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Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Sales Manager: Arfan Qureshi sales@engineeringcapacity.com Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services. For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company number 10567217 ISSN 0306-0179 COMING UP IN OUR MARCH 2019 ISSUE Turned Parts, Forming & Fabrication, Aerospace & Defence, Heat & Surface Treatments, Measurement, Inspection & Testing Services Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website
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Editor’s View Whatever happens in the political and economic world in the coming year – and it would take a braver man than me to make any predictions there – the relentless advance of technology will continue regardless of what our politicians do. According to the Chief Technology Officer for Manufacturing, Utilities and Services at Fujitsu UK, Graeme Wright, the advance of digitalisation will raise new questions and opportunities. In 3D printing, for example, he points out that 2018 saw some significant milestones for additive technology, including NASA using additive manufacturing to produce a rocket engine, the first 3D printed home and – very on trend this – 3D printed vegan steaks. He points out though that as new business models and services come to the fore the way manufacturers manage their digital rights and intellectual property will change as this will then become a critical factor for their business. He says: “Manufacturers will need to think about how they are going to effectively control the digital rights of their designs, as well as the warranty for their products and how they adjust their business models in accordance with this.” One big company that is looking at new business models in the digital economy is Singapore-based Spare Parts 3D which has been working with white goods giant Whirlpool on a project to industrialise the 3D printing of spare parts (see story on page 11). Spare Parts 3D digitally analysed the designs of over 11,000 part numbers and identified 7% where it would make economic sense to produce them using additive manufacturing. Whirlpool says that while it won’t 3D print large production batches, this is an efficient way to cope with providing spare parts for obsolescent models and component shortages. That suggests to me that in future, designers may well be called upon to come up with parts that can be produced using both traditional and digital methods rather than simply optimising them for one production route. Andy Sandford, Editor
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Contents January 2019
14 MACHINED COMPONENTS
News
Features
06 Composites for Overfinch 06 Fully finished parts for bespoke
13 Machined Components 06 Patience pays off for Standfast Adaptive machining for better blades Measuring up for efficient service Larger machining capability
Land Rovers
08 Getting stressed up 06 Improving spring life and capacity
09 Spain’s main event for subcontracting 06 SUBCONTRATACIÓN 2019
20 Casting & Forging 06 Oil and gas forge ahead
20 CASTING & FORGING
is in Bilbao in June
09 Two shows alongside Subcon 06 From design to machine tools
22 Southern Manufacturing Preview 30 Laser & Waterjet Cutting 06 Ackerman focusses on fibre
and services
32 Additive Manufacturing 06 Sealing the deal on AM parts
10 Hot spot in Rotherham 06 Advanced manufacturing base for Bodycote
11 3D print for white goods spares 06 Whirlpool industrialises digital approach 4
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33 ADDITIVE MANUFACTURING JANUARY 2019
Engineering Capacity | INDUSTRY NEWS
New brand for Norfolk machinist Norfolk-based CNC machining specialist Stokes & Rowe has celebrated its 10th year in business and rebranded as Accuturn. As well as the rebrand, 2018 has seen directors Nicola and Robert Stokes invest in new CNC milling capability, gain ISO9001:2015 and ISO 14001:2015 standards and hire their first mechanical engineering apprentice. The expanded milling capability comes from a new Haas Super Mini Mill with a machining envelope of 406 by 305 by 254 mm. It features an upgraded, faster tool changer, faster spindle and higher rapids for improved production and part finish. Accuturn manufactures a range of safety critical devices for a range of sectors that require precision machining and a very high-quality finish. It has developed its machining processes to remove the need for additional post machining polishing for specific projects. Nick Groom, Managing Director of Hertford-based Qualiturn Products Ltd is the new President of the British Turned Parts Manufacturers Association (BTMA). He took over the role from Phil Smith of Wealdpark at the turned parts manufacturers’ association AGM on Friday 16 November at the Shankly Hotel in
JANUARY 2019
The company’s new apprentice is sixteen-year-old Joshua Mallett, who originally came to the company on work experience from Reepham High School for two weeks, he stayed in touch with the business and after finishing school this summer joined as its first engineering apprentice. Nicola Stokes said: “As a company, we have experienced first-hand through our attempt to recruit skilled engineers that there is a skills gap, so we know the importance of encouraging young people into the sector. We can see already how having an apprentice has benefitted our
business and are making a commitment to take on further apprentices alongside the planned growth of the company.” Joshua is attending City College Norwich for the next 2 years, on day release. He said: “I’ve always enjoyed working with my hands. I loved looking into how things worked and were made and was always taking things apart and rebuilding them. This was mainly computers and on cars, but when I saw the opportunity for some experience in a proper engineering environment, I jumped at the chance.” 8 accuturn.co.uk
New BTMA President Liverpool following the end of Phil’s two-year term. Nick is a long-standing member of the BTMA. He has been vice for the last two years and has a lot of experience as a member of the BTMA Officers Committee. Nick is also a strong supporter of the BTMA's involvement in the Syndicate International
Décolletage (SID), the international group of turned part trade associations. He will be building on the work of Phil Smith to make the BTMA an active part of the SID during his period as BTMA President. 8 btma.org
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INDUSTRY NEWS | Engineering Capacity Prodrive Composites is supplying carbon fibre composite components to allow bespoke Land Rover specialist Overfinch to significantly increase production. Prodrive is fully integrated into Overfinch’s supply chain, providing finished, ready-to-fit components matching the company’s demanding build schedule As well as manufacturing the components, Prodrive Composites worked with Overfinch to design the new conversion packages for the Range Rover and Range Rover Sport models. Using state-of-theart scanning techniques, accurate dimensions of the vehicle were used to produce CAD models of the conversion packages. Once the design was finalised, Prodrive prepared the tooling and produced prototype parts to ensure fitment and aesthetics were as expected. “Prodrive’s expertise in composite manufacture was critical to optimising the design, ensuring that high-quality, Asurface components could be produced consistently,” explained Kevin Sloane, Chairman, Overfinch. “Our partnership with Prodrive has enabled us to significantly increase production and move into new markets. Prodrive collaborates with us on an ongoing basis including design work, product revisions and production. It can deliver fixed volumes each week to match our build order and provide components that are significantly easier to install than those we were using in the past.” Prodrive utilised a new additive manufacturing technology to 6
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Composites for Overfinch
produce a backing that accurately secures the mounting bracketry and clips to the carbon components, ensuring it fits directly to the vehicle’s OE fixings. This process has significantly improved ease of fitment and directly reduced the build time per vehicle. “Often companies like Overfinch request composite parts from suppliers, only to receive pieces that require modification and adjustment to make them fit,” explains Richard Gregory, Quality and Engineering Director, Prodrive Composites. “Not only are we able to design and deliver components that fit straight on using the OE fixtures, we are also able to deliver the parts as and when they need them.” Prodrive is producing both ‘visual’ and painted carbon composite conversion packages. Using its own paint facilities, Prodrive Composites was able to supply Overfinch with completed components, this ensured that
regardless of how the car was specified, the composite parts were supplied to match specific vehicles within the build order. The streamlined process has reduced Overfinch’s average build time for a vehicle’s exterior from a week down to a day. “We sequence delivery and have a dedicated project manager that resolves any queries, concerns or difficulties that arise,” concluded Mr Gregory. “Being able to paint inhouse and deliver components to Overfinch’s build schedule is a significant advantage. These factors have led to a strong working relationship between Overfinch and Prodrive Composites and we are excited to continue building this relationship.” 8 prodrive.com/composites JANUARY 2019
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Exceptional Knowledge. Exceptional Ser Service. errv vice. Industry Expertise Helps Customer Achieve Big Dividends. Hadley Group is an international manufac turer of cold rolled s teel profiles used in the cons truc tion indus tr y. They wanted to broaden their produc t of fering and bring work in-house with CNC punching, but had limited experience with the proces s. Hadley had previously known about Mate Precision Tooling’s reputation for ser vice and qualit y, and decided to contac t Mate t o l e a r n m o r e. “Before we entered turret punching the challenges we faced were great,” said Nathan Annand, Hadley Group Produc t Manager. “Ever y thing from choosing tooling t ype, planning setups and runs, adjus ting lengths, and maintenance, all had to be learned. Mate’s Craig Let t y had the in- depth knowledge and experience we needed to overcome these is sues. Ultimately, we decided Mate UltraTEC® fully guided tooling was the bes t solution for us,” said Mr. Annand. “Our move into turret punching has paid big dividends, quickly contributing to new produc t s and higher produc t qualit y. It has also resulted in accolades and higher order volumes from our cus tomer s.” Mate’s inspire sheet metal professionals professionals around around the world with Mate’s mission and promise promise to you: To To personally respect, respect, support and inspire high-quality precision precision tooling, laser accessories and services. Phone Number: umber: 01604 630 646 www www.matetoolingsolutions.co.uk w..matetoolingsolutions.co.uk .matetooli
INDUSTRY NEWS | Engineering Capacity European Springs & Pressings (ESP) has invested in the design and manufacture of an automated pre-stressing machine that improves spring life and load bearing capacity. Working alongside Design & Automation Solutions and Bosch Rexroth, ESP has seen its conceptual plans taken from the drawing board, designed and delivered, reducing waste across multiple processes. Michael Gibbs, Managing Director of ESP in Cornwall says: “In the last decade, since we were acquired by the Lesjofors Group, we have seen turnover increase by over 700%, which has recently led to the acquisition of a second
Getting stressed up
Safe rail structures
there is a risk of endangering passengers due to part failure in use. TRB, which is IRIS approved (International Railway Industry Standard), has for over 60 years been manufacturing high quality rail interior products. These are used in new and refurbished trains and transportation systems worldwide. The DIN 6701 A1 rating, certified by TBBCert, has been achieved for
TRB Lightweight Structures Ltd has achieved the highest rail safety DIN 6701 (Parts 1-4) A1 type certification. This approval is for bonding safety critical rail vehicle parts which covers applications where d
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factory in Cornwall and a 40% increase in recruitment in the last year. Lean manufacturing has been key to our success and enhanced automation not only increases our efficiencies in operations and production but also on the budget sheet, as we estimate a pay-back period within just 5 years.”
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FM10101
Manufacturers of High Quality Mill-Turned Parts
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Mick Stallwood, Director of Design & Automation Solutions adds: “Manufacturers are under constant pressure. Multiple factors demand more out of them and manufacturers demand more out of their facilities and infrastructure. This is where we step in. Our specialisms, in advancing technologies and automation, have been utilised world-wide and to design a world first for one of the world’s leading spring manufacturers, is something we’re very proud of.” 8 europeansprings.com designandautomation.com the main Huntingdon facility, where TRB designs and manufactures lightweight metal and composite parts, as well as complete assembled interior units for passenger train interiors and other rolling stock. Attaining the top level (A1) approval enables TRB to bond any product required in a rail vehicle under any of the four DIN 6701 A13 and Z type classifications. Safety critical products needing A1 approval that are manufactured and supplied by TRB, include emergency detrainment door systems and passenger exit doors. As well as Rail, TRB also supplies Electric Vehicles, Aerospace and other industrial applications, where lightweighting is required. 8 trbls.com JANUARY 2019
Engineering Capacity | INDUSTRY NEWS Running from 4 to 6 June in Bilbao, Spain, SUBCONTRATACIÓN 2019 is the only trade show in Spain for subcontractor SMEs and a leading platform for advanced manufacturing. The organisers say it will give subcontractors the chance to win new customers, reinforce relationships with other companies and access foreign markets. At the last event over 600 exhibitors from 23 countries made around 15,000 commercial contacts. The event also hosted the European Industrial Subcontracting Meeting, the largest B2B platform held in Spain. This year the European Industrial Subcontracting Meeting will attract close to 100 contractors. The meetings will be divided into three large blocks, one per day. They will be aimed at purchasers from the railway, iron and steel, energy, electrical-electronic, machinery, general subcontracting, automotive and aeronautics sectors, as well as the additive manufacturing sector. The event is organised by the Barcelona Chamber of Commerce, Subcon 2019 will be collocated with the Advanced Manufacturing Show and The Engineer Expo at the NEC for the first time this year. The show, which runs from 4-6 June at the NEC, Birmingham, is a key event for subcontract manufacturing buyers and suppliers. Over three days, the three events will showcase
JANUARY 2019
Spain’s main event for subcontracting
the Bilbao Chamber of Commerce and the Bilbao Exhibition Centre, with the collaboration of the Spanish Subcontracting Network. Participant satisfaction in 2017 was high: two thirds of participants said they would sign new contracts with the companies they had met.
Six shows run alongside SUBCONTRATACIÓN and cover additive manufacturing, industrial tools and supplies, maintenance, pumps and valves, digital manufacturing and used machinery. 8 subcontratacion. bilbaoexhibitioncentre.com/en/
Two shows alongside Subcon design, prototyping and development, contract and subcontract products and services through to machine tools, systems and equipment. The Engineer Expo is dedicated to the advanced engineering that drives UK manufacturing and design and will feature 36 free-to-attend conference
sessions on the latest industry developments and the most interesting engineering projects. The Advanced Manufacturing Show is a platform for next-generation technologies, showcasing innovative solutions that enhance advanced manufacturing performance. 8 subconshow.co.uk
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INDUSTRY NEWS | Engineering Capacity
Moulders strike silver again Northern Ireland-based IPC Mouldings has again achieved the Silver Award in the SC21 Aerospace Supply Chain Programme. The Carrickfergus company is sponsored through the programme by Collins Aerospace (formerly Rockwell Collins); the newly formed aviation giant which combines the strengths of two of aerospace’s leading innovators, Rockwell Collins and United Technologies. IPC Mouldings is a single source solution supplying a full service with mould tool design and manufacture, CNC machining, production and assembly. 8 ipcmouldings.com
Hot spot in Rotherham
Thermal processing specialist Bodycote has opened a new facility on Rotherham’s Advanced Manufacturing Park (AMP) to support UK and European aerospace and power generation markets. It also announced that it was investing in further capacity and technology and would take on
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additional space that was nearly three times the size of the existing unit. The Rotherham facility was officially opened by Andy Greasley, Executive Vice President of RollsRoyce’s Turbines Supply Chain Unit, in recognition of the enduring partnership between Bodycote and Rolls-Royce. Mr. Greasley commented: “Heat treatment and processing is a vital part of our supply chain and Rolls-Royce are delighted to be supported by Bodycote on the Advanced Manufacturing Park in Rotherham. Close coupling of this capability to our own Rolls-Royce business is critical for our future success and our relationship with Bodycote is one that we truly value.� Also speaking at the event, AMRC (Advanced Manufacturing Research Centre) CEO, Colin Sirett, said the new centre will bring a key capability to the Advanced Manufacturing Park: “We’ve got everything from aircraft parts through to carbon fibre chassis for supercars all being manufactured on this site; the one piece of the process that was missing was materials processing. We can cast, we can forge, we can assemble, we can machine, but the one key element that was missing is exactly what Bodycote brings to the park. So it’s great to welcome the Bodycote team here and we are looking forward to working with them for many years to come.� 8 bodycote.com JANUARY 2019
Engineering Capacity | INDUSTRY NEWS Spare Parts 3D and global home appliance manufacturer Whirlpool are working together on a new 3D printing project based on spare parts production. Whirlpool is partnering with the Singapore-based company to apply leverage to its 3D printing expertise and accelerate industrialization. The first part, a Nylon push button, paves the way of a new way of thinking spare part management in aftersales. “Spare Parts 3D gave me a pragmatic view on how to use 3D printing in our business. I know we won’t make large production batches with this technology, but there is an excellent value to solve obsolescence and shortage issues which generally fold into low volumes demands. This way 3D printing can have a direct significative impact on our customer care” Says Franco Secchi, Head of Consumer Services and Quality for Whirlpool EMEA and responsible for the collaboration’s success. Spare Parts 3D has already succeeded in convincing large manufacturers and industrial spare parts users that additive manufacturing is a great way to improve spare parts supply. The Singaporean start-up, launched in 2015, developed an online software called “Digipart” to enable their partner to estimate the benefits they would get from using 3D printing and to determine which part would be the most profitable. Additional features such as the digital inventory repository, and the JANUARY 2019
3D print for white goods spares
quotation and ordering system are an on-going beta test and shall be released to all Spare Parts 3D’s customers by end of the year. Paul Guillaumot, CEO of Spare Parts 3D, stated: “We are proud to count Whirlpool as one of our most valuable partners. Committing in 3D printing is proof of a creative mindset and leadership for such a well-known company. We are glad to inspire them trust and innovation.” The collaboration between the two companies started back in November 2017 with a pilot project led in Singapore on 150 parts covering various typologies, materials and technologies. Once the technical suitability had been validated in January 2018, Whirlpool empowered Spare Parts 3D to perform a catalogue analysis. More than 11 000 part numbers were reviewed to tackle
two key issues: obsolescence and shortages cases. 7% of these were found to be profitable and as a result, suitable for a production by additive manufacturing. Using three kinds of technology (HP, FDM, SLA) combined with 5 materials (ABS, ABS V0, PA12, Rubber-like resin, and PP-like resins), additive manufacturing could cover a wide range of needs in terms of spare parts for the home appliance industry. With the first project now launched, the next step will be to expand the digitization process to a larger pool of parts. Some few models have already been produced on demand and delivered to customers. Going forward Whirlpool and Spare Parts 3D plan to intensify their collaboration to scale up the production in the coming months. 8 spare-parts-3d.com www.engineeringcapacity.com
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Trade Leads from the EIA
PEOPLE | Engineering Capacity
The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk Spain – Plastics Recycling Machinery A Spanish company is looking for Partner Company or distributors for the supply second-hand machinery for the recycling industry and extrusion of plastics for the market of Mexico. Reference: JV1241 Closing Date: 02/05/2019 Germany – Rubber and Plastic Partnering opportunity with a German engineering company with more than 30 years’ experience in injection-moulding production processes for rubber and plastic parts. It offers in-depth know-how and expertise to optimise injectionmoulding production processes for rubber and plastic parts. Reference: JV1242 Closing Date: 03/05/2019
John Rowley has taken over as Managing Director of Newbury Electrics from Philip King, who becomes Chairman. John developed his career in a range of positions, including Operations Manager, Operations Director and culminating as Managing Director at SMT Developments.
Trevor Harreld has joined XYZ Machine Tools as its new Commercial Director. Trevor has had a long career in finance in chartered accountancy firms, construction and support services sectors prior to setting up his own consultancy business supporting clients’ focus on strategic objectives.
Andrea Thompson is to head up the steering board of the £20m Made Smarter pilot in the North West. Andrea is BAE Systems’ MD for Europe & International Programmes and is responsible for BAE’s role in the F-35 Lightning II fighter aircraft programme.
Geoff Cousins former Managing Director at Jaguar UK, has been appointed as Chairman of automotive and aerospace quality management service provider G&P. He started in finance and he went on to be Jaguar Land Rover CFO North America before leading Jaguar UK.
Saudi Arabia - Blockchain systems A company is looking for providers of blockchain technology. Reference: 32380 Closing Date: 01/10/2019 Switzerland - Raw materials PVC processing A distributor needs raw materials and additives to sell to PVC processors and masterbatch producers. Reference: 32483 Closing Date: 22/02/2019 For more information please email head.office@eia.co.uk quoting reference number. Please remember to use due diligence in responding to Trade Leads. Engineering Capacity provides you with the above information in good faith, but is unable to accept any responsibility or legal liability arising from any use of these leads.
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JANUARY 2019
Engineering Capacity | MACHINED COMPONENTS
Patience pays off for Standfast Aptly-named subcontractor Standfast Precision decided to hold its ground when the oil and gas market fell away and resisted the temptation to downsize. When work started to return it was well placed to take advantage of increasing demand and has now updated its turning capacity with the latest TC400 models from XYZ. Standfast Precision Engineering Director Malcolm Fraser said: “Most of our work is in the oil & gas sector, mainly providing parts for instrumentation and logging systems. When we bought the business in 2000 we started without any work whatsoever, then one customer appeared with a wad of drawings and told us to ‘crack on’. Which we did, and we have not looked back since. That customer has stayed loyal to us throughout and it was relationships like this that gave us the confidence to work through the latest downturn. This is the third oil and gas sector slump we have experienced, meaning we knew that things pick up eventually, so it was a case of take it as it comes while maintaining the skills that we had.” Prior to the cooling off of the market Standfast had looked at further machine investment, but delayed that until this year, replacing its existing two XYZ TC 250 turning centres with the latest TC 400 models. “Working with materials such as Super Duplex and Inconel we JANUARY 2019
needed a substantial machine and while the TC 250 machines coped well, the TC 400 has improved things considerably. The machines may look similar, but the construction of the TC 400 is more substantial, and their added rigidity means it can handle bigger cuts in these materials, while holding tolerances for longer, our tooling consumption has also reduced.”
“We work on some tight deadlines with extremely short lead-times and having a second machine was important to have capacity available at short notice. Therefore, when it came time to upgrade to the XYZ TC 400 machines it made perfect sense to bring two in at the same time, with XYZ taking the old machines away in part exchange. 8 spe.switchedonsystems.com
Aerospace Oil & Gas Nuclear Defence
Automotive Electronics Hi Fi
Industrial & High Volume Machining
PRECISION ENGINEERING www.thomas-brown-engineering.co.uk Tel: 01484 548903
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MACHINED COMPONENTS | Engineering Capacity JJ Churchill is working closely with machine supplier Starrag to apply in-process probing and adaptive milling to turbine blade machining. This builds on JJ Churchill’s success in machining blades from solid in a single setup rather than producing them from larger batches of forgings. The aim is to develop specific production processes that consistently produce world-beating time and manufacturing benefits. Both techniques are forecast to result in unprecedented savings in overall production times as well as improved surface finishes to eclipse the 0.7/0.8 Ra currently being achieved by JJ Churchill when using a ‘super finish mode’ on the Starrag machines. The developments are among a number of initiatives being led by JJ Churchill’s Head of Engineering, Will McAleese and his team. According to Mr McAleese: “It is some time now since we’ve proved that machining blades from bar has a number of advantages over the traditional route of machining forgings, not least the fact that the process negates the need for relatively large batch sizes – one-offs to 90off are feasible compared to a minimum batch of, say, 300-off when oversize (usually by 3 mm) forgings are used. And the resultant time savings can be enormous when it is accepted that lead times for forgings can sometimes be one year. “In addition, blade integrity from billet compares with that from a forging, and milling from solid 14
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Adaptive machining for better blades
means that blade aerofoils can be held to the same tolerances – at least 25 microns radially and axially as well as on alignment.” The springboard into such a highly flexible method of blade production was mapped out by the Market Bosworth (Midlands) company in 2008, when it started its association with Starrag UK for machine supply and with Starrag Switzerland on the joint development of the process and programming/cutting parameters
for the machining of doubleended stators. Its so-called ‘fast-make’ strategy has since been applied to a number of contracts among its blue-chip customer base that includes first-tier status with companies such as Rolls-Royce, Siemens and Safran. Now, however, blade machining continues to be refined, as Mr McAleese explains: “A blade is conventionally held by clamping on the machine’s tailstock/driven head JANUARY 2019
Engineering Capacity | MACHINED COMPONENTS and, rather than machining commencing on the assumption that the blade is positioned and held accurately every time – which isn’t always the case - we’re now probing the root (using a probe held in the machine’s tool magazine) to accurately locate its position. “Using Starrag’s RCS CAM software, the machining program then automatically adjusts to the blade’s true position within the machine and determines the ‘best fit’ position of the blade in relation
to the root. This means we can eliminate the need to measure the blade (by co-ordinate measuring machine) after machining and, if necessary, adjust and re-write programs then undergo a period of post-programming before we can re-start machining. “The potential time savings are extraordinary if we can ensure this probing regime is consistently faultless.� RCS’s capability for adaptive milling is also being put to work
by JJ Churchill on creating perfect blends on aerofoils, on both bar and forged blades – a technique where Haimer heat shrink tooling and 2 mm diameter ball nose cutters also play key roles. “Better surface finish is the result of improving and decreasing the cutter step-over,� says Mr McAleese, “as well as creating far less stress on the material and improved process capability as well as extended tool life.� 8 jjchurchill.com
Wealdpark Limited Stand number 5126
Subcontract Capacity #.# MILL TURN FACILITIES USING SLIDING AND FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER -IYANO FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER (URCO VERTICAL MACHING CENTRE 03, $ATATRACK MANAGEMENT SOFTWARE
BS EN ISO 9001:2008. Approved by BSI since 1991.
Company Contact Details Phil Smith, Director, Wealdpark Limited Sutton Road, St. Helens, Merseyside, WA9 3DJ Tel. 01744 22567 / 732083 Fax. 01744 451339 E: sales@wealdpark.co.uk www.wealdpark.co.uk
JANUARY 2019
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MACHINED COMPONENTS | Engineering Capacity Investment in advanced metrology equipment at APT Leicester means a more efficient service for customers. The Keyence IM-7070T Image Dimension Measurement technology system is a significant advance on conventional measuring devices – saving time, increasing productivity and producing consistent, accurate results. With newly developed features and user-friendly interface, it has never been easier for APT to carry out inspections on the products it manufactures. The width, radius and height of a part can easily be measured at one time, regardless of the shape or size of the object. APT can now measure up to 99 dimensions in a matter of seconds, as well as allowing multiple components to be inspected on the expanded stage simultaneously. Together, this will reduce the time and effort required for the inspection of precision turned parts or CNC milled components. The system features automatic orientation, positioning, focus adjustments, edge detection and the ability to save and manage measurement data instantly.
Visit our website or contact us for a quote or advice
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Measuring up for efficient service
The Keyence IM-7030T will help quickly verify that APT’s machined components have been made to the exact specifications, accurately measuring crucial dimensions at a rapid rate. This will increase productivity across the manufacturing process. APT Leicester’s customers will benefit from this immensely, with faster inspection times ensuring that parts and components are delivered more quickly than ever before, but to the same high standard that APT Leicester has always provided. Operating to AS 9100 and ISO 9001 accreditations for all
precision turned parts and CNC milled components, APT is proud of its expertise and of producing products of an outstanding quality, something which is integral to exceeding customer expectations. Offering full traceability and tracking of the products it makes throughout the entire process gives APT’s clients peace of mind when ordering from them. Nick Baller, Managing Director at APT, said: “This new Image Dimension Measurement system by Keyence has given APT the ability not only to check a part more quickly but it gives us an auditable history of measurements and SPC results if required. This data is also offered to our customers if required, resulting in total transparency.” The IM-7030T will ensure APT exceeds the expectations it is held to regarding subcontract manufacturing. The company manufactures subcontract parts for many industries across the engineering sector, including automotive, security and aerospace. 8 aptleicester.co.uk JANUARY 2019
Engineering Capacity | MACHINED COMPONENTS Cheshire Seals & Components can offer a larger machining capability following the purchase of a new Harrison Alpha 1550XS manual/ CNC lathe from Colchester Machine Tool Solutions. Warrington-based Cheshire Seals is a family-run, independent manufacturer of machined parts in a wide variety of materials, ranging from aluminium to zirconium, taking in duplex stainless steels and nickel alloys and many exotic metals, through to plastics and rubbers for seal manufacture. It also takes initial customer design concepts and converts them into fully finished products, whether it’s a one-off prototype or a full production run. Cheshire Seals was set up in 2008 by managing director, Paul Wallace and his fellow director, David Kennedy after they saw an opportunity to extend into both metal and plastic machining when working with their previous employer, a large industrial multinational who concentrated on higher volume, standard machining production. Their initial decision to go it alone led to immediate success, resulting in having to quickly expand their factory as their specialist business grew. Paul Wallace explains “We started with only 3 customers, but when some older contacts found out about our new venture, they quickly asked us to work on projects for them. Our competitors in the general machining sector now also come to us for certain bespoke high specification work that they don’t get involved with and we can JANUARY 2019
Larger machining capability spend the time getting the processes right when developing prototypes for them. “We service many markets from oil and gas, pharmaceuticals, food, hydraulics and rail transport so it’s essential to keep our skilled staff. We maintain this by taking on work that is increasingly varied - they like to be challenged and we like to challenge them too. We now have 5 qualified engineers and 3 apprentices through this process and the quality of work we get from them is outstanding.” The recently purchased 2-metre between centres, Harrison Alpha 1550XS has a swing over bed of 554mm and a 104mm spindle bore. The new machine also allows Cheshire Seals to manufacture products up to 450mm diameter (370mm diameter for components with a
maximum length of 2,000mm). Where dedicated CNC machines are used for large batches, the Alpha machine can be used for the smaller runs and their overall flexibility is now fully maximised. Paul Wallace said “We had an existing Colchester centre lathe that had been very useful to us, but we needed the machining flexibility that the Alpha could bring. We bought plenty of extra kit from Colchester for the Alpha and from day one it’s been put through its paces, is performing well and certainly earning its money. “We’re also pleased to announce that we have our first female apprentice starting with us in January 2019 and one of the machines that she will be quickly trained on our Alpha XS lathe.” 8 cheshireseals.co.uk www.engineeringcapacity.com
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CASTING & FORGING | Engineering Capacity The resurgence of the oil and gas market has seen KimberMills International, which offers high quality forgings and machined parts, post a 15% increase in sales after securing new contracts to supply fluid handling, pipeline, valve and pump components. The recent successes make it the company’s most popular sector and it is looking to build on this even further by becoming a member of NOF Energy, a business development organisation dedicated to helping firms win new contracts in the energy industry. Bosses at the firm believe the decision could pave the way for over £1m of additional orders, with a number of factory visits already planned for potential clients to visit. Hamish Campbell, Sales Manager at KimberMills International, commented: “The last twelve months have seen a rise in price per barrel and this is driving a number of new projects in the oil and gas sector. “We are certainly benefitting from this, with a lot of our core customers growing their export markets and turning to us for support in meeting increases in volume and involvement in the design and manufacture of new components.” He continued: “The challenge for us now is to get into markets that we haven’t previously been in and that is why we’ve joined NOF Energy. It has an amazing wealth of contacts and works with members 20
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Oil and gas forge ahead
to secure opportunities in power, downstream/ upstream oil and gas and the rapidly growing offshore wind arena. “Once we have the contacts and the initial enquiries, our speed of response and front-end engineering solutions speak for themselves, ensuring we can deliver on budget and to the highest possible quality.” Established in 1919, KimberMills International offers high quality forgings and machined parts in steel, stainless steel, carbon, aluminium and super duplex. The company currently exports 25% of its annual turnover to customers in Canada, Dubai, Europe, Malaysia and the United States. It has recently invested £1m into a state-of-the-art forge in Cradley
Heath that will speed up lead times and increase capacity, whilst it is also exploring a number of potential projects to incorporate more automation into the process. Larry Joyce, Chairman of KimberMills International, concluded: “All the talk about next year is focused on Brexit and uncertainty. Whilst we are mindful of this, we prefer to look at the opportunities currently emerging and there’s lots of enquiries we are currently quoting that could be reshored to the UK.” KimberMills International is part of the Manufacturing Assembly Network, an eight-strong group of sub-contract manufacturers and an engineering design agency who work together to win orders and share best practice and resource. 8 kimbermillsint.co.uk JANUARY 2019
Engineering Capacity | CASTING & FORGING Sarginsons Industries has won the Component of the Year Award for its innovative work on a front sub-frame for the Jaguar Land Rover L551 21MY for its prototype launch. The Coventry-based lightweight castings business picked up the Cast Metals Federation’s Component of the Year at the Casting Industry Achievement Awards 2018. Sarginsons was asked to create the part from single piece aluminium frame – something which had never been done before and many in the industry felt was impossible. Not only that, the Coventry firm had just 12 weeks to deliver 250 components, commencing six weeks from receipt of the 3D CAD model. Sarginsons used the very latest software and sandblasting technology and worked with partners at Alphateq and Midland Alloy to create the sub-frame. There were a variety of complexities to consider around the strength and safety of the component in order to meet roadworthy standards, despite it being a prototype vehicle. And after just a few weeks of working on the project, Sarginsons delivered the ‘impossible’ and helped to ensure the prototype of the L551 21MY was ready for its launch with its single piece aluminium sub-frame. Kevin Brierley, Sarginsons Technical Manager, who led the programme and received the award on the night, said: “We are so pleased to pick up this award as JANUARY 2019
Top cast component We are so pleased to pick up this award as it is recognition that we are at the cutting-edge of lightweighting technology and that we push the boundaries on behalf of clients
‘‘
it is recognition that we are at the cutting-edge of light-weighting technology and that we push the boundaries on behalf of clients.
“The fact that others had deemed this particular component as, almost, a mission impossible but we managed to find a way to deliver what JLR wanted is testament to the team here and some of the partners we work with in the supply chain. “I am delighted for everyone involved that we have been recognised in this way and would like to thank the judges and all those from the Cast Metals Federation for this fantastic award.” 8 sarginsons.com
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SOUTHERN MANUFACTURING | Engineering Capacity
Biggest Southern show yet Southern Manufacturing & Electronics lands once more at Farnborough International from February 5 to 7, for what promises to be one of the biggest yet. The annual engineering show entered a new phase in its two-decade history last year when it moved into the brand new £35m venue developed on the site of the illustrious Farnborough Airshow. With nearly a quarter of the UK’s aerospace businesses located the South East, the show has always been an important one for engineering subcontractors and the aerospace supply chain in particular. For 2019 those ties have been considerably strengthened with the involvement of several influential industry bodies, namely the Farnborough Aerospace Consortium, the Confederation of British Metalforming, The British Gear Association, Composites UK, the SMMT and the GTMA. Visitors to Southern Manufacturing 2019 can expect to be putting a lot of mileage on their footwear over the three days of the show, with the event at full capacity of around 800 exhibitors. As usual, the show features exhibitors covering every aspect of commercial engineering enterprise, from the latest machinery to subcontract services; from consumables to state-of-the-art Industry 4.0 wizardry. Exhibitors are drawn from all over the UK, complemented by a substantial contingent of firms from continental 22
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Europe and beyond. Encouragingly, bookings from overseas firms spiked 26% for 2019, providing much-needed reassurance that the engineering sector has retained its keen eye for opportunity in the postBrexit world. Southern Manufacturing is one of Europe’s pre-eminent marketplaces for engineering subcontracting. The directory of these kinds of enterprises available at Southern 2019 is impressively extensive and includes names such as Smith & Jewell, Jenks & Cattell, HEC Precision, Jota Advanced Engineering, GW Martin and Machined Precision Components among many others. Manufacturing technology Given its location and significance for the subcontract precision engineering sector, Southern Manufacturing is an important show for the major machinery manufacturers and is widely
acknowledged as one of the prime marketplaces for machine tools and accessories in the UK. For visitors, Southern is a rare opportunity to witness the latest offerings from many of the world’s top brands cutting metal in live demonstrations. 2019 will be no exception, with the return of many familiar faces plus a few notable names that haven’t been seen at Southern for quite some time. As exclusive distributor of Doosan machine tools in the UK and Ireland, Mills CNC will showcase the DVF 5000 simultaneous five-axis machine at Southern Manufacturing 2019. A demonstration will machine a complex, high precision aerospace component live at the show. Additive and subtractive five-axis CNC machine tools and 3D printers can be seen working in harmony on the Matsuura Machinery stand to demonstrate the production strategies now available to UK manufacturers. The JANUARY 2019
Engineering Capacity | SOUTHERN MANUFACTURING show will also mark the first appearance of the MX-850, the largest capacity five-axis CNC machine the company has ever demonstrated, using fixtures and work-holding printed on the company’s HP Multi-Jet Fusion 580 colour 3D printer. Bystronic will demonstrate its Xpert 40 press brake with Mobile Bending Robot. The robot is available for feeding the press brake, turning it into a compact, automated bending cell for producing 3D sheet metal components. Retrofittable to any Xpert 40 press brake, the robot is suitable for subcontractors, as it allows automatic production for larger runs of components, or rapid access for manual bending of smaller batches and one-offs by quickly setting the robot module aside. Citizen Machinery returns to Southern Manufacturing for the first time since 2008, highlighting two leading manufacturers of CNC automatic lathes. It will highlight Low Frequency Vibration (LFV) – a technology designed to increase productivity that has been taken up by many leading subcontract machinists. Advanced manufacturing is well represented at Southern Manufacturing 2019, with leading hardware vendors such as Laser Lines and Creat3D, and specialist services providers such as Industrial Plastic Fabrications and Digits2Widgets (D2W), a manufacturer of quality models, functional prototypes, timesensitive short runs and end-use engineering components en masse. JANUARY 2019
Free lecture programme Running in two lecture theatres on all three days of the exhibition, the 2019 programme features a notable roster of speakers and addresses a wide range of topics. Highlights this year include several aerospace and automotive-related sessions, giving fascinating insights into the advanced manufacturing techniques being employed in these sectors, as well as the latest developments in new composite materials, such as Senior Technology Analyst Richard Collins’ look at the uses of “Smart” polymer composite applications. The benefits of incremental sheet forming (ISF) processes are explained by Roger Onions, Business Development Director of the GTMA. Stewart Williams, Professor of Welding Science and Engineering at Cranfield University will discuss the large-scale additive manufacture of engineering components using Wire + Arc Additive Manufacture (WAAM). Peter Harris and Joseph Bellis of Matsuura Machinery will
also take a look at some applications in 3D Printing and Component Post Processing using the HP Multi-Jet Fusion. Two of the most consistently popular speakers return for 2019. Tim Scurlock, Director of ALC, takes a detailed look at Porsche’s Lean journey. Ailsa Carson of Onsite Insights looks at some of the world’s greatest manufacturers and draws from them 10 practical steps to improve business efficiency that delegates can take towards implementing these ideas in their own enterprise. Farnborough International Conference and Exhibition Centre offers free car parking for 3,500 vehicles and is well-served by road and public transport links. A regular free shuttle bus service operates from both of Farnborough’s mainline railway stations directly to the show. The venue itself offers a high standard of facilities including a free WiFi service in the foyer area and high quality catering outlets. 8 industrysouth.co.uk
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SOUTHERN MANUFACTURING | Engineering Capacity Subcontractors exhibiting at Southern Manufacturing include: Precision casting and machining Expromet Technologies Group (M180) combines the capabilities of precision casting and machining businesses to deliver engineering solutions to its global customers. At the show it will be exhibiting the wide range of design, casting, finishing and machining solutions provided by its subsidiary companies, Investacast and Haworth Castings.
Investacast is a leading supplier of investment castings with its UK manufacturing base in Devon and a global sourcing network spread throughout Asia and Europe. Haworth Castings specialises in manufacturing fully-tested, machined and finished sand and gravity die castings, with two UK locations in Hampshire. Both companies serve customers throughout the defence, aviation, marine, medical, energy and automotive sectors. The group says its wealth of knowledge and experience ensures a seamless manufacturing and supply process for its customers – from component design and prototyping through to casting, testing, finishing and stockholding. 24
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Treatments and coatings The Wallwork Group (L75), one of the UK’s largest heat treatments and hard coatings suppliers to aerospace, automotive, motorsports and surgical implant industries is starting 2019 with increased capacity coming online. It operates from four locations, Manchester, Birmingham, Cambridge and Newcastle to provide a rapid service to customers in all corners of the UK. Operating capacity has increased as several new investments in equipment went live at the end of 2018. These include a large capacity Seco vacuum furnace and Rübig Plasma Nitride furnace in Cambridge. A new 1200kg payload furnace for processing aluminium is coming on stream in Birmingham and this will be followed closely by a new sealed quench furnace due to be in operation early 2019. Processing aluminium and vacuum brazing, particularly, are seeing greater demand, so the new capacity is coming on stream just at the right time. In the light of REACH and also important is the in-house developed
environmentally safe PVD coating that is a full HCP (hard chromium plating) replacement. £3m investment in added value Fife Fabrications (FiFab) (B85) is a manufacturer of precision sheet metalwork, electro-mechanical assemblies and precision machined components and has been in business more than 45 years. It has invested £3m in the last five years in state-of-the-art plant, lean manufacturing, CANDO, TQM and employee development to provide added value to its customers. FiFab offers a complete subcontract service from design, manufacture, paint, assembly, delivery and support. At the Southern Manufacturing & Electronics 2019 it will be showcasing its next fibre laser & turret punching centre. Celebrating biggest win Grenville Engineering (J130), the Stoke-on-Trent-based sheet metal fabricator, recently secured the biggest contract win in its history. Following a successful year of exceptional growth, it sealed the £400,000 deal with a major player in the petrochemical industry. The company aims to continue this success and is exhibiting at Southern Manufacturing once again after a positive show in 2018 where it acquired new customers from a range of sectors. Exhibiting at the show will highlight the company’s complete fabrication solution from laser cut components to complete fabrications. JANUARY 2019
Engineering Capacity | SOUTHERN MANUFACTURING Sale Director Stuart Rawlinson said: "We are continuing to grow year-on-year, with continual investment in machinery, expanding our skilled workforce and taking on additional units, the business is strong and agile. This has increased our capacity and opportunities, whilst fitting into our overall long-term business plan. Having had another great year at Southern Manufacturing we are seeing more enquiries from outside of our traditional area - so the future is looking great!�
Overlays and control panels can incorporate LCD windows, secrettil-lit areas, embossed switches, clear led windows and a choice of durable finishes. A range of adhesives is available to suit the environment in which the overlays will be used. These can be
LASER CUTTING
selectively applied around the window and switch areas on the rear of the overlay. Laser cutting resource Midtherm Laser (L130) has one of the largest available resources of flat-bed laser cutting in the UK,
Phone: 01782 577929 Phone: E mail: sales@grenville-engineering.co.uk Email: Website: W ebsite: www.grenville-engineering.co.uk
PUNCHING
METAL FORMING
Prototypes with ease With the latest technology in under surface digital printing and laser cutting, GSM Graphic Art (B190) is well positioned to produce prototypes and low volume production runs, offering fast turnarounds and without incurring tooling or origination cost. The company also offers screen printing and platen cutting, enabling it to manufacture full production runs using the most efficient process.
WELDING
ASSEMBLY
MACHINING
FINISHING
LOGISTICS
Visit us at Visit stand J130 JANUARY 2019
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SOUTHERN MANUFACTURING | Engineering Capacity serving a wide range of market sectors including transport and distribution, food and pharmaceutical, agriculture, oil and gas. Its Bystronic laser machines can accommodate sheet sizes up to 4000mmx2000mm alongside offering secondary operations such as folding up to 4000mm on two Bystronic CNC press brakes. If the need to avoid cross contamination is critical, Midtherm
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Laser offers a machine solely dedicated to non-ferrous materials. Midtherm works with a variety of materials including carbon steel, stainless steel, aluminium, copper and brass. The thickness range is from 0.5mm thick going up 25mm with tolerances of +/0.25 and better. Midtherm Laser has recently been accredited with BS EN 1090-1 (EXECUTION Class 4) CE mark. More machining capacity MJ Allen Castings & Machining (N90) has invested in two more additions to its machine shop. Both from Dugard, the HD 1886B and HD 2210B are heavy duty, box way, vertical machining centres which provide additional capacity for the machining of castings, fabrications and solid materials.
The Dugard HD 1886B allows for traverse in X of 1800mm, Y of 860mm and Z of 700mm, with a maximum weight of 2000KG, whilst its bigger brother, the Dugard HD 2210B has a traverse in X of 2200mm, Y of 1000mm and Z of 900mm, with a maximum weight of 3000kg. Operating foundries alongside its machine shop in Ashford, Kent, M J Allen provide a “one stop shop� for aluminium, bronze and iron castings, machining, painting JANUARY 2019
Engineering Capacity | SOUTHERN MANUFACTURING redesign of legacy items. Many spring examples will be on display with expert engineers to discuss your application.
and assembly, all ISO Certified to 9001, 14001 and 18001. CNC machining investment Regina Industries (J130), which provides plastic injection moulded parts and tubular glass processing invests in its machining services with the introduction of a new CNC lathe and milling machine. The investment is a result of increased demand from its diverse range of clients following its debut exhibition at Southern Manufacturing in 2017. The company is now able to offer precision machining as a standalone service complementing its toolmaking department. In conjunction with sister company Grenville Engineering, Regina Industries will be showcasing solutions in plastic injection moulding, tool making, tubular glass processing, prototyping and precision machining. Director and General Manager, Mike Beardmore adds "Regina Industries has been producing plastic injection moulded components for over 50 years to a loyal and diverse customer base. The recent addition in precision machining has opened up our capabilities not only to new customers but our existing customers also.”
in metric DIN-Plus dimensions, new extension springs in SS316, new torsion springs in SS316 and added High Pressure compression springs, including new 600 PSI designs. The Lee Spring philosophy makes finding the right specification simpler with many features such as grinding and plating options, alongside additional available services such as 1st Article inspection, blanket agreements and many material and finish options. Global Flexibility on the other hand means that wherever your design or production is based, Lee Spring can offer a service package from concept of new products to
Aluminium diecasting & machining MRT Castings Ltd (C195) operates one of the most technically advanced gravity and high pressure die casting foundries in the UK, supported by an industryleading in-house CNC machine shop, surface finishing, and electro-mechanical assembly facilities. Principal markets for MRT are in the medical device, aerospace, defence, lighting, and electronics industries. Many of MRT’s customers have little prior experience of die casting as a manufacturing approach, and hence MRT’s experienced team always enjoy working with potential customers’ design teams to optimise components for casting, to create the maximum competitive advantage for their component.
New spring collection The new Lee Spring (D245) catalogue of over 25,000 standard parts will be available with 2,000+ new items including 500+ new compression springs JANUARY 2019
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SOUTHERN MANUFACTURING | Engineering Capacity
Vacuum thermal processes MSL Heat Treatment (E 175) was created from the acquisition of CNC Vacuum Processes by the Magnetic Shields group in 2017. Building on the former company’s legacy of quality vacuum heat treatment and brazing, it has been investing heavily to refurbish and replace its vacuum furnaces to meet the demands of modern manufacturing. Two vacuum furnaces were commissioned in December 2018 with the latest control and data acquisition technology designed to meet NADCAP standards. The company
has also committed to improving the quality management system, recently achieving ISO9001:2015 and working our way towards AS9100 RevD. Vacuum brazing is a process that is often overlooked when designing complex assemblies but holds many advantages over traditional joining techniques. As well as being able to join dissimilar metals in a controlled way with high joint strength and integrity, it is also useful for large batches of components or parts with many joints that can all be brazed at the same time, potentially lowering per-unit cost of the joining process. Drag, drop, source! Qimtek (K235) is returning to Southern Manufacturing for the second year running to showcase its Drag, Drop, Source! service. Drag, Drop, Source! allows manufacturing buyers to quickly
From design, sampling and technical support to manufacture, Simpson Springs & Pressings Ltd provide the complete service.
Tel: 0118 978 6573 Email: sales@simpsonsprings.co.uk
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and easily upload their drawings and in turn, receive multiple quotes directly from quality UK subcontract engineering suppliers. Designed to save time and resources, Drag, Drop, Source! is a free, online service that is already used by hundreds of OEMs every year. Qimtek says it is passionate about introducing manufacturing buyers to subcontract suppliers and therefore, it wants to raise awareness of the doors it can open for both parties. Alongside Drap, Drag, Source! Qimtek will also be taking the opportunity to speak with machinists, fabricators, sheet metal workers, plastic moulders and casting companies alike. It is always on the hunt for UK subcontract engineering vendors to join its membership and assist its buyers; in turn, Qimtek’s members are provided with a steady stream of live enquiries that match their in-house capabilities, complete with buyer contact details to provide a quote directly. 10 years of precision Sub-CNC Precision (F100) was established in 2008 and has just celebrated its 10th year in business, providing quality machined turned/milled components to a diverse range of industry sectors. The company says it has always accommodated customers’ requirements, be it a one drop order on a subcontract basis, or contract manufacturing. This includes stockholding for scheduled deliveries, just in JANUARY 2019
Engineering Capacity | SOUTHERN MANUFACTURING time or Kanban, allowing the customer to benefit from large volume price breaks. Sub-CNC Precision machines materials from mild and stainless steel to plastic and aluminium, and many more. Continuous investment in the latest technology means all its CNC machines are less than 5 years old. Technical plating information Navigation enhancements to Twickenham Plating Group’s (B70) website are accompanied by additional technical information and specifications for individual finishes. The company provides specialist technical plating services for electronics, telecommunication, aerospace, automotive and military applications. The plating
ferrous metals, including stainless and carbon steel, to aluminium alloys and tellurium copper.
production facility in Poole, Dorset, delivers a range of plating services for customers throughout the world, including selective gold plating, reel to reel plating, and barrel/vat/rack plating. The company specialises in plating on various substrates from copper, copper alloys, such as brass and phosphor bronze, and
Multifaceted offering Bowyer Engineering (C265) offers a subcontract piece part manufacturing service using multi-axis CNC and conventional machines. It also offers a design and build service for special purpose machines and manufactures temperature and pressure monitoring probes for aerospace engine applications. In addition, it offers an EDM notching service to support NDT and NDE inspection techniques as well as a design and build service for robotic assembly jigs, assembly tooling, welding fixtures, inspection fixtures and robotic end effectors.
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PR Mark Marketing eting Social Media Copywriting Copywriting Events Events Awards Awar w ds Design Desig gn Media Relations Relations Web Web & SEO
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JANUARY 2019
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LASER & WATERJET CUTTING | Engineering Capacity
Ackerman focusses on fibre Bridport-based sheet metal subcontractor Ackerman Engineering has phased out its CO2 machine and is now focused on fibre laser cutting. In August 2018 a 4.4 kW CO2 machine was part-exchanged for a Bystronic ByStar Fiber 8 kW fibre laser cutting centre, which joined a 3 kW BySprint Fiber installed four years earlier. Both are of 3 m x 1.5 m sheet capacity. At the same time, a Bystronic Xpert 150-tonne, 3.1-metre press brake was added to the six Bystronic models already on-site, one of which dates back to 2001 and is badged Edwards Pearson, which the Swiss manufacturer acquired in 2002. Managing Director Graham Ackerman commented, "Fibre laser cutting is massively faster than CO2. When we installed the 3 kW BySprint Fiber alongside the 4.4 kW BySpeed CO2, the former was so productive that we could have sold the other machine and still hit production targets. The only reason we didn't was to retain back-up capacity for servicing or unusual peaks in order to guarantee customer service and deliveries." He added that the Bridport factory mainly processes aluminium, stainless steel and mild steel sheet from 0.7 mm to 8 mm thick, with a lot of material in the 1.2 mm to 2 mm range for the manufacture of electrical cabinets destined for the electronics and telecommunications industries. 30
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When cutting these gauges, the 3 kW fibre machine is typically two to three times faster than CO2. When the 8 kW fibre laser was installed, a further increase in throughput was seen, as processing times are less than half those using the 3 kW fibre source. Mr Ackerman notes that the firm's larger fibre source draws less than half the power of the previous CO2 machine yet delivers nearly twice the power to the point of cutting. The wasted energy previously had to go somewhere, which was into the factory in the form of heat, so the
fibre-only working environment was more pleasant during the summer months. Appraising his company's use of fibre laser cutting, Mr Ackerman made a couple of interesting observations. One was that the 8 kW machine is so fast that the expected increase in nitrogen usage did not materialise due to the short cycle times, so it has not been necessary to increase the size of the gas generation plant. Another comment was that on some delicate parts the 8 kW laser beam can be too strong for cutting 0.8 mm or 1.2 mm material, a problem that is easily overcome by turning down the power of the source. To maximise productivity, however, the lower power fibre machine is designated to cut the thinner gauges and the 8 kW laser cutting centre is kept on full power for processing thicker materials. 8 ackermanengineering.co.uk JANUARY 2019
Engineering Capacity | LASER & WATERJET CUTTING Founded as a subcontract machining business for sister company Hobbs Valve, Hobbs Precision Engineering has recently invested in a 3m by 2m Optima 320 twin head waterjet machine from Kerf Developments. Hobbs Valve manufactures, assembles and supplies more than 3000 triple offset butterfly valves every year. With more than 40 machined parts per valve and hundreds of variants, the machine shop has reduced average leadtimes from 12 weeks to just 4 since it was founded. The Optima 320 twin head waterjet machine has further reduced these lead times since its recent introduction. Hobbs Precision Engineering Machine Shop Manager, Mr Craig Llywellyn says: “We identified that we could produce over 1500 clamp ring parts in-house every year, something that would reduce our subcontract reliance, valve unit costs and improve overall production scheduling and leadtimes – and waterjet was the only feasible option for our components. Laser or plasma cutting would introduce heat to our components and with complete certification, traceability and standardised conformity of all constituent valve parts from the steel mill through manufacturing to delivery; heat introduction would impact the properties and conformity of our parts. We investigated the options and the Kerf Optima 320 had the best build quality, software, productivity performance and value for our business.” The clamp ring components are JANUARY 2019
Waterjet cuts subcon costs manufactured from aluminium bronze and a range of stainless steels that vary from 316 to super duplex with dimensions from 50 to 1200mm diameter in thicknesses from 4 to 12mm. “By bringing production of clamp ring parts inhouse, we have reduced our subcontracting costs by over £30,000 per year. Furthermore, we have gained greater control over our processes and quality whilst reducing our lead-time for these parts from 4 weeks to just 1 day.” Hobbs Precision Engineering has now applied the machine to the production of end plates for the butterfly valves. Manufactured from the same materials and quantity levels as the clamp rings, the inhouse production of the 25mm to 100mm diameter end plates has reduced subcontracting costs by an additional £20,000 per annum. “The Optima 320 twin head waterjet machine from Kerf
Developments has reduced our subcontracting costs by over £50,000 a year on just two component types whilst slashing our lead-times and alleviating supply chain issues. We are achieving all this and the machine still has a long way to go before reaching capacity. We are now looking at other Hobbs Valve components that can be cut on the waterjet to contribute to further savings. Beyond that, we are also selling the waterjet capacity to create an additional profit centre for our business. “This capacity and flexibility of the Optima not only reduces internal costs and lead-times, it has become a self-sufficient costcentre and we are selling the capacity to fabrication and plating companies that require precision cutting and profiling of sheet materials.” 8 hobbspe.co.uk www.engineeringcapacity.com
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ADDITIVE MANUFACTURING | Engineering Capacity
Sealing the deal on AM parts Solving porosity problems has allowed a breakthrough in additive manufacturing applications and quality at Graphite AM. In a few short years, additive manufacturing has evolved from a revolutionary technology into a mainstream process. Enabling the fast and cost-effective production of complex high-quality components in a range of materials, it’s helping revolutionise manufacturing in an increasing number of industries. But for all its state-of-the-art advantages, it can also be subject to a more traditional and well recognised manufacturing problem: porosity. In a quest to resolve this challenge, additive manufacturer Graphite AM turned to the porosity sealing specialist Ultraseal International. The result is a breakthrough in both applications and quality. In recent years, additive manufacturing – often referred to as 3D printing – has seen a significant growth in applications. It’s easy to understand why. The process is clean and simple, and produces high-quality components on demand, all without the need for expensive tooling or machining. 3D printing enabled the quick development of prototypes, while small and intricate parts could be costeffectively produced as one-offs or in low volumes. For these reasons, the process was quickly adopted by cutting edge and hi32
www.engineeringcapacity.com
tech industries including motorsport and aerospace. As the technology has become more familiar however, its benefits have been more widely recognised. Today, additive manufacturing is becoming an increasingly viable manufacturing option across all sectors, and a new breed of companies has emerged to meet the demand. Graphite AM’s original customer base was almost exclusively hi-tech sectors including automotive, motorsport, aerospace and defence. While the company still serves these sectors, it has seen a real growth in other industries. Says Jonathan Warbrick, Sales & Marketing Manager of Graphite AM: “Additive Manufacturing is no longer a revolutionary process for prototyping and limited production runs. The cost and turnaround mean it’s of huge benefit for lowmid volumes – typically 250-500 component runs and tooling. Manufacturers have seen this and
are turning to 3D printing for the fast and reliable supply of high quality parts. It’s an area of huge potential, and has become a strategic focus of our work.” Working to a 3D model, Graphite AM primarily uses SLS (selective laser sintering), an additive manufacturing process which deploys lasers to sinter powdered material, binding it together to create a solid structure. While the majority of 3D printing bureaus use standard or glass filled Nylon materials - such as PA11 and PA12 - Graphite AM has developed its own range of SLS blends, including the use of fine graphite particles. As well as having anti-static properties, the use of graphite also improves impact and thermal resistance (up to 170°C), meaning it is particularly suited to lightweight applications where strength and performance are critical factors. Combined with the ability to produce complex shapes and highly detailed designs without the need for metal tooling dies, Graphite AM is now supporting a wide range industry. These include components for
Additive Manufacturing is no longer a revolutionary process for prototyping and limited production runs. The cost and turnaround mean it’s of huge benefit for low-mid volumes – typically 250-500 component runs and tooling
‘‘
JANUARY 2019
Engineering Capacity | ADDITIVE MANUFACTURING automotive applications, turbo system components, plenum chambers, oil and water pipework and manifolds, fuel cells and EV battery cooling systems. They also produce components for mission critical applications including environmental monitoring systems and unmanned aerial vehicles (UAVs). “For manufacturers, the potential is huge,” says Mr Warbrick, Yet while the manufacturing technology has changed, a familiar old challenge remains: porosity. During additive manufacturing, microscopic holes are formed within the body of a part. Though invisible to the eye, these reduce the overall density of the component, potentially leading to cracks, leaks and fatigue. In applications with pressure differentials or which need to be air or fluid tight - for example in cooling systems – this can be an especially critical issue. In 3D printing, this porosity is typically caused either by the printing process itself, or by the powder used in the process. To help minimise this issue, Graphite AM began the search for a specialist porosity sealing partner and chose Ultraseal International which develops, manufactures and supplies porosity sealing chemicals, impregnation equipment and services – and like Graphite AM, has a track-record in the automotive industry. Dr. Mark Cross, Commercial Sales Director at Ultraseal says the company has experience in dealing with porosity in die-casting and electronic component manufacture. JANUARY 2019
He says: “Though the technology is different, the challenge is similar, and we’ve been able to use our knowledge to create an effective solution. It’s pleasing to see that our technology will continue to have a key role to play in sealing components manufactured from new materials and processes such as additive manufacturing.” Ultraseal’s solution involves sealing the component using vacuum impregnation, a process which uses three key stages. First, components are placed into an autoclave containing Ultraseal PC504/66 resin, a high performance thermocure methacrylate sealant. The sealant is applied to the component under vacuum in an autoclave. Once components are immersed in sealant the vacuum is released, allowing the sealant to penetrate into the micro-porosities and leak paths within the 3D printed part through the resultant change in pressure, which draws the sealant into any microporosities and leak paths. Second, a cold wash module removes excess sealant from
external component surfaces and tapped holes. The third process stage is a hot cure cycle. This exposes components to heat for a predetermined time period using a hot water bath which polymerizes the sealant, changing it from a liquid state to solid polymer by applying heat. As a further quality test, the components are pressure tested to ensure they are leak free. Approached initially as a consultant and solutions provider, Ultraseal now delivers an end-toend sealing service for Graphite AM from its UK Service Centre in Slough. This has added real value to Graphite AM, explains Jonathan Warbrick: “Our customers rely on quality components, and we rely on Ultraseal to ensure they’re sealed effectively against the problems of porosity. Our partnership means we’re able to deliver reliable and leak free components, an essential characteristic in high performance parts. Ultraseal also deliver reliable and rapid turnaround. I’ve been impressed both the with service, and product quality.” 8 ultraseal.com graphite-am.co.uk www.engineeringcapacity.com
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Qualiturn are a very modern subcontract machining service. We offer CNC precision Turned and Milled components to your specifications and quantities. We work with all sizes of customers, offering the same service to all. Supplying various market sectors across the world. 18 Merchant Drive Mead Lane Industrial Estate Hertford, Hertfordshire SG13 7AY Tel. +44 (0) 1992 584499 www.qualiturn.co.uk
LATHES.CO.UK Lathes.co.uk store.lathes.co.uk - where Manuals, Catalogues Drive Belts Books Accessories & Spares are listed The world’s largest machine tool reference archive. Manuals, Catalogues, Books, Pictures Specifications, Technical Guides Wardlow, Tideswell, Buxton, Derbyshire, SK17 8RP Tel. 01298-871633 (from overseas: +44-1298-871633) from 09:00 to 23:00 UK time www.lathes.co.uk
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www.engineeringcapacity.com
MANAGEMENT SYSTEMS 8
Qualiturn Products Limited
PRECISION ENGINEERING 8
Mini Gears is a subcontract manufacturer of machined components, gears and racks. Winner of 17 Industry Awards, it has a global customer base, 35,000 sq. ft. facility and over 100 machines. Top Gear House, Bletchley Road Heaton Mersey Industrial Estate Stockport SK4 3ED Tel: 0161 432 0222 www.minigears.co.uk
PSL Datatrack PSL Datatrack is an affordable, modular production control system. The software streamlines the entire production process from quotation to invoice encompassing sales orders, purchasing, planning, shop floor, quality, financial and management.
Bridwey Precision Manufacturing Ltd A one stop shop for…. Competitive CNC machining service. Responsive to customers’ needs & deadlines. Prototype & development parts and assemblies. Low- to medium-volume production parts and assemblies.
DAWSON PRECISION COMPONENTS Manufacturing precision machined components since 1965 Services include: CNC milling, CNC turning, turn/mill machining, sub contracted services, finishing and project management. Greenfield Lane, Shaw, Oldham, Lancashire, OL2 8QP Tel: 01706 842311
dpc.co.uk
DKW Precision Engineering Celebrating our 49th year supplying CNC Turned and Milled Components to all Sectors in both UK and Export markets. From 1 off to Volume, 1-450mm diameter turning, 1x1mtr milling, fast turnaround. Quartremaine Road, Airport Service Estate, Portsmouth PO3 5RD Tel: 023 9267 7747 www.dkwengineering.co.uk
Lily Hill House, Lily Hill Road, Bracknell, Berkshire RG12 2SJ Tel: 08456 345931 www.psldatatrack.com PRECISION ENGINEERING 8
MACHINE TOOL MANUALS 8
CNC PRECISION COMPONENTS 8
Unit 2, Deethe Farm Industrial Est, Cranfield Rd, Woburn Sands, Milton Keynes, Bucks MK17 8UR Tel: 01908 585103 www.jflbroaches.co.uk
Mini Gears (Stockport) Ltd
PRECISION ENGINEERING 8
JFL are broach and broaching specialists with amost 40 years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms.
PRECISION ENGINEERING 8
JFL Broaches and Broaching
MACHINING (5 AXIS) 8
BROACHING 8
DIRECTORY | Engineering Capacity
5 High quality precision machined components 5 Trusted technical support service 5 Complete and bespoke service from conception to completion 5 AS9100D & ISO 9001:2015 approved Oldfield Street, Crosland Moor Huddersfield HD4 5AJ T: 01484 548903 www.thomas-brown-engineering.co.uk
8 Albany Road, Weymouth DT4 9TH Tel: 01305 774 552 www.bridwey.co.uk
JANUARY 2019
Subcontract Machining
13 - CNC Sliding Heads up to 1”; 14 CNC Twin Turret Fixed Heads up to 65mm; 5 - Twin Turret Twin Spindle; 5 - Twin Turret with Sub-Spindle and 4 - Twin Turret; 4 - CNC Single Turret Fixed Heads up to 6” Billet. Centreless Grinding & T/rolling. All materials - Stainless Steel; Nickel Alloys and other exotics a speciality. Prestwood Place, East Pimbo, Skelmersdale, Lancashire WN8 9QE Tel: 01695 727401 www.kirkhamengineering.co.uk
With more than three decades of experience and dedication in producing the highest quality products, Grenville maintains its position as the leading precision sheet metal fabrication company. Unit 3 Newfield Industrial Estate, High Street,Tunstall, Stoke-on-Trent ST6 5PD Tel: 01782 577 929 www.grenville-engineering.co.uk
JANUARY 2019
AS AS 9100 & ISO 9001 Design & Engineering Support Service
TURNING (CNC) 8 TURNED PARTS 8
Parts Assembly Parts
Grenville Engineering (Stoke-on-Trent) Ltd
Budbrooke Road, Warwick, Warwickshire CV34 5XH Tel: 01926 492889 www.batchflow.co.uk
Precision Turned Turned P Parts arts
Kirkham Engineering Co Ltd
Batchflow Engineering Ltd CNC turning capacity from 2mm200mm using high precision Fixed and Sliding Head CNC Lathes. Experience in machining a range of materials, from Low to Medium volumes, to customers specifications.
CNC Milled Components
Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts Accredited to AS9100 Rev D Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk
SPRING MAKING 8
SHEET METAL WORKING 8
REPETITION TURNED PARTS 8
Sutton Road, St. Helens Merseyside WA9 3DJ Tel: 01744 22567 www.wealdpark.co.uk
APT Leicester, Leicester, the ar artt of precision precision..
Simpson Springs & Pressings Ltd Precision manufacturers of a wide range of compression tension and torsion springs. Also circlips, wireforms, contacts, antennas and light pressings. Quality approved to BS EN ISO 9001:2000. Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk
WATERJET CUTTING 8
Wealdpark Ltd CNC mill-turn facility using Star sliding head lathes with bar capacity up to 32mm diameter. Miyano and Doosan fixed head lathes with bar capacity up to 65mm. Hurco vertical machining centre.
SUBCONTRACT CNC TURNING 8
PRECISION ENGINEERING 8
Engineering Capacity | DIRECTORY
ICEE Comprehensive fabrication facilities offering complete turnkey solution. Design, Precision Engineering, Sheet Metal Fabrication and Welding. Prototypes, one off or batch work. Waterjet Capacity: 4m x 2.25m & dash; materials up to 230mm depth. Aluminium Alloy Specialists. 20 Arnside Road, Waterlooville, Hampshire PO7 7UP Tel: 023 9223 0604 www.icee.co.uk
www.engineeringcapacity.com
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FARNBOROUGH | Hants | GU14 6XL
5th – 7th February 2019 9.30am – 4.30pm (3.30pm close Thurs)
The UK’s must-attend event for every industrial engineering and manufacturing professional
FREE SEMINARS & PARKING
Meet over 800 national and international suppliers under one roof in the brand new Farnborough venue next February at Southern Manufacturing & Electronics (inc AutoAero) 2019. See live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labeling & marking, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment. Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 5th February.
Pre-register online now for your free entry badge and show preview at www.industrysouth.co.uk Supported by:
SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd Tel 01784 880890 email philv@etes.co.uk
Register here with your smartphone