A ‘UK-first’ for multi-cavity high production toolmaking

In fact, the group believes the cell is “very likely a world-first”, which it hopes will enhance the quality and efficiency of its mould tool manufacturing. The production cell particularly supports multicavity, high-production tooling.

The manufacturing cell will feed both the 5-Axis and spark erosion machines, enabling automated changes of electrodes and of workpieces, further increasing capacity for high cavity tooling.

For example, the tool pictured has 16 impressions, and is guaranteed for a million shots and moulds at a seven second cycle time. Faulkner Moulds recently reduced the cycle time on a new 12 impression packaging tool for a household name, from a target of 8.5 seconds to just 6.98 seconds.

Faulkner Moulds’ managing director Duncan Faulkner said: “Our success lies in focusing on three things –customer service, skills and training, and technology. We never stay still – we are constantly innovating and finding ways to move forward for our customers”.

In 2022, the three-times UK ‘Toolmaker of the Year’ winner also took delivery of a new Hurco TM8i 2 axis CNC turning centre (lathe) and Mitutoyo Crysta-Apex S CNC Co-ordinate Measuring machine. The CMM machine responds to increased demand for ever tighter tolerances in toolmaking, allowing highly accurate 3D measurements at high speed. Dedicated software algorithms eliminate even miniscule geometrical imperfections in the guideways.

The turning centre has in-built features to ease programming, enhance machine speed and ensure outstanding accuracy and surface finish. Faulkner Moulds’ recent experience in high precision