. As a multi-material system, the platform is capable of bringing together and integrating diverse engineering disciplines—from pure mechanics to ancillary manufacturing processes - within the same digital environment.

The central role of integrated PDM

A highly distinctive technical feature lies in the PDM (Product Data Management) module natively integrated into the platform. This tool allows G.S.G. Metal to securely manage data, revision cycles, and complex document workflows without relying on external software. The engineering department can thus work on large files with the assurance that data is aligned and that the history of design changes is properly organized.

From design to the workshop: operational continuity

The fundamental objective of the investment is achieved through operational continuity between the engineering department and the shop floor. With TopSolid'Steel, the 3D model ceases to be a mere visual representation and becomes the direct source of production, thanks to the automatic and immediate generation of all shop-floor documentation.

• One-click generation of shop drawings, cutting lists, and the complete bill of materials.
• Drastic reduction in transition times and intermediate manual tasks.
• Native integration with CAM modules for direct control of machine tools (laser, plasma, and waterjet cutting).

From 3D scanning to the real-world environment

A further step forward in workflow optimization is the seamless integration between design and on-site surveying. G.S.G. Metal uses 3D scanners to capture the reality on-site with millimeter precision. The resulting point cloud is imported directly into TopSolid'Steel, completely eliminating traditional manual measurements on paper.

This approach allows designers to develop metal structures by working directly on real-world data from the construction site. This makes it possible to perform crucial preventive checks - such as automatic checks for structural interferences and collisions - before the material is physically cut or assembled in the shop, thereby reducing non-conformance costs.

The visual value of 3D for production and the customer

In addition to the strictly numerical and operational advantages, the parametric 3D model has proven to be an extraordinary tool for both internal and external communication. While it facilitates the end customer’s immediate understanding of the project during the approval phase, it also provides essential support to shop floor operators.

“A 2D drawing can sometimes be difficult to interpret at the workbench, whereas the 3D model makes the final result immediately clear and transparent. For our workshop operators, having such a detailed visual reference is essential, as it helps them better understand the part’s geometry and drastically reduce errors during assembly and welding.”

Gil Ghiggi, Owner of G.S.G. Metal

Thanks to the direct technical support provided locally by TopSolid Italia and a targeted, structured training program (also delivered remotely), G.S.G. Metal has successfully integrated these technologies into its daily operations, consolidating a hybrid model that combines the attention to detail typical of custom metal fabrication with the power of the digital industry.

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