Engineering Capacity January 2022 Digital Edition by andy sandford

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

January 2022

MACHINED COMPONENTS | ELECTRONIC | SHOW PREVIEW

Bespoke equipment enclosures and structures: complete solutions from ICEE Managed Services See story on page 14

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FOR BUYERS OF CONTRACT MANUFACTURING SERVICES Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Commercial Director: Arfan Qureshi sales@engineeringcapacity.com Tel: 0207 241 4627 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: 01737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company no. 10567217 ISSN 0306-0179 COMING UP IN OUR MARCH 2022 ISSUE Turned Parts, Forming & Fabrication, Aerospace & Defence, Heat & Surface Treatments, Heavy Engineering, Measurement, Inspection & Testing Services, MACH 2022 Preview 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

Editor’s View What does 2022 have in store for us? Well, your guess is as good as mine, but I expect more of the same with an added twist of political turmoil and rampant inflation. If you are under 40 you will never have seen inflation rates in double figures so the upcoming cost of living crisis could be a dreadful shock to the system. At the moment though, the subcontract manufacturing market is holding up pretty well. As usual, activity tailed off a bit at the end of the year, but at the last BTMA General Meeting (see report on page 12) members reported that they were almost all experiencing high levels of enquiries and orders. The difficulty part will be fulfilling these orders in the face of material supply problems, material and energy price rises, and ongoing recruitment issues. Staffing problems have been a constant for manufacturing for some time, but constraints on materials and rising energy costs are more recent worries. Materials costs are on a constant upward trend with no end in sight and the lack of availability fuelling the rise – and we will soon find out for ourselves the real impact of energy price rises. Material lead times are going out from weeks to months and those shortages are further fuelling inflation. The latest Make UK/BDO Manufacturing Outlook Survey confirms the reality of the threat. It concludes that prices had increased for the fourth quarter in a row, and this was expected to continue into 2022 – with the Q4 figures the highest in the survey’s history. So what’s the answer? Well, one thing manufacturers can do is invest in more productivity now, lock in current interest rates and protect their margins. Andy Sandford, Editor

Member of the Engineering Industries Association

JANUARY 2022

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Contents JANUARY 2022

24 CASTING & FORGING

News

Features

06 FRP moulded lock gates 06 ECS innovates for Sunbury Dry Dock

12 BTMA: Learning from each other 16 Laser & Waterjet Cutting 06 Flexible micro-manufacturing

08 Neida invests in skills 06 Academic Support for engineer

19 Machined Components 06 Five-axis for tank hatch

09 Quality has no borders 06 44 cars, 5 countries 3.5 days 10 Presses ready for reshoring 06Cotmor adds capacity

26 ELECTRONICS

24 Casting & Forging 06 First casting for new V12 26 Electronics

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

January 2022

MACHINED COMPONENTS | ELECTRONIC | SHOW PREVIEW

30 Automotive 06 The road ahead in 2022 32 Southern Manufacturing Bespoke equipment enclosures and structures: complete solutions from ICEE Managed Services See story on page 14

39 BTMA Directory

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Front cover Fuel Cell System's HyQube is a cost effective, redeployable hydrogen refuelling system and ICEE manufacture the product enclosure. (see page 14).

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31 AUTOMOTIVE JANUARY 2022

Engineering Capacity | INDUSTRY NEWS A manufacturing match made in the West Midlands has provided a much-needed reshoring solution for innovative new body drying technology. Tooling2000, which is located in Winson Green, came to the rescue when iDry Limited’s roll-out of its iDry product was set to stall due to the existing Chinese supplier giving a nine-month lead time for three crucial parts. The metal stamping and precision component specialist used its expertise in forming and prototyping, combined with a wide array of CNC and laser cutting machining, to produce an emergency tool that could produce the same parts used in the fan housing - in just seven days. In even more positive news, the components are better quality and more aesthetically pleasing thanks to the use of stainless steel and the new process, with initial orders placed worth more than £50,000. This UK reshoring success story could well become a millionpound opportunity for both companies, with Much Wenlockbased iDry expected to sell 200 units every week as its unique airdrying technology is embraced by local authorities, care homes and luxury hotels. “The iDry fits onto a wall and uses a patented design to push air through vents to dry your body in as little as two minutes,” explained Gary Seale, Managing Director of iDry Limited, the UK’s only manufacturer of body dryers. JANUARY 2022

Reshoring saves product launch

“It is a breakthrough that is proving extremely popular with the care sector where it can help the elderly or disabled enjoy independent living for longer. This has seen a major spike in interest, but just has the orders were rolling in an existing Chinese supplier tried to hold us to ransom with lead times and minimum order quantities. “I won’t lie, it felt like they were putting a gun to our head, so we knew he had to accelerate our desire for more UK content by switching supply to a domestic company - the only issue being we had to find an answer in seven days.” He went on to add: “A chance intro on LinkedIn has proven a match made in heaven with Tooling2000 delivering a solution

that is better in what was an unbelievably stringent lead time. Better still, the early signs are that we can place more parts with it, something we are currently looking to explore.” The engineers at the Birmingham-based firm quickly got to work with some soft tooling that allowed it to get to grips with the initial three parts and then a second tool was put in place that offered greater repeatable quality and facilitated a change from galvanised steel to stainless steel. Using laser cutting technology and the latest CNC 3-axis machines, a new process has been developed that reduces manual work and assembly time – two important features as volumes escalate. 8 tooling2000.co.uk www.engineeringcapacity.com

INDUSTRY NEWS | Engineering Capacity ECS Engineering Services has installed the UK's first ever set of moulded fibre reinforced polymer (FRP) lock gates on the River Thames at Sunbury Dry Dock. The new gates, fitted on behalf of the Environment Agency, offer significantly reduced maintenance requirements and whole life costs, compared to steel or timber alternatives. The mitred lock gates are a critical part of the dry dock facility; enabling the Environment Agency to maintain its vessels adjacent to the navigable River Thames. The gates retain a large volume of water upstream, and with personnel often working in the dry dock area behind the gates, maintenance of the gates and the surrounding civil structure is crucial for both functionality and safety. Environment Agency surveys determined that the previous timber gates had reached the end of their service life and needed to be replaced to maintain safe usage of the dry dock facility. Consisting of glass-fibrereinforced polymers and a special thermosetting resin, FRP is layered for exceptional strength, durability and lightweight construction. With FRP used already for large lock gates in the Netherlands, ECS took the opportunity to apply the technology to lock gates for the first time in the UK. "FRP has a leading edge over other materials," Steve Crapper, Precontract Director at ECS explains. "Thanks to tremendous longevity, FRP lock gates are essentially maintenance free - the 6

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FRP moulded lock gates

lifespan of an FRP panel is at least 100 years. Timber gates would need structural maintenance within 10-15 years, while steel gates require a full repaint with an anti-corrosion coating every 15-20 years. This excludes any ad-hoc repairs that may be needed. "The maintenance of lock gates involves a significant amount of temporary works. Dewatering the channel using extra equipment not only poses additional challenges for maintenance engineers, but also impacts on the use of the lock and disturbs the surrounding environment. Considering this, FRP lock gates provide a great value advantage in terms of both maintenance costs and service life." FRP is stronger than steel, wood and concrete. Furthermore, FRP offers a lower CO2 footprint due to improved material sustainability an important factor for all infrastructure development

projects. Each FRP lock gate is prefabricated, which speeds up the installation process and minimises work on-site. The material is also inherently fire resistant. Each of the two replacement FRP gates measures 4m high x 4.5m wide and has a mass of approximately 10 tonnes. David Searle, Operations Manager at ECS, said: "FRP gates can be designed to be lighter than timber and significantly lighter than steel alternatives. This lightness means that operating forces to open and close gates are reduced, which results in less energy consumption. Another benefit is less wear on components such as bearings, along with reduced strain on the surrounding dock chamber structure. The Sunbury gate design also enabled the existing hydraulic control system to be retained." 8 ecsengineeringservices.com JANUARY 2022

INDUSTRY NEWS | Engineering Capacity Neida is sponsoring, Isle-of-Wight Process Engineer, Drew Macarthur through a Bachelor's with Honours in Mechanical and Manufacturing Engineering Degree at the University of Portsmouth. Neida is a UK contract manufacturer of precision turned and milled components with headquarters and distribution located in Stoke-on-Trent and Neida Blue 62 production located on the Isle-of-Wight. After completing a BTEC Level 3 Extended Diploma in Engineering, achieving Triple Distinction in June 2019, Drew took the decision to extend his Higher apprenticeship through an HND Engineering course at the University of Portsmouth. Originally a week of work experience at Neida Blue 62 Isle-of-Wight cemented Drew's decision to commence a University of Portsmouth HND in Mechanical Engineering course run by Isle-of-Wight College (CCEAAM). This course covered the fundamentals of engineering sciences, theories, and management. Drew has been continuously mentored and supported throughout his apprenticeship by the team at Neida Blue 62. With hands-on experience of setting machines to estimating new projects, all the hard work paid off earlier this year when Drew graduated with a Merit HND in mechanical engineering. "The opportunity to continue my studies with sponsorship 8

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Neida invests in skills

from Neida will enable me to achieve an industry-recognised qualification, within a leading turned parts manufacturing company, without the debt of student loans," said Drew Macarthur. With the passion and drive to continue his academic studies in engineering in October 2021, Drew commenced a Bachelor's with Honours course in Mechanical and Manufacturing Engineering at the University of Portsmouth, only possible with sponsorship from Neida. The modules will include the study of Materials and Engineering Systems, Design and Sustainable Development and Quality Management. Drew will focus on Robotics and Automation in manufacturing for his dissertation project, calling on

support from market leaders and innovators in robotics technology. So far, Neida says it has had great buy-in from a number of leading companies and organisations, with special thanks to Fanuc, Mazak and the MTA for their support to date. Drew's focus on problemsolving and process improvements are already proving invaluable in supporting Neida's continued growth. "This is an exciting time for technology, and I hope my work with local schools and colleges will inspire the next generation of scientists and engineers." During his studies, Drew has also enrolled as a STEM Ambassador, supporting and promoting the engineering sector to local students in Hampshire and the Isle-of-Wight. 8 neida.co.uk JANUARY 2022

Engineering Capacity | INDUSTRY NEWS

G&P’s capabilities of being able to react quickly and efficiently to resolve potential quality issues, no matter where they are.” 8 gpqm.com

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reassurance that all of its vehicles had passed the test and, subsequently, that no faulty vehicles were released for sale. “It also clearly demonstrated

JANUARY 2022

Quality has no borders

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A complex cross-border quality inspection by quality management provider G&P involved visiting five countries and inspecting 44 cars with potential mechanical issues. Not only this, the project was completed in just three and a half days by two of G&P’s vehicle technicians using an electrical measuring device to inspect the potentially faulty component. Thankfully, all the components passed the test. However, had the tests on the potentially faulty components not taken place then there was a risk of vehicle noise and drive failure. The manufacturer could not take the risk of any damage to its reputation by allowing the deliveries to go ahead without the additional quality checks. Geoff Cousins, chairman at G&P, said: “This particular project required a very tight schedule for a round trip to Belgium, Germany, Poland, Sweden and Switzerland to plan the appointments in each country so that deadlines could be met. “Added to the mix was that the cars had already been built and were distributed in these countries ready to go to market. It needed, and had, military style precision planning.” Even before the project started, G&P only had 24 hours to plan for the challenge which involved specialist training for the two vehicle technicians. Geoff added: “The importance of the project was that it protected the brand reputation of the car manufacturer as it had the

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INDUSTRY NEWS | Engineering Capacity Brierley Hill-based Cotmor Tool & Presswork has invested £250,000 in new presses and ancillaries to take advantage of new domestic and reshoring opportunities The investment with Worcester Presses includes two 110 tonne and one 160 tonne Chin Fong machines along with two Tomac decoilers and Titan monitoring technology designed to improve tool and press life and a die cushion to help accommodate multi-functional tools. Cotmor has seen sales soar to £2m following the easing of lockdown and is now setting its sights on an additional £1m of orders over the next twelve months. “Volumes have bounced back stronger than any of us expected and this has given us the impetus to look at new equipment that will make us faster and give us capacity to take on up to £1m of new work,” explained David Cotterill, who runs Cotmor with his wife Wendy and daughters Louise and Natalie. “80% of our work is overseas and we ship deep drawn, precision and progression

Visit our website or contact us for a quote or advice

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Presses ready for reshoring

presswork to clients in Brazil, China, Germany, Japan, Turkey and South Korea. A lot of these components are technically difficult to produce and, since lockdown, we are seeing an increasing number of enquiries from firms looking to reshore to achieve security of supply.” He continued: “We knew we needed more capacity so started talking to Worcester Presses about our future requirements and the flexibility of the machines to be able to produce components destined for agriculture, commercial vehicle, foundry and the food and drink sector. Worcester Presses has experienced a similar upturn in

fortunes, seeing demand for its range of hydraulic and mechanical presses and ancillary equipment rise by 30% over the last six months. The Dudley-based company, which has taken on an additional two people, has been working with Cotmor to deliver a tailored ‘production’ solution for about nine months, culminating in the installation of the three presses. It is now exploring the possibility of sourcing a 400 tonne Chin Fong to give the press and toolmaking specialist access to one of its biggest machines to date. Russell Hartill, Managing Director at Worcester Presses, went on to add: “The Cotmor partnership is a fantastic example of two Black Country businesses working together to deliver world class manufacturing. “David and his team’s expertise is second to none and, when this is combined with our technical knowledge and the performance of our presses, you have all the ingredients you need to be competitive and win work from overseas.” 8 cotmor.co.uk JANUARY 2022

BTMA | Engineering Capacity At its November meeting in Cambridge the British Turned Parts Manufacturers Association (BTMA) welcomed its new President and shared insights from members on the state of the market and the issues facing them. Incoming President Stephen Doyle of Trust Precision, who took over the reins from Nicholas Groom of Qualiturn, highlighted the value of this type of meeting of like-minded peers. He said: “In these times of information overload these meetings provide a chance to close out the white noise and look at what we are doing in our daily business and learn from those who are treading, or have trod, the same path.” In his President’s Report, Stephen Doyle explained what he saw as the three key benefits that were the cornerstones of BTMA membership. The first of these, he said, was credibility by association, which was particularly important for young and growing businesses. He said: “You can’t just buy this credibility, membership is awarded not purchased. Everyone is vetted.” The second cornerstone was the tangible benefits of membership, such as discounts on goods and exhibitions, inclusive advertising and the Buyers Guide. He also pointed to the value of trade leads that come from the BTMA. He explained how his company had followed up on a RFQ in a member communication that led it to win a new export 12

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Learning from each other

8 Incoming BTMA President Stephen Doyle

customer in a market they hadn’t previously touched. That had now generated a six-figure turnover. The final cornerstone was the intangible benefits that come from sharing experiences as part of a truly focussed collective. At the meeting he said: “There is massive experience in this room

and you can’t buy that resource. Despite being in competing companies we all work together for mutual benefits.” As one member pointed out: “When you look at the return of investment on membership we are all net recipients. You learn something every time you come to a meeting.” The value of this shared information became clear as members discussed the state of the market and the issues facing them. Almost without exception members were experiencing very high levels of enquiries and orders. Companies were winning a lot of new business, with reshoring a significant factor for some, and this was leading JANUARY 2022

Engineering Capacity | BTMA several companies to invest in new machinery. The difficulties came in overcoming problems of material supply, material and energy prices and the difficulty of attracting and retaining staff. As one member put it: “Materials are an hourly discussion that is a massive constraint on what we can do. We are learning to manage it by spreading the sizes and grades of material we use.” The inevitable result was that many turned parts manufacturers are having to extend their delivery times and prices are going up. There was little consolation to be had from material suppliers who reported lead times going out from a matter of weeks to several months. Customers can also expect energy and alloy surcharges. One supplier said: “I can see nothing on the horizon that will significantly reduce lead times and nothing that will lead to a reduction in prices. Suppliers were prioritising existing customers and there were lots of new business opportunities that they were not able to service at the moment. Delivery times on new machine tools were lengthening significantly too – many manufacturers are having problems getting the semiconductors and other materials they need to build the machines. Subcontractors were advised to plan well ahead for future investments. A problem common to all JANUARY 2022

members was the difficulty of training and retaining suitable staff. “Skills are always an issue,” said one member. “We need to recruit and it is a challenge.” Attracting trainees and apprentices with the right mindset was also a problem. One member had been forced to sack three out of four apprentices they had taken on because of embedded behaviour issues. Still, there was now some light on the horizon as engineering was back on the curriculum in some schools. Following the discussion on the state of the industry the meeting welcomed a guest speaker, Terry Boniface, Assistant Director Electronics and Machinery at the department of Business, Energy & Industrial Strategy. He explained aspects of the Government’s ‘Build Back Better’

8 BTMA President Stephen Doyle with Jimmy White

strategy in areas such as the decarbonisation of industry. What became clear during members’ questions was that the Government was not offering much in the way of direct support to SMEs to help deliver these top line strategies. The pressure is on the OEMs and Tier Ones to drive objectives such as Net Zero Carbon down the supply chain to their suppliers. Following what was universally agreed was an interesting, informative and enjoyable day, members and their partners enjoyed a black tie dinner and disco with an auction in aid of Children in Need and a special guest, snooker legend Jimmy White, who entertained everyone with anecdotes from his career. 8 btma.org www.engineeringcapacity.com

SUSTAINABILITY | Engineering Capacity

Changed times, new methods With the restrictions on face-toface meetings during the Covid pandemic manufacturing contractor ICEE Managed Services turned to online remote methods for external meetings with customers. Using video-conferencing, coupled with Solidworks 3D CAD and modelling software, it was able to continue working closely with its customers, including Fuel Cell Systems Ltd (FCSL), a leading specialist in cutting-edge fuel cell applications. Both companies gained significant benefits including higher productivity arising from no time-wasting travel, more opportunity to explore iterations, faster design reviews and for FCSL, reduced time to market. FCSL’s newest product, HyQube, is a re-deployable hydrogen refuelling system. The enclosure is built by ICEE and then shipped to FCSL to be incorporated into the product. Before HyQube, ICEE first became involved when FCSL required an adaptable enclosure for a power generation product to serve several different applications. It accommodates three hydrogen fuel cells linked together, producing a 12kW output. ICEE already had relevant experience in the application of hydrogen fuel cells and the production of its own product, a hybrid electricity generator for off-grid power supply, based on an 14

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advanced fuel cell from a world leading third party manufacturer. FCSL began working with ICEE in October 2019. FCSL’s Chief Technical Officer, Tom Chicken sent the contractor concept sketches plus a specification, so these could be turned into a design for manufacture. The work was delayed until March 2020, but this coincided with the first Covid-19 lockdown, which prevented further face-to-face meetings. Instead, ICEE suggested using video-conferencing, with design details displayed on screen in Solidworks, modelled in three dimensions and manipulated dynamically in real time, as if all participants are sitting at their own CAD workstation.

8 Fuel Cell System's HyQube is a cost effective, redeployable hydrogen refuelling system and ICEE manufacture the product enclosure

“In some ways videoconferencing is better than faceto-face meetings,” says Tom Chicken. “I feel you still need the latter, but what videoconferencing allowed us to do was quick reviews. ICEE would send out a 3D model beforehand, I could review it first and come up with questions. “We would then have a threeway video chat, where we had the 3D model on the screen and I could talk through my alterations or modifications. Most changes could be made immediately in real time.” JANUARY 2022

Engineering Capacity | SUSTAINABILITY Design of an enclosure is crucial The first order was made for a fuel cell manufacturer, enabling FCSL’s customer to use the product as a test unit to evaluate an application. For another customer, a unit will provide electricity to run Europe’s first self-sufficient, highly publicised hydrogenpowered house. Dimensionally, the enclosure looks like a nineteen-inch computer rack, but the similarity ends there. Inside, the hydrogen fuel cells located in the upper part of the enclosure generate heat. Cooling is achieved with thermostatically-controlled fans and ducting. ICEE has substantial experience in equipment enclosure design and in particular, the vital topic of cooling – gained in applications such as telecommunications. With hydrogen and methanol fuel cells, providing the right protection and efficient cooling is key to safety. “The design of an enclosure is crucial, fundamental to the whole project,” says Tom Chicken. “ICEE’s experience in cabinet design, manufacturing and build is so useful. They already know about relevant details, such as how to design and fit a door and seals, how shelves can best be bolted together, or designing special ducting to go on the back of fuel cells to ensure hot air is only directed one way, safely. “Whilst we are capable of designing individual parts and we’ve designed prototype enclosures in the past, ICEE’s existing and combined knowledge of design, manufacture, JANUARY 2022

8 FCSL’s Chief Technical Officer Tom Chicken says video conferencing allowed quick design review

installation and maintenance is, I think, the key factor for us here.” Virtual prototyping For some years and using the advanced features of its Solidworks CAD system, ICEE has done ‘soft’ prototyping on-screen. Often, a physical prototype is unnecessary, as the design for manufacture software is so well developed it is possible to go straight from the screen into production. There are several major benefits. All possible issues and risks may be identified and rectified at this flexible stage. More iterations may be usefully explored in less time. Thanks to optimisation capabilities, sheet metal components may be prechecked for the best and least costly way to cut or fold a part – ICEE has both laser and waterjet cutting, plus bending, welding and assembly capabilities. It all ensures functionality and fabrication is

right-first-time, rather than finding out costly mistakes after one or more physical prototypes are made. Waste is minimised or eliminated, reflecting true lean manufacturing principles. “That’s the way everything is going now,” says Tom Chicken, “3D modelling packages are so accurate you don’t need to build something first.” But he adds, “. . . sometimes you just need to see the physical structure before you can fully understand the possibilities.” A case in point is the FCSL HyQube mobile hydrogen refuelling product the fuel cell specialist designed and developed, part of a range of refuelling options offered for different transport sectors. This is a 1.8m square structure, housing hydrogen tanks and electrical plus fuel delivery systems, used outside in the open air. Before ICEE became involved, a prototype enclosure had been built by a local fabricator from steel sheet metal. Evaluating this ICEE suggested a number of changes, aimed at making the product less costly to make, but maintaining the high quality FCSL demanded. For example, using aluminium parts and panels to reduce weight and improve weather resistance; bolting parts together rather than welding to reduce costs. FCSL expect a healthy demand for this product, so getting design for manufacture right and hence economic to produce is very important. 8 icee.co.uk www.engineeringcapacity.com

LASER & WATERJET CUTTING | Engineering Capacity

Enhanced design to delivery offer Nuneaton-based Unifabs is enhancing its ‘design to delivery’ offer with a new automated fibre laser and an automated press brake. The equipment includes an Amada Regius CNC fibre laser profiling centre with load/unload automation and storage, which has improved laser cutting speeds by 50% on some parts. The press brake on order is an Amada HRB-ATC, the first mid-range press brake in Amada’s portfolio to feature automatic tool-change capability. Founded in 2007, Unifabs has grown into a £12 million turnover business with 125 people. Supplying precision sheet-metal parts to an enviable customer base of blue-chip manufacturing companies across a host of industries. “Our goal is to be much more than just a supplier of sheet metal fabrications and parts,” says Managing Director Tom James. “We want to be a manufacturing partner to our customers, supplying a start to finish service. Whether we’re supplying sheet metal components just in time to a manufacturing line, or controlling the entire production process on a contract manufacturing basis, we operate as an extension of our customers’ business.” Unifabs has seen growth of around 65% over the past two years and today operates from a single site with five factories 16

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that total 52,000 ft2 of manufacturing space. “We don’t specialise in one particular sector, but strongperforming industries right now include HVAC, catering equipment and construction,” says Mr James. “To ensure timely deliveries to our customers we continuously invest in the latest manufacturing technologies.” The company’s laser cutting capacity was struggling to keep pace with rising demand, with a lot of cutting still outsourced, so the Unifabs decided to invest in the new laser to improve lead times for its customers and regain control of its parts, It is primarily processing mild steel, galvanised steel and Zintec from 1 to 8 mm thick with batch sizes typically from 50 to 200. At present the company is running a double shift during the week, plus a weekend shift. “The REGIUS is a 6 kW laser, whereas our other Amada laser

capacity is 4 kW,” says Mr James. “Combined with the more intelligent head movement, we find that any parts over 4mm thick are around 50% quicker to cut, shortening lead times for customers without any compromise in quality. It’s a great step forward for Unifabs and our partners. The new press brake is Unifabs’ first with automatic tool change capability. “We manufacture a lot of samples, prototypes and small batch runs to help get components ready for serial production,” explains Mr James. “We have 10 people in our CAD team, so a lot of our work comes from the product development side of our business. However, these parts often have long setup times, so we’re really hoping that the new press brake’s ATC capability will have a big impact on throughput in this area.” 8 amada.eu/uk-en JANUARY 2022

Engineering Capacity | LASER & WATERJET CUTTING Laser technology investments at ES Precision allow it to use erosion cutting to fabricate precision components from sheet metal on a scale which traditional laser cutting cannot efficiently achieve. The laser erosion cutting workstation and computer microscope measuring system were part funded by a ‘bounce back’ grant from the Getting Building Fund in recognition of the important innovation that this technique brings to precision manufacturing companies. The laser is a Coherent-Rofin PowerLine F100, a galvodelivered 100W fibre laser, and the microscope is a turnkey digital system from Keyence. All metals can be processed with the equipment and the same laser technology can also produce detailed functional or decorative markings on the cut components. Erosion cutting uses a deflection head to direct the focused laser beam across the working area. Each pass removes several microns of material and even thousands of passes can be completed in minutes until the pattern is cut cleanly. In one application, intricate CAD cog patterns from the customer were simply uploaded to the laser and cut from 0.35mm brass. These prototype designs were produced economically at a batch volume of only five, but volumes of thousands could economic before other mass-production techniques need to be considered. After cutting on the laser, the parts were subjected to a semiJANUARY 2022

Flexible laser micro-manufacturing

automatic QA process using the measuring system: extracting key dimensions for first-off units. Subsequent parts were 100% QA tested against a pre-set tolerance window of critical dimensions on a simple, one-click inspection which provides a simple pass/fail response. ES Precision has been receiving enquiries for laser micromachining from companies

operating in a diverse range of industries such as medical devices, fuel cell and battery, lab-on-a-chip and motorsport. Suitable applications are trialled without charge; erosion cutting is particularly well matched to intricate metal cutting of components from a few millimetres to about 20 centimetres from metal sheets of up to 2mm thickness. ES has so far processed many thin metals including precious (gold, silver and platinum), specialist (molybdenum, tungsten, tantalum, vanadium and titanium) as well as more commonplace engineering materials (stainless and carbon steels, brass, copper and aluminium). 8 https://esprecision.co.uk/

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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LASER & WATERJET CUTTING | Engineering Capacity

Laser manufacturing partners Needham Group, which employs 70 people at its Whitchurch base, has selected PP Control & Automation (PP C&A) as its new manufacturing partner responsible for the assembly of its N-Lase range of laser marking products. The initial agreement will see up to 10 laser systems being built every month at a dedicated production cell at PP C&A’s world class facility in Cheslyn Hay, with the prospect of monthly volumes rising to 20 units as sales increase towards the £10m mark. This will eventually include the N-Lase Desktop, Desktop Pro, Benchtop, Handheld, Workstation and Integrated Solutions models. Aled Ellis, Managing Director of Needham Group, said: “Our ‘USP’ is not in building the machines, but in developing the innovative uses and applications for laser technology - that’s where we come into our own and where we anticipate the real growth to come from. “Once PP Control & Automation proved it could build the prototype machine successfully, it made complete sense to look at a more strategic arrangement, first starting with the Desktop and Desktop Pro models and then, over time, moving on to the rest of our range. “We have handed over the complete assembly process, including management of the supply chain.” 18

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A few weeks into low volume production and the strategic partnership is already reaping dividends, with lead times halved to just two weeks from the bill of materials arriving at PP C&A. Quality guidelines have been surpassed and several efficiency improvements have been identified that could speed assembly up even further or give Needham Group designers the opportunity to modify standard models to encompass additional features. Four people are directly employed on the dedicated assembly line, plus a wider support team covering the shared functions of Engineering, Supply Chain and Customer Services. Tony Hague, PP Control & Automation’s CEO, said: “It’s all about making sure we fine tune the build and explore ways in which we can standardise processes to make assembly and customisation slightly easier than it is at the moment.

“The longer-term picture is that we will need to be in a position to build over 300 laser marking machines every year, something we can comfortably do at our site in the West Midlands. “Our aim is to become a true partner in every sense of the word and to play an important role in Needham Group achieving its £10m ‘laser’ blueprint, delivering capacity, efficiency and, as the relationship develops, innovation in design.” A spin-off benefit of the outsourcing deal is creating more capacity in Needham Laser Technologies’ special projects team. Prior to this agreement, R&D experts and engineers were limited to how many custom machine builds they could take on, but these restrictions have now been lifted and could pave the way for a new £multi-million opportunity. 8 ppcanda.com JANUARY 2022

Engineering Capacity | MACHINED COMPONENTS Birmingham-based Tooling 2000 is celebrating 25 years in business with a six-figure investment in new machinery. Tooling 2000 specialises in the manufacture of both prototype and production parts, through the manufacture of tooling, 3 & 5-axis machining, press work and 5-axis laser cutting. The company has invested over £1m in new machinery including 5-axis milling, large capacity 4.2m x 2.6m machining and a 500mm x 1m CNC lathe. Together with additional investment made in CNC coordinate measuring, an inhouse scanning and reverse engineering facility and Auto form die simulation – allow it to provide a complete in-house service. The company says this investment is part of ambitious growth plans founded on a philosophy of providing a complete metalworking solution, encompassing design and feasibility, CNC machining, prototyping, precision tooling, presswork and laser cutting under one roof. The company was founded in 1996 to specialize in offering tailored solutions for the metal stamping and component manufacturing industries, from initial concept and part feasibility, through to the finished component. Managing Director Gary Williams said: “Our existing largescale capabilities and flexibility has enabled us to build a strong customer base including blue chip brands such as Aston Martin, Rolls Royce, Bentley and Jaguar, Land Rover. JANUARY 2022

Blue chip supplier invests £1.75m

“In what will be our 25th year in business, the significant investment in new machinery and plant further adds to our capabilities enabling us to offer the complete metalworking solution in house setting the foundation for our plans to double turnover within the next three years. “Our investment also extends beyond CNC machinery. For example, our new press brake and spot-welding capabilities will be live by the end of Q4 2021, and we have also invested £750,000 on a

new Trumpf Trucell 7040 Fiber laser with 4m x 2m bed, arriving in Q1 2022 to complement the same size CNC and press capabilities.” Gary Williams added: “As a specialised engineering firm, we recognize that having the latest machining technology and largescale production capabilities only takes you so far. Our differentiator is the expertise of our people and our continued commitment in developing our team together with the investment in new technology. 8 tooling2000.co.uk

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 NuMachine has installed two five-axis turnkey systems to machine cast aluminium automotive components for sister company Sarginsons. Two Doosan five-axis machining centres, a VCF 850LSR and a DVF 6500, with customised workholding systems were supplied by Mills CNC in collaboration with a number of its technical partners and installed in NuMachine’s Hereford factory. They are being used to machine small batches of high precision components for Coventry-based Sarginsons Industries to fulfil a long-term contract with one of its automotive customers. NuMachine managing director Brandon Davies said: “Although we are an independent precision subcontract engineering company in our own right – some 30-40% of our business, year-on-year, does derive from Sarginsons. “As such the strong and mutually beneficial relationships between both companies has enabled us to build up significant in-house knowledge and expertise in machining lightweight components for those sectors and industries served by Sarginsons…the automotive sector being particularly prevalent. “As a company with a reputation for taking on, and succeeding with, difficult machining jobs we were approached by Sarginsons in 2020 to see if we could help them with a specific machining contract – one where their existing supplier was finding it difficult to meet the customer’s stringent quality and lead time requirements. 20

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Machining auto castings

“Having looked at the parts in detail it was clear that we would need new 5-axis machining capacity to be able to machine the parts in question…in the quantities required.” The machines were acquired to machine two specific components: the VCF 850LSR is used to machine long, thin and asymmetrically-shaped (left and right) B Pillars, and the DVF 6500 to machine (left and right) performance-critical front suspension mountings. The B Pillars and suspension mountings parts have complex profiles. They are machined to tight geometric tolerances and exacting surface finishes, and feature a number of intricate details including thin walls, multiple cavities, blind holes etc. To ensure that the parts’ structural integrities are maintained during machining, and to make job set-up and cycle times

as productive and efficient as possible, both machines were supplied to NuMachine with innovative and highly-customised workholding solutions that, prior to the machines’ delivery, had been designed, developed and proven out by Mills CNC at its campus facility in Leamington. Brandon Davies added: “Although the machines were installed at our facility in May 2021, the project, in reality, began some months’ earlier and involved us working closely with Mills and a number of the company’s technical partners to design and integrate ‘best-in-class’ turnkey fixturing to both machines. “To ensure we were able to meet our customer’s lead times and to help keep costs down we needed one workholding solution for machining both (left and right) parts, and to machine the parts in one hit.” 8 numachine.co.uk JANUARY 2022

Engineering Capacity | MACHINED COMPONENTS Fareham-based CNC machining company, Penta Precision, has increased its measurement capabilities by investing in a Baty R400 ‘Shadowgraph’ profile projector supplied by Bowers Group. Penta Precision is an ISO 9001:2015 accredited company with extensive experience in machining high-quality components for several industries, including aerospace, military and defence, R&D, medical and pharmaceutical. In 2021, the company devoted significant investment into new, larger premises, as well as boosting its workforce and its capital equipment to include 5axis machinery as well as the Baty R400 profile projector. In doubling the size of its workshop, Penta Precision has increased both the capacity and capability of its dedicated CNC machining service. The R400 at Penta is used daily by the quality department for first-off checks and final batch inspections of CNC milled and turned parts, as well as being used by its machinists to carry out inprocess checks. The projector enables the company to measure a much wider range of parts due to the increased measuring range available when compared with the previous projector. This had caused an overreliance on using the CMM for simple dimensional checks, so investment in the R400 is preventing delays in inspecting first offs, as well as releasing the CMM for more complex work. The Baty R400 bench-mounted profile projector is suitable for JANUARY 2022

Precision enhanced both the shop floor and the standards room and combines high accuracy non-contact measurement with inspection with a large 300mm x 150mm measuring range. With a choice of digital readouts and optional automatic profile edge detection, the R400 ensures a projector that fits a wide range of requirements. Mike Steppens, Lead Quality Inspector at Penta Precision

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said: “We have a high mix of work, and so there are high demands on inspection. The R400 has helped to free up the CMM and prevent delays in first off inspection. The majority of the parts which can now be measured on the R400, we were having to use the CMM as the previous projector had too small a working window." 8 pentaprecision.co.uk

FM10101

Manufacturers of High Quality Mill-Turned Parts

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MACHINED COMPONENTS | Engineering Capacity PRV Engineering, Pontypool, has invested in new 5-axis capacity for the manufacture of a steel hatch for an armoured tank. The German-built Spinner U5630 trunnion-type, 5-axis, vertical-spindle machining centre was delivered in mid-2021 by Whitehouse Machine Tools. The U5-630 is devoted to producing a fabricated steel hatch measuring approximately 300 x 200 x 200 mm for an armoured tank in a cycle time of 5.5 hours, halving the cycle time of the previous production route. This involved milling and boring the three-part fabrication on either of two much larger 5-axis machining centres. Three setups were required and the total production time was 10 hours, which meant that it was not feasible to produce one hatch per day during a single shift. Apart from raising the efficiency of production, another reason for investing in a machine dedicated to the job was a need to free up the larger capacity plant to fulfil an increasing amount of plate work. In any case, it is more difficult and therefore more time consuming to hold tolerance on a larger machine, as the heavier moving elements tend to cause vibration. A factor in PRV Engineering's managing director Simon Jones and works director Alun Cox choosing the Spinner machine was its generous 630 x 530 x 465 mm working envelope in a footprint of just 2.75 x 2.53 metres. The U5-630 has to be highly accurate, as some tolerances on 22

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Five-axis for tank hatch

the hatch fabrication, which comprises three pre-machined and welded parts, are very tight. The run-out of two holes bored from either side of the component after rotation through 180 degrees has to be to within 0.04 mm TIR (total indicator reading), while their diameter tolerance is 25 μm total. Better accessibility of the cutters to the workpiece on the smaller machine is a major benefit. CNC setter-programmer at the Pontypool factory, Darek Krochmalny, explained that it is possible to use shorter and

therefore more rigid tools than on the larger machine, enabling faster feeds and speeds for higher productivity. Furthermore it is now practicable to reduce the time needed to mill some features such as a locking pin pocket by interpolating all five axes simultaneously, whereas the production cycle on the B-axis machine was entirely 3+2. Mr Cox concluded, "Over half of our turnover is defence industry work, with the rail, high voltage switchgear and Formula 1 sectors also regularly served. "We pride ourselves on providing a full service from design-for-manufacturability through fabrication and machining to wet spray painting and powder coating. Only heat treatment and electroplating are bought in.” 8 prv-engineering.co.uk JANUARY 2022

Engineering Capacity | MACHINED COMPONENTS With 70% of its turnover in aerospace, Rugby-based subcontractor Technoset was badly hit when COVID-19 grounded most aircraft and orders plummeted seven-fold. Towards the end of 2021, the company's production of aircraft parts is still below one-quarter of previous volumes. With the business facing an existential crisis, managing director Kevan Kane and the firm's owners set about restructuring the operation, positioning Technoset as a solutions provider rather than a supplier of components. It also started targeting challenging contracts for the supply of tighttolerance components to more industries, notably lasers, fibre optics and telecoms. The success of these policies has seen the number of components going through the shop floor for the first time for both existing and new customers more than treble from 10 to 33%. A large proportion have benefited from design-formanufacture expertise from Technoset engineers to reduce piece part costs for customers. The first new machine tool the company has bought since the onset of the pandemic was a highly specified, twin-spindle Cincom M32-VIIILFV bar-fed, sliding-head mill-turn centre, which was delivered by Citizen Machinery UK in spring this year 2021. A primary reason for acquiring the latest M32 was a need to machine complex telecoms components, in particular a family of 12 mainly aluminium JANUARY 2022

Covid drives refocus

connector parts for use in the defence industry. Many of them are complex, with a lot of milled detail, and drawing tolerances are below 10 microns. That level of accuracy is achieved reliably, even when running lights-out, partly because the lathe incorporates Citizen's LFV (low frequency vibration) software in the Mitsubishi control's operating system. Variants of the LFV function can be called up automatically in any part program to break what would normally be stringy swarf into manageable chips. It is no longer necessary to stop the lathe to untangle and clear potentially harmful swarf from the tool and/or component. In anticipation of acceleration in the return of aerospace work, the subcontractor introduced a second shift in early September 2021. It is to ensure that contracts for aircraft components, which

typically involve batch runs of 1,000 to 2,000-off, do not dominate the shop floor and dilute the production of new work that has been taken on in other industries. Consequently, aerospace work at the AS9100accredited contract machinists is unlikely to exceed 50% of throughput in the future. Looking ahead, Technoset has wide-ranging plans for digitalisation and automation. The turning side of the business, which currently accounts for around two-thirds of turnover, is already automated through the use of bar magazines. The milling side will take a significant step forward in spring 2022 with the installation of a 5-axis machining centre with built-in robotic component load/unload and on-board part probing. It will be the first automated prismatic component manufacturing cell on-site. 8 techno-group.co.uk/ www.engineeringcapacity.com

CASTING & FORGING | Engineering Capacity Grainger and Worral has cast the first bespoke 4.0-litre lightweight V12 engine block for GTO Engineering’s new Squalo sports car. The new ground-up built Squalo has been designed, developed and engineered in-house by GTO Engineering. Squalo is designed, devised and developed as a sub-1,000 kg sports car celebrating the best of Sixties motoring combined with modern, motorsport-derived engineering. It will be powered by an all-new 4.0-litre quad-cam V12 engine, which will be designed, developed and assembled inhouse and targets an ambitious weight of less than 165kg. The first engine blocks will be transported to GTO Engineering’s UK HQ to be assembled using its bespoke in-house machined engine internals. Once assembly has been completed, the first engine will be installed in one of the company’s Revival platforms for on-road mule testing and extensive dynamometer time in Q2 2022. GTO has also appointed Alexander Aucken as Chief Technical Officer. His responsibilities include planning and coordinating engineering operations to ensure key development targets are met and production specification is homologated for international markets. Alexander, with the internal team and external consultants, have one strict purpose - to make the Squalo both as light and as enjoyable to drive as possible. 24

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First casting for new V12

Managing Director and Founder of GTO Engineering, Mark Lyon said: “2022 is a pivotal year for Squalo, to build on the foundations and strict goals we’ve set for our bespoke ground-up build. The engine, which is one of the most integral parts of Squalo, is entering an exciting phase with our new partner, ready for assembly and testing from our facility next year. In order to bring the project together we’ve brought in industry talent in the form of Alexander Aucken, who we are thrilled to have on board as Chief Technical Officer.” Executive Director of Grainger and Worrall, James Grainger said: “GTO Engineering’s Squalo engine

build is a project that we are very excited to be a part of. It’s not every day that we get the opportunity to build from scratch the lightest V12 engine ever seen in a road car. With our combined experience in castings, engineering, technical and material solutions, we are confident that Squalo’s V12 engine will not only hit the weight target of sub-165 kg, but will also be one of the most engaging and probably last-of-the line naturally aspirated V12 engines ever fitted to a production road car.” GTO says that the appointment of Alexander Aucken and the Squalo project will take it from being a leading historic Ferrari specialist to the forefront of high tech, modern automotive engineering with a Sixties styling and modern driving feel. It adds that the partially composite structure of the Squalo, developed in collaboration with Randle Engineering, is at the forefront of current automotive practices. JANUARY 2022

Engineering Capacity | CASTING & FORGING Randle Engineering is the technical partner for Squalo’s suspension and chassis development. Its team of engineers will be responsible for testing and consulting on manufacturing processes to retain the key characteristics of Squalo, such as its light weight, driving involvement and engineering quality. Manufacturing the chassis and high-performance suspension is crucial to not only keeping the

overall weight of Squalo to sub1,000kg, but also to enhance the overall driving experience both on

the road, on track and daily driving duties for customers. A half-scale prototype of Squalo has already been revealed and exhibited at the 2021 Goodwood Revival, creating a lot of excitement and bringing positive feedback. The model will soon become a full-scale production vehicle and scheduling is still on track with first production cars expected Q4 2023. 8 gtoengineering.com gwcast.com

Wealdpark Limited Stand number 5126

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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 2022

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ELECTRONICS | Engineering Capacity

Don’t get lost on the Moon European Engineering & Consultancy (EECL) and SpacePNT have been awarded a contract by the European Space Agency’s (ESA) Navigation Innovation and Support Programme (NAVISP) to manufacture, test and deliver a Moon GNSS (global navigation satellite system) module. The space-borne receiver will be flown aboard ESA's Lunar Pathfinder Spacecraft in a low orbit around the Moon and is due for launch in 2024. EECL will deliver the necessary hardware for the advanced satellite navigation payload. Dr Ben Kieniewicz, EECL founder, said; "The world is heading back to the Moon. The major space players including NASA, SpaceX, and ESA are advancing towards a permanent colony on the Moon." He continued; “In preparation for this, ESA has commissioned the Lunar Pathfinder Spacecraft (LPS). This spacecraft will be placed in a low orbit around the Moon to provide high speed communications from the Moon to Earth (400,000 km). We will provide the navigation system for the LPS, which is a world first and we’re delighted that EECL has been chosen to be part of it." Earth-based GPS technology does not currently work on the Moon making it impossible to accurately locate satellites in its orbit or astronauts and other objects on the surface. However, 26

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LPS aims to change this by flying an ultra-sensitive high-gain antenna receiver pointing towards Earth. The antennas pick up weak signals from Earth-based GPS which leak into space, allowing an accurate position fix, timing and velocity anywhere around the Moon or on its surface to be generated. Javier Ventura-Traveset, leading ESA’s Galileo Navigation Science Office and coordinator for ESA lunar navigation activities, explained more: "This is an exciting and challenging project because acquiring satellite navigation signals and performing a positioning fix has never been achieved from distances required for lunar orbit. The signals involved will be millions of times fainter than those employed for satellite navigation on Earth, making the engineering requirements extremely

demanding. However, we have full faith in our project partners." The antenna requires an amplifier and receiver module which is one of several components being manufactured by EECL. EECL’s unit measures only 24cm x 12cm x 7cm and is a highly complex microwave radio receiver with advanced signal processing technology. EECL is also providing custom best-inclass, low noise amplifier technology to pull these weak signals from Earth out of the background radiation of deep space. The receiver technology and its complex software algorithms are being manufactured in partnership with Swiss Company SpacePNT, who have decades of experience in weak signal tracking and specialist GNSS algorithms. EECL will bring its extensive RF (radio frequency) design skills, manufacturing and JANUARY 2022

Engineering Capacity | ELECTRONICS space experience to ensure mission success. The radiation in the Moon's orbit is particularly challenging and the hardware will be sufficiently robust to survive this hostile environment. "If successful this will be the first demonstration of navigation using GPS away from the Earth and it will enable precise navigation, timing and positioning on the Moon's surface. It is a once in a lifetime opportunity;" said Dr Kieniewicz. Significant investment to meet exacting manufacturing standards The design, manufacture and testing are taking place at EECL's laboratory in Kingston-UponThames, UK. The company has made significant investments to bolster its production capability and support its industry-leading skills in RF and Space electronics. These include a new ISO-Class-7 cleanroom and thermal test chamber allowing EECL to minimise contamination from unwanted particles during construction. EECL has also acquired sophisticated testing instruments, high-end manufacturing equipment and invested in quality-assurance expertise, mechanical and electrical engineering resources with the expectation to serve the UK Space Sector as it sees exceptional growth over the next decade. The contract was awarded in April 2021 and envisages a tight time frame. The first two engineering models are due for delivery in early 2022, and the flight unit in Summer 2023. UK JANUARY 2022

Space Agency chief executive, Dr Paul Bate, said; "With humans set to return to the Moon and ambitious plans to explore even further, we need more advanced navigation systems to guide the way. By bringing SatNav to the Moon, EECL is making a significant contribution to global space exploration efforts, and it is fantastic to see a UK SME demonstrating such expertise and innovation." “This is a great example of how our leading role in the European

Space Agency is building UK space capabilities and supporting our thriving space sector, in line with our National Space Strategy.” The project is a key milestone for EECL. This mission is exceptional due to the requirements for hardware to be flown to the Moon. "This is a big deal. For us to be selected to provide this, before larger, more established suppliers, is significant. It shows that UK SMEs have the capability to make an impact in a domain that was once only supported by government agencies or transnational companies such as NASA or Airbus;" said Dr Kieniewicz. The close collaboration of EECL with SpacePNT, experts in providing GNSS algorithms and the highly complex technology to track small signals, reflects the UK's continuing supporting for international collaboration. The SpacePNT GNSS receiver module will be validated on the most prestigious of missions. "This demonstration will provide a critical step in humankind’s return to the Moon;" said Dr Kieniewicz. 8 euroecl.com

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ADDITIVE MANUFACTURING | Engineering Capacity

Bridging supply chain gaps Optimised supply chains can offer huge potential for OEMs to increase profitability, writes Dr. Henrike Wonneberger, and additive manufacturing methods can bridge supply chain gaps and add resilience Reducing inventory costs with punctual delivery has been, for many years, the focus of supply chain management. Over the years, supply chains have been optimized to perfection, using algorithms and digital tools, but it is a balance on a knife’s edge. COVID-19 and the subsequent closing of borders have revealed the limits of planning and the fragility of supply chains to suppliers, OEMs, and end customers. Ways to mitigate supply chain risks When a part is needed urgently, every hour can cost manufacturers hundreds and thousands of pounds with the cost of the spare part itself often negligible compared to the economic and reputational damage caused by its absence. Increasing the buffer in warehouses could minimize the risk of supply gaps, but counteracts previous efforts to reduce inventory and increases tied up capital, warehousing costs and obsolescence. Another option is to source from several suppliers in multiple 28

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locations; should one supplier fail, others can cover the demand. However, interconnected global supply chains are often dependent upon a few suppliers of basic materials. Subsequently, for specific parts or components, all worldwide suppliers might be affected by the material shortage. A better solution is not only supplier diversification, but also in material alternatives. A third way to improve the resilience of the supply chain is to return to localized manufacturing – as witnessed at the beginning of the COVID-19 pandemic. This saw many manufacturers 3D print critical parts needed to fight COVID-19 – such as face shields or valves for respiratory devices. This manufacturing philosophy, named bridge manufacturing, can be used as a blueprint to generally improve supply chain resilience. Essentially, bridge manufacturing means having a technically viable alternative to

bridge a gap. This gap can be economic if other technologies are too expensive, or an availability gap, if parts produced in another manufacturing technology are unavailable. Bridge manufacturing requires a manufacturing alternative for the part that allows on-demand, decentralized production. This ensures the part can easily be made available anywhere globally in the event of a sudden unexpected shortage. Consequently, should supply chains be disrupted, the OEM or supplier has alternative options, potentially saving money and reputation. As a concept, bridge manufacturing comprises three different types: provisional solution, equivalent manufacturing solution, and ramp-up/phase-out bridging. Provisional solutions Well known in dentistry, this is where a transitional prosthesis – JANUARY 2022

Engineering Capacity | ADDITIVE MANUFACTURING using a different material and a different technology – is provided as a makeshift solution while the actual prosthesis is manufactured. Requirements for a makeshift solution are often lesser than for the original, making bridge manufacturing a second-best alternative from a technological standpoint. Whether a part is used as a stop-gap until the ‘original’ spare part is delivered, or until it breaks down and is replaced by the ‘original’ spare part, bridge manufacturing of the part takes place in parallel to ordering a standard ‘original’ spare part. Like this, the machine downtime is reduced in the same way, saving the OEM money and reputation. Equivalent Manufacturing However, bridge manufacturing can meet all requirements and specifications of the ‘original’ part. In this case, bridge manufacturing might be more expensive, making it inappropriate for standard production, but it might have certain advantages when other constraints occur. For example, a polymer part could be manufactured at low cost per part in large quantities in a central location. In the event of a global supply chain disruption and the part is needed overseas, this can be bridged by localised 3D printing close to where it’s needed in the required (probably low) quantity. If the manufacturing alternative was set up conforming to specifications, a part produced JANUARY 2022

correspondingly might last as long as an ‘original’, eliminating the need to parallel order the ‘original’ spare part.

time, is flexible insofar as quantities and is locationindependent. Few manufacturing technologies meet these criteria.

Ramp-up/phase-out bridging Change in demand over a product’s lifecycle can vary drastically and upon launch, it’s hard to forecast future demand. For small and mid-volume series, additive manufacturing is an attractive option throughout the whole lifecycle. If product demand rises quickly, manufacturing methods like injection molding are best from a price-per-part standpoint. Once manufacturing alternatives are in place, bridge manufacturing enables companies to switch as needed to optimize manufacturing costs. 3D printing is often favourable upon a product’s launch when only small quantities are needed, but when demand increases the OEM would benefit from another manufacturing method. Towards the end of the lifecycle, when demand decreases, the OEM can easily switch back to 3D printing. With bridge manufacturing, it is important the technology does not need significant ramp-up

Adding value with additive manufacturing The most viable option for bridging is additive manufacturing. Once a part is qualified and print parameters are set, it does not need any ramp up but can simply be sent securely to a 3D print service bureau for fast, costeffective production. That’s to say, exactly where the part is needed, when it is needed and in the precise quantity needed – even a lot size of just one. It is these basic principles of 3D printing that continue to make it an agile and benefit-enhancing option for low-volume manufacturing requirements among OEMs large and small.

8 Dr. Henrike Wonneberger is COO and Co-Founder of industrial 3D printing platform Replique

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AUTOMOTIVE | Engineering Capacity

The road ahead in 2022

Jimmy Saunders, Managing Director of Kroll Restructuring Advisory, asks what 2022 has in store for the automotive supply chain. As we look ahead to 2022, the automotive sector continues to face structural issues within the industry alongside the wider economic challenges. Structural Issues During 2019, growing uncertainty around Brexit led to a number of vehicle manufacturers announcing the movement of production to mainland Europe. This was at the same time as customers were already cautious when buying cars because of the evolving electrification of vehicles and concerns around the diesel emissions scandals. Compounding this during early 2020 was the impact of the pandemic, and according to the Society of Motor Manufacturers and Traders (SMMT), new car registrations between 2019 and 2020 fell by 29%. The impact of this downturn in 30

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vehicle sales on the automotive supply chain was in part mitigated by the raft of government support schemes, not least the ability to furlough employees, the various government loan schemes and the VAT deferral scheme. As different countries emerged from lockdown at different times, the uncertainty of demand and fluctuating availability of parts supply led manufacturers to rationalize their number of vehicle programs to focus on producing core models. This served to create capacity in factories that, as demand improves going into 2022, is being used to accelerate electric vehicle production. Recent statistics from the SMMT suggest that there will be more electric vehicles registered in 2021 than were registered between the whole of 2010 through to 2019. In fact, in the year to October 2021, new car

registrations have only grown LFL by 2.8%, behind this number is a reduction in petrol and diesel cars (which for now make up the majority of vehicles) of 22.1%, which is offset only by the significant growth in electric vehicles and hybrids of 65.4% and 82.5%, respectively. What this shift from internal combustion engines to electric vehicles means is that significant investment is expected in both research and development of the new electric technologies but also into capital expenditure (capex), particularly powertrain suppliers, at a time when businesses are already struggling. Furthermore, both original equipment manufacturer (OEMs) and lenders are putting heavy emphasis on environmental, social and governance (ESG) and sustainability matters, which potentially brings a whole new JANUARY 2022

Engineering Capacity | AUTOMOTIVE layer of cost into the supply chain. The landscape for large vehicle manufacturers themselves is also increasingly competitive and this is also creating significant downward pressure on the supply chain to deliver price efficiencies. Supply Chain Disruption Unfortunately, these structural issues have arisen at the same time as the global supply chain problems. We are now familiar with the chronic shortages of microchips in the automotive (and other) industries and many commentators suggest that this will not regularise until well into 2023. At the same time, shipping costs to bring in parts and materials from the Far East have increased significantly to over USD 15,000 per container, and this follows a period of relative stability during the previous 10 years when the cost didn’t exceed USD 2,000 per container. There is a well-documented labour shortage, particularly in the UK. The UK needs another 100,000 heavy goods vehicle (HGV) drivers, and this is all contributing to delays in moving goods from port to Tier 1 and 2 suppliers and difficulties dispatching finished goods to the OEMs. To add to this, steel and aluminium prices hit ten-year highs in October 2021 and most other commodity prices have also followed a similar trend, partly due to the surge in energy prices, which, therefore, impacts suppliers both directly and indirectly. All of these factors cause concerns about the impact JANUARY 2022

of inflation on interest rates and the future debt servicing costs for businesses. Many OEMs operate on a justin-time basis on a rolling 13-week production cycle; this is designed to give the Tier 1 or 2 suppliers time to order in raw materials and parts and to plan production and staffing. Given the shortages in supply of key components, when the production lines have to stop, this then ripples back through the entire supply chain. The problem is that these stoppages come quite late—sometimes in the week an order is due for delivery; this means the supplier has already invested in both materials and the labour, therefore tying up vital working capital. This level of volatility is extremely difficult to plan for. Finally, pressures on the management team to juggle all of

these issues means day-to-day running of the business might not get the attention it needs. Summary The rapid pace and scale of change in the automotive sector presents huge challenges to management teams, and many businesses that are already dealing with acute financial and operational challenges are also having to find the means to transition towards electrification. Most balance sheets today carry far more debt as a result of the pandemic, and there is less capacity to simply take on additional borrowing to fund working capital and capex needs. Management teams should take action now to address these issues to ensure the security of their businesses in the future. 8 kroll.com www.engineeringcapacity.com

SOUTHERN MANUFACTURING | Engineering Capacity

Confident return of Southern showcase Southern Manufacturing & Electronics makes its longawaited return to Farnborough from February 8th to 10th 2022. Southern Manufacturing 2020 was one of the last trade shows to occur before the pandemic and lockdown hit. Despite all the harm wrought on the industrial community over the subsequent 20 months, the speed with which the show has recovered is surely an encouraging sign that the manufacturing sector is dusting itself off and beginning the long, hard slog towards recovery. The show’s organisers report strong interest in reservations from firms eager to get back to face-to-face business. In particular, the show’s many longstanding exhibitors – a good proportion of whom have been with the show throughout its 24 year history – lost no time in securing their place at the UK’s largest and longest running annual industrial exhibition. As a result of this remarkable response, Southern Manufacturing 2022 will return in its customary format as arguably the most comprehensive engineering show in the country. The three-day event is where the worlds of electronics and industrial production hardware converge with component 32

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distributors and subcontract engineering services, creating an event with almost universal appeal across the entire engineering spectrum. Whether it’s seeing the latest machine tools in action, sourcing components or specialist engineering services, Southern Manufacturing & Electronics is the place to find it. And this is particularly pertinent in the current situation where travel remains difficult. Being able to solve multiple procurement issues at a single show is surely a very compelling motivation to consider a visit in February. The cavernous 20,000m² main hall of the Farnborough International Exhibition Centre is expected to be fully booked by the time the doors open, with only a few stands remaining at the time of writing. Vendors from all around

the UK take part, together with a significant number of international exhibitors from Europe and beyond. The event is divided roughly equally between electronics and manufacturing, and further subdivided into specific areas for components, production hardware and so on. There is also a specific feature area within the show, AutoAero, for firms operating within the aerospace and automotive sectors. Southern Manufacturing & Electronics is a key international marketplace for subcontract services. The show offers an incredibly diverse range of specialist skills, from electronics to precision engineering. The scope is truly international and brings together firms from around the UK, from continental Europe and the Far East. JANUARY 2022

Engineering Capacity | SOUTHERN MANUFACTURING Exhibitors include CNC machined parts manufacturers such as DKW, Precision Products (Brighton), GW Martin and SubCNC Precision, moulders including Nordell and Rutland Plastics, castings suppliers including MRT Castings and Alucast as well as sourcing specialist Qimtek and industrial PR and Marketing company ARO. Engineering Capacity is an official media partner of Southern Manufacturing and is exhibiting on Stand M260. Not surprisingly, given its

JANUARY 2022

location in the birthplace of the UK’s aviation industry, many of the subcontract engineering firms taking part are AS9100 accredited with substantial aerospace experience in a wide variety of disciplines from precision engineering, composites and advanced plastics to wiring, electronics and testing. Certified to AS9100 REV D, Hertfordshirebased Elder Engineering offers a precision CNC machining and an extensive range of products in plastic and metal machined to exacting requirements. Its

“Start to Finish” subcontracting machining service goes from initial CAD drawings to a broad range of finishing options. The machine shop includes fiveaxis milling, twin spindle lathes and a router. The firm’s security division offers and maintains a range of bespoke products for dual view x-ray machines as required by the Department of Transport and ECAC. Precision casting, machining and fabrication businesses in the Expromet Technologies Group, deliver engineering solutions for

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SOUTHERN MANUFACTURING | Engineering Capacity performance-critical applications. The group’s businesses draw upon UK manufacturing capabilities and global supply chain for customers across the defence, aviation, marine, medical, energy and industrial automation sectors. Investacast supplies investment castings, pressure die castings and forgings from a manufacturing base in Ilfracombe, Devon. Haworth Castings is a specialist in manufacturing fully-tested, machined and finished sand and gravity die castings with manufacturing sites in Romsey and Basingstoke, Hampshire. Metaltech Precision manufactures precision components based in Chard, Somerset, and has extensive capabilities in CNC turning, milling, fabrication and welding. Specialist manufacturer of high purity stainless steel manifolds and control systems, Orbital Fabrications will showcase its latest developments and innovations in TIG welding techniques for fabricating

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complex assemblies in stainless and high nickel content alloys. The company uses automated orbital welding techniques alongside lathe and turntable TIG welding and has recently invested to expand its in-house CNC machine shop, giving greater control and management of the entire fabrication process. Its products typically are for use in the semiconductor, pharmaceutical, chemical and process industries. Services available in-house range from design services, through to test and qualification processes including in-house helium mass spectrometry for leak detection, alongside high pressure testing capabilities up to 400 bar. For high purity applications, all fabrication, assembly and test are conducted

within Class 5 and Class 6 cleanroom facilities. Returning to Southern Manufacturing for 2022, Twickenham Plating Group will highlight its specialist technical plating services for electronics, telecommunication, aerospace, automotive and military applications. It delivers a range of plating services for customers throughout the world, including selective gold plating, reel to reel plating, and barrel/vat/rack plating. Finishes available include gold (pure and hard), silver, palladium, palladium/nickel, electroless nickel, nickel, black zinc nickel, tin, zinc cobalt (olive drab and black). The company can plate to a design specification or develop a specification or process to cost effectively deliver the desired finish. The technical team is able to carry out materials investigations and material specialists can advise about the different characteristics of finishes. The company specialises in plating on different substrates from copper, copper alloys, such as brass and phosphor bronze, and ferrous metals, including stainless and carbon steel, to aluminium alloys and tellurium copper. Off-shore manufacturing is also an option explored at the show through companies such as China Outsourcing. Established in 2002, the firm offers options for low cost, low risk manufacturing for customers wishing to reduce production and supply costs. The company specialises in the supply of machined parts, castings, forgings, fabrications and assembly JANUARY 2022

Engineering Capacity | SOUTHERN MANUFACTURING work. In 2019 the firm announced the expansion of its manufacturing base into Vietnam, allowing customers, particularly US customers, to avoid import tariffs on Chinese-manufactured parts. Representatives from the plastics and advanced materials sector include Precision Engineering Plastics, a specialist in close tolerance injection moulded components and added value assemblies. Its London facility is equipped with 30 injection moulding machines ranging from 12 to 650 tonnes, and its own fully-equipped toolroom, enabling it to deliver a comprehensive service from initial design evaluation through to new tool manufacture with in-house tool maintenance and service. Servicing customers in the automotive, aerospace, medical, electronics and defence sectors, the company delivers a wide range of injection moulding, insert moulding, two-shot moulding and secondary / post-processing operations. Part sizes range from small medical devices and micro mouldings for electronics to large parts for automotive trim and ULEV parts. Returning for 2022, IPFL utilises 3D printing and CNC technologies to produce plastic parts for medical, defence, product development, motorsport and scientific components. This year, the company is showing innovations in diffusion bonding and laser welding for microfluidics. The processes fuse together layers of precisely machined panels at a molecular JANUARY 2022

level without chemicals or adhesives, resulting in highly accurate and complex components. Investment in the process provides microfluidic plates and medical manifolds, which are used for scientific analysis and chemical mixing. Such parts require complex internal track features which cannot be achieved using conventional methods. Alongside machining and fabrication services, it will

exhibit its versatile range of additive manufacturing technologies, using high resolution clear materials to tough polyamide production. Additive manufacturing will also feature on the Röchling Industrial (UK) stand, The firm was an early adopter of additive layer manufacturing technology and will be exhibiting many examples of its additive manufacturing capabilities and

5DLVLQJ WKH SURƩOH RI engineering, composites DQG VFLHQWLƩF FRPSDQLHV

01752 894786 www.aroprandmarketing.co.uk

www.engineeringcapacity.com

SOUTHERN MANUFACTURING | Engineering Capacity competences. Printing technologies available include powder bed fusion – multi jet fusion (MJF), selective laser sintering (SLS) and selective laser melting (SLM). For material extrusion, there is fusion deposition moulding (FDM), Arburg plastic freeforming (APF) and for material jetting, the company offers poly jetting technology. Materials options include PA12, ABS, PP, PC, ASA, PEEK and aluminium (SLM). The electronics manufacturing aspect of the show is similarly broad, and ranges from design through to PCB manufacture, assembly and full box build, both on-shore and off-shore. Electronics design and software development consultancy Ignys will be offering specialist advice on designing-around the global chip shortage. Highlighting the different centres of excellence in the Vanilla Group, Bela EMS and new-joined group members Interconics and Vanilla Electronics will highlight its combined

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services and offerings. The three brands are from three different regions within the UK and are all experts in their respective fields. Bela offers PCB design, rapid prototyping and low-mid volume PCB assembly, Wiltshire-based Interconics is the group production centre, offering automated volume and high complexity PCB assembly and in Norfolk, the group supply chain centre, Vanilla Electronics, offers value add supply chain services.

PCB fabrication and assembly from a single location is offered by Glasgow-based European Circuits, along with other services including cable assemblies, test and product build. Its customers include medical, security, broadcast and automotive, throughout the UK, Europe and beyond. Over the last 18 months, the company has installed new equipment in both manufacturing and assembly areas. The investment in excess of £350,000 includes new CNC drill / routing machine, additional ATE tester, solder paste inspection systems, new pick and place machines and a 3D AOI system. Another leading name in PCB assembly services exhibiting this year is Corintech. Headquartered in Hampshire, the firm offers a complete range of services from initial concept design support through to component procurement, production mixed assembly and functional testing. All products are manufactured and delivered in accordance with AS9100 and ISO9001 accreditations. The firm’s UK base provides electronics manufacturing for fast turnaround of low and high volume PCB assemblies, while its Hong Kong site allows customers to take advantage of Far Eastern high volume and low source-cost production without compromising on quality. Offshore manufacturing services highlighted at the show include those sited closer to the UK. Once such firm, Lithuaniabased CEMS, Volburg, has been JANUARY 2022

Engineering Capacity | SOUTHERN MANUFACTURING providing services to the UK market since 1996. Its facility is well-equipped with the latest technologies, like EOL test, ICT flying probe and a recently added SMT line equipped with the latest machines. The firm operates to ISO9001 and ISO14001 and holds automotive IATF16949 certification to ensure a high level of quality. The show’s Machinery area is one of the most popular, allowing visitors the chance to see that latest machine tools in action from many of the UK’s leading vendors. Most of the show’s traditional bigname vendors return for 2022, including Haas Automation, Hurco, Unison and C.Dugard. Mills CNC will showcasing its latest automation solutions, including a SYNERGi Premier automated manufacturing cell comprising a Lynx 2600SY lathe integrated with an industrial robot and featuring a large-capacity part loading/unloading station, a part inspection conveyor and a 17” touchscreen HMI powered by SYNERGi software. A highproductivity Doosan cobot will also be demonstrating the significant operational efficiencies

JANUARY 2022

that can be achieved through automation. MACH Machine Tools returns to Farnborough, showing, for the first time, a selection of both new and previously owned machines. Highlights include the MACH VS2-SP manual turret milling machine and its Wi-Fi enabled DynaPath controlled CNC/Manual lathes & bed mills. XYZ Machine Tools will provide UK exhibition visitors with the first sight of the brand new XYZ SS 65 twin/sub-spindle turning centre, which was recently added to XYZ Machine Tools’ range. The XYZ SS 65 breaks new ground,

says the firm, being its first foray into multi-spindle turning centres, a move driven by demand from customers looking for increased productivity and reduced spindle downtime. The ability to machine parts in one-hit, thereby reducing part handling and idle time, its says, will enable machine shops to maximise productivity and spindle up-time while making use of available labour. Other machines on show on the XYZ stand include the XYZ 750 LR vertical machining centre and the latest versions of the popular ProtoTRAK controlled mills and lathes including the RMX 3500 bed mill and RLX 355 ProTURN lathe. The latest generation ProtoTRAK control adds a host of new features and benefits, not least of which is its 15.6” touchscreen that puts machining information at the users’ fingertips. Combining the touchscreen with DXF capability removes any requirement for a mouse to interact with editing of programs. www.engineeringcapacity.com

SOUTHERN MANUFACTURING | Engineering Capacity AMOB UK will unveil the latest version of the eMOB Super Heavy Duty electric tube bending machines that have the ability to bend tubes up to 225mm in diameter. 1st Machine Tool Accessories exhibits a comprehensive range of automation solutions to speed-up loading and unloading of machining centres, and there are workholding systems from Thame Workholding amongst others. Advanced manufacturing is represented by leading proponents such as Laser Lines, which returns to Southern 2022 with live demonstrations of three new additive manufacturing technologies, namely saturated absorption fabrication (SAF), stereolithography (SLA) and P3 polymerisation, together with DyeMansion post processing technology to create a full end-toend manufacturing solution. Bowyer Engineering will launch its in-house designed 3D printer, Orochi. The system is designed to overcome the limitations of existing 3D printers in the manufacture of components and assemblies used in applications such as on-wing inspection equipment manipulators. Boxford will highlight its range of professional, affordable and reliable laser cutting, engraving and CNC machines, while advanced manufacturing specialists IPFL will be displaying its outstanding work in 3D print and engineering plastics. On the electronics production side, hardware exhibitors include Mycronic, showing its adaptable 38

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PCB manufacturing solutions designed to help reduce operational overhead and enhance yield. Components showcased includes the MY300 compact placing machine, MY700 stenciless solder paste jet printing, K series 3D AOI system and the MYTower flexible storage units. Together with its regular exhibits, this year Blundell Production Equipment is launching the i-Pulse Yamaha M20 auto-placement machines, with specialists present to guide visitors through set-up and functionality. Cupio returns to highlight its range of leading-edge inspection technologies, such as X-ray and Confocal Scanning Acoustic Microscopy (CSAM). XRay inspection is used to find faults such as BGA ball voids, while CSAM reveals air gaps, voids, and de-lamination in materials that X-Ray cannot see. Away from the busy show floor, the ever-popular free seminar programme also makes a welcome return for 2022 in a sociallydistanced format. Among the topics discussed this year are HMRC R&D Tax Credits, developing strategies to drive continuous improvement in your

business, practical tips on energy usage reduction in manufacturing and advice on how to handle a product safety incident. Sessions run over all three days and a full list is available on the show’s website at www.industrysouth.co.uk Extensive anti-infection measures will be in place throughout the event, including the requirement to submit a negative test result and/or evidence of vaccination prior to entry. Farnborough International Exhibition Centre is one of Europe’s most modern event venues, equipped with state-ofthe-art filtered fresh air ventilation. Access to the show by private vehicle is easy, with 3,500 free onsite parking spaces. A dedicated free shuttle bus runs from the railways stations direct to the show. Once on site, visitors can benefit from a high standard of facilities which includes a selection of catering options and free WiFi service in the foyer. Southern Manufacturing & Electronics 2022 opens from February 8th to 10th. Admission to the exhibition is free of charge. 8 Come and see Engineering Capacity on Stand M260. JANUARY 2022

BTMA MANUFACTURING MEMBERS | DIRECTORY

ACSL Precision Engineering sales@acsleng.co.uk www.acsleng.co.uk

CTN Group Ltd charlie@ctn-group.co.uk www.CTN-GROUP.co.uk

G W Martin and Co Ltd sales@gwmartin.co.uk www.gwmartin.co.cuk

Atkinson Engineering sales@atkinson-engineering.com www.atkinson-engineering.com

Currie & Warner Ltd tonyfox@curriewarner.com www.curriewarner.com

H P C Services Ltd sales@slidinghead.com www.slidinghead.com

Auto Turned Products (Northants) Ltd shad@autoturned.co.uk www.autoturned.co.uk

Davromatic Precision Limited sales@davromatic.co.uk www.davromatic.co.uk

Haydon Precision Turned Parts Ltd haydontool.co@btconnect.com www.haydon-precision.co.uk

Batchflow Engineering info@batchflow.co.uk www.batchflow.co.uk

Dawson Precision Components Ltd. sales@dpc.co.uk www.dpc.co.uk

Herve Engineering Ltd sales@herve-engineering.com herve-engineering.com

Cambion Electronics Ltd sales@cambion.com www.cambion.com

Dawson Shanahan (Wales) Ltd info@dawson-shanahan.co.uk www.dawson-shanahan.co.uk

JCF Engineering Limited john.felton@jcfengineering.co.uk jcfengineering.co.uk

Cambridge Precision Ltd sales@cambridgeprecision.com www.cambridgeprecision.com

DKW Engineering Ltd karl@dkwengineering.co.uk www.dkwengineering.co.uk

M&M Turned Parts Ltd sales@mmturnedparts.co.uk www.mmturnedparts.co.uk

CK Precision Engineering Ltd Info@ckprecisionengineeringltd.com www.ckprecisionengineeringltd.com

Falcon Engineering Productions Ltd sales@falconengineering.co.uk

Machined Component Systems sales@machinedcomponent.com www.machinedcomponent.com

Colpa Precision Engineering Ltd steve@colpa.co.uk www.colpa.net

GS Brown (Precision Engineers) Ltd malcolm@gsbrown.com www.gsbrown.com

Manton Engineering (Bedford) Ltd sales@mantonengineering.co.uk www.mantonengineering.co.uk

JANUARY 2022

btma.org

DIRECTORY | BTMA MANUFACTURING MEMBERS

MaS Precision Engineering Ltd sales@masprecision.co.uk www.masprecision.co.uk

Precision Products (Brighton) Ltd ian@precisionproducts.co.uk www.precisionproducts.co.uk

Techfore Turned Parts Ltd info@techfore.co.uk www.techfore.co.uk

Muller England Limited sales@muller-england.co.uk www.muller-england.co.uk

Qualiturn Products Ltd sales@qualiturn.co.uk www.qualiturn.co.uk

Tenable Screw Co Ltd nigel@tenable.co.uk www.tenable.co.uk

NC Precision Ltd sales@ncprecision.com www.ncprecision.com

Quantamatic info@quantamatic.co.uk www.quantamatic.co.uk

Tercet Precision Ltd Alex.Burns@tercet.co.uk www.buyturnedparts.com

Neida Products Engineering Ltd sales@neida.co.uk www.neida.co.uk

Rodmatic Ltd enquiry@rodmatic.com www.rodmatic.com

Thomas Brown Engineering Ltd info@thomasbrownengineering.co.uk www.thomas-brown-engineering.co.uk

Normec (Manchester) Ltd sales@normec.co.uk www.normec.co.uk

Rowan Precision Limited sales@rowanprecision.co.uk www.rowanprecision.co.uk

Oracle Precision Ltd shaun.palmer@oracle-precision.co.uk www.oracle-precision.co.uk

Salcey Precision Engineering Ltd info@salceyprecision.co.uk www.salceyprecision.co.uk

TKM Engineering Ltd Sales@tkmengineering.co.uk www.tkmengineering.co.uk

Plastic turned Parts Ltd sales@plasticturnedparts.co.uk www.plasticturnedparts.co.uk

Scot Bennett Engineering Ltd rob@scotbennett.co.uk www.scotbennett.co.uk

Trust Precision Engineering Ltd info@trustprecisionengineering.co.uk www.trustprecisionengineering.co.uk

Precision Component Services Ltd shane@precision-components.co.uk www.precision-components.co.uk

Swissmatic Ltd info@swissmatic.co.uk www.swissmatic.co.uk

Wealdpark Limited sales@wealdpark.co.uk www.wealdpark.co.uk

btma.org

JANUARY 2022

BTMA MANUFACTURING MEMBERS | DIRECTORY

Wharf Engineering Ltd sales@wharf-engineering.co.uk www.wharfengineering.co.uk

Wilco Manufacturing Ltd sales@wilcomanufacturing.co.uk www.wilcomanufacturing.co.uk

Yorkshire Precision Engineering Ltd info@ypel.co.uk www.ypel.co.uk

BTMA TECHNICAL MEMBERS | DIRECTORY

Arno (UK) Limited sales@arno.de www.arno-tools.co.uk

C Dugard Limited sales@dugard.com www.dugard.com

Mills CNC Ltd tdale@millscnc.co.uk www.millscnc.co.uk

The Amodil Group tkd@amodil.co.uk www.amodil.co.uk

Filtermist Systems Limited sales@filtermist.com www.filtermist.co.uk

Optimum Oils cliff.thrussell@optimumoils.com www.optimumoils.com

Badger Anodising (Birmingham) Ltd sales@badgeranodising.co.uk www.badgeranodsing.co.uk

Floyd Automatic Tooling Ltd sales@floydautomatic.co.uk www.floydautomatic.co.uk

Premier Machine Tools UK Ltd avid.dunn@premiermt.co.uk www.premiermt.co.uk

Bowers Group sales@bowersgroup.co.uk www.bowersgroup.co.uk

Kumi Solutions simon@kumi-solutions.com www.kumi-solutions.com

PSL Datatrack engcap@psldatatrack.com www.psldatatrack.com

Ceratizit UK & Ireland Ltd info.uk@ceratizit.com www.ceratizit.com

LNS Turbo sales.uk@lns-europe.com www.lns-europe.com

Citizen Machinery UK sales@citizenmachinery.co.uk www.citizenmachinery.co.uk

Matsuura Machinery Ltd imichie@matsuura.co.uk www.matsuura.co.uk

JANUARY 2022

Smiths Metal Centres info@smithmetal.com www.smithmetal.com

btma.org

DIRECTORY | BTMA TECHNICAL MEMBERS

SolidCAM UK Ltd info@solidcamuk.com www.solidcam.com

Stelstocks Ltd info@stelstocks.co.uk www.stelstocks.co.uk

Wickman Coventry Ltd o.coyne@wickman.co.uk www.wickman-group.com

Wieland-Nemco Ltd. sales@wieland-nemco.com www.wieland-nemco.com

Star Micronics GB Ltd sales@stargb.com www.stargb.com

JFL are broach and broaching specialists with many years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms. Unit 2, Deethe Farm Industrial Est, Cranfield Rd, Woburn Sands, Milton Keynes, Bucks MK17 8UR Tel: 01908 585103 www.jflbroaches.co.uk

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

Qualiturn Products Limited 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. 7 Fountain Drive, Hertford, Herts, UK, SG13 7UB Tel. +44 (0) 1992 584499 www.qualiturn.co.uk

MACHINE TOOL MANUALS 8

JFL Broaches and Broaching

CNC PRECISION COMPONENTS 8

BROACHING 8

DIRECTORY | Engineering Capacity

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

September 2017

INDUSTRY NEWS | MACHINING | AUTOMOTIVE | SHOW PREVIEWS | COMPONENTS MACHINED

Get your company noticed with an Engineering Capacity classified profile advert MACHINED COMPONENTS: Prismatic parts from bar

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Capacity Engineering

supports Mill-turning ach lean appro

year half of this In the first has committed to g Roscomatic investment, includin More than Engineering of 1000 Capacity | £750,000 tion of the latest medium-sized small to INDUSTRY xis the installa NEWS (SMEs) have manufacturers MSY multi-a been given Miyano BNE-51 business a centre. boost turn-mill months thanks over the last ten g-based company The Worthin to a new £9.7m business machinist support million parts subcontract The Manufac initiative. some 1.5 ted dispatches from comple Programme turing Growth (MGP), funded emblies a year – ranging European and sub-ass s and Regional Develop by the assemblies Fund (ERDF) ed casting ment is to large machin Economic and delivered by parts – and Growth turned small a record Solutions has helped (EGS), achieving of 98%. companies currently rate the UK to across 13 mins to just grow, Martello from on-time delivery products and develop been cut new further complex director Joe y is driven A Managing which Keet says: overcom the compan Seanproducti y 2.5 emins.s steel component on issues explains that hy of constant Cell Leader nal flexibilit that previous were stainles ns taking of operatio us ly holding to a by a philosop of lean manufacturing “The levels them three operatio Thisenabled BNE has has already ing ledhad back. is now reduced developmentsupported by machin in the Miyano reduce tominutes new nute cycle. tment ntly jobs, with an addition 11 400 four-mi ng £1 techniques, to significa al 359 n-inves important, often exceedi mostpositions expected to single, ivity.” investment and an ‘open-liaison’ times and Further return-o up setters to be created once product ongoinge projects year the freeinghas the million a improve overall which keeps are complet comes from tasks and from new machin ed.machin By the es other people strategyto date on the He says the£1.6m end of perform for each 3-axis July, up grant contribu um d existing ofalumini arising. n of lost time g the workforce replace issues 10 been reductio on, reducin errors and any four tions have inspecti family ofmade, withdmoney in company require so that a to support first-off We’ve relocati got aonlot of “We invest e in place andstill previously another He says: s. grants to deliver a separat 2200 firms parts that between risk of setting and progres ns and and the latest we want MSY leadership nownow work in operatio be and which manufac automation cutting March ogy and manage and the BNE-51 n canHolmes, cycle.2019. 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The to help / superim “Since October l. manufac the nised to synchro two Citizen grow and on, turers MDs are talking language centre machin highest barrier 2016, the both 12-stati . forimprove turn-mill es, a Citizen L20-VIII them and can guide This control is being Ideal for cy on was ‘Continu with 15% of clients achieved turrets. an 18-stron two machin low frequen adecision making the right through all-driven g featuring followed by ous Improvement’, s, before bringing ogy) and experienced network of LFV (LFV ‘Environmental’ specialists in BER 2017 cutting technol will bring manufacturing ‘Marketing on specific SEPTEM and growth manage vibration and Market e M16-V issues are facing to 14. 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www.eng ineeringc apacity.co m

JANUARY 2022

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

Subcontract mill turned parts up to 65mm in diameter from bar and 300mm billet work.

REPETITION TURNED PARTS 8

DAWSON PRECISION COMPONENTS

SUBCONTRACT CNC TURNING 8

PRECISION ENGINEERING 8

Engineering Capacity | DIRECTORY

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dpc.co.uk

Kirkham Engineering Co Ltd 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

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.

Oldfield Street, Crosland Moor Huddersfield HD4 5AJ T: 01484 548903 www.thomas-brown-engineering.co.uk

JANUARY 2022

Wealdpark Ltd

TURNED PARTS 8

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

PRECISION ENGINEERING 8

Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk

Precision Products (Brighton) 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.

Accredited to AS9100 Rev D

Sutton Road, St. Helens Merseyside WA9 3DJ Tel: 01744 22567 www.wealdpark.co.uk

Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk

A one-stop-shop for high-quality turned parts

www.engineeringcapacity.com

FARNBOROUGH | Hants | GU14 6TQ

8th | 9th | 10th FEBRUARY

9.30am - 4.30pm (3.30pm close Thurs)

Where Industry and Innovation converge Over 600 national and international suppliers come together to exhibit at Farnborough International Exhibition and Conference Centre this February for Southern Manufacturing and Electronics (inc AutoAero) 2022. Meet the power behind UK manufacturing industry and see live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment. Free industry seminar programme online @ www.industrysouth.co.uk

FREE SEMINARS FREE PARKING

AUTOMATION DEFENCE FOOD & DRINK AUTOSPORT MARINE AEROSPACE TRANSPORTATION PACKAGING ELECTRICAL & MECHANICAL ENGINEERING ADDITIVE MANUFACTURING LOGISTICS ELECTRONICS ENERGY SPACE ENGINEERING R&D

The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 8th February.

PRE-REGISTER TODAY for your Fast Track Entry Badge, Preview Magazine and Event Catalogue at

www.industrysouth.co.uk

MEDICAL COMPOSITES CONSTRUCTION

SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd

Tel 01784 880890 · email philv@etes.co.uk

Engineering Capacity January 2022 Digital Edition

Articles inside

Engineering Capacity January 2022 Digital Edition

CASTING & FORGING

ELECTRONICS