Engineering Capacity July 2017 digital edition

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

July 2017

INDUSTRY NEWS | TURNED PARTS | AEROSPACE & DEFENCE | CASTINGS

INDUSTRY NEWS: Manufacturing outlook for US and Mexico

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EventCity | Manchester | M17 8AS 27th – 28th September 2017 9.30am – 4.30pm (4.00pm close Thurs)

The Leading Manufacturing Technology Exhibition in the North Over 300+ national and international suppliers will gather in Manchester this September for Northern Manufacturing & Electronics 2017 together with the RoadRailAir event. The exhibition will feature live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D printing, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment.

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Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Sales Manager: Arfan Qureshi sales@engineeringcapacity.com Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services.

For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company number 10567217 ISSN 0306-0179 COMING UP IN OUR SEPTEMBER ISSUE Machined Components, Waterjet & Laser Cutting, Automotive, Moulding, Northern Manufacturing & Electronics Exhibition Preview, Advanced Engineering Show 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

Member of the Engineering Industries Association

Editor’s View There’s a classic moment in more or less every Road Runner cartoon where he runs off the edge of a precipice and just keeps on running. It’s only when he notices the abyss below that starts to plummet to the ground.

Some people seem to think that this is the situation the UK economy is in as we move forward into an extremely uncertain future. I tend to disagree. I think that there are enough encouraging vital signs in the economy, and manufacturing in particular, to suggest that we are not currently suspended over a chasm.

The automotive industry in particular seems to be shrugging off Brexit concerns. As we report on page 8, foreign direct investment in the West Midlands automotive industry was up 10% on the previous year, with 58 new deals helping to generate around 3,000 new jobs in the region. The projects involved investors from the US, China and India, showing that the wider global economy still sees the UK as a viable manufacturing base.

A report from the automotive industry trade body, the SMMT entitled ‘Growing the Automotive Supply Chain – Local Vehicle Content Analysis’ shows that 44% of components used by UK carmakers come from UK suppliers. A figure that is up from 36% in 2011. A total of 1.7m vehicles were made in the UK in 2016 – a 17-year high – so that is a lot of local content and a lot of UK component suppliers.

The latest contract manufacturing index (see page 7) suggests that the encouraging outlook persists as you go down to the lower tiers in the supply chain. On top of strong figures for the first quarter, the index edged up a further 6.7% from April to June – with machining being particularly strong in June. The index represents a cross-section of the market with a £3bn purchasing budget, so the implication is that it is not just automotive that is doing well. So at least on an anecdotal basis it doesn’t appear to me that we are about to plunge off a cliff edge. But the future remains uncertain and I could be wrong.

So keep on running, and don’t look down.

Andy Sandford, Editor

Pr Precision ecision Machined C Components omponents Est. 45 y years ears ISO Appr Approval oval 20 y years ears

Tel: +44 (0)23 9267 7747

JULY 2017

Email: info@dkwengineering.co.uk

1969 - 2014

45 years

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Contents July 2017

25 FORMING & FABRICATION

News

Features

06 Second plating cycle for Brompton bikes 06 Surface Technology mixes up

14 Turned Parts 06 On track for growth Muller still on form at 90

a special edition

07 Subcontract market making steady progress 06 Market index is up by 6.7% 08 R & D grants jump-start new alloys 06 Copper specialists puts tax

19 Aerospace & Defence 06 More Makinos for JJ Churchill

26 FORMING & FABRICATION

25 Forming & Fabrication 06 Fuses for fighter jets

relief into products

Rail electrification fabrications

10 Environmentally responsible engineering 06 Copper specialists puts tax

30 Castings & Forgings 06 Forgemasters back in offshore business

relief into products

11 Cover Story: Industrial prospects for USA & Mexico 06 Special seminar at EMO machine tool show 4

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Kenard for chosen growth initiative Grinder for flap actuators Fuses for fighter jets

32 Composites 06 Lightweight defence structures

33 COMPOSITES JULY 2017

Engineering Capacity | INDUSTRY NEWS A new subcontract machining firm has been boosted by the purchase of a Hurco VM5i to help it undertake small batch manufacture and project work.

Coventry-based Overstone Engineering brought the 3-axis vertical machining centre (VMC) for its compact footprint of slightly over 1.6 x 2.2m, working envelope of 457 x 356 x 356mm and height of less than two metres tall with its ram lowered.

Richard Dunn, company owner, said: “I could not offer contract machining services during a twoyear exclusion period after selling my previous company, Drurys Engineering in Hitchin. Now that I am free to re-enter the industry, I have chosen the Hurco VMC for its size and capability.”

Installed and commissioned earlier this year, a number of contracts were completed on the VM5i in the first months of operation, involving materials from nylon and aluminium to phosphor-bronze and steels.

Shortly after installation, a contract was won for the production of a robotic test rig to be used for non-destructive testing in the aerospace industry.

Most recently, the machine was used to produce a single assembly made largely of phosphor bronze for an unspecified application.

A majority of Overstone Engineering's work is programmed directly at the control using Hurco's conversational programming software. In this case, however, it was simpler to export a DXF file from Mr Dunn's OneCNC CAD JULY 2017

VMC boosts Coventry start-up

Ultimotion software was supplied as part of the package, giving fast, smooth, dynamic motion that is exceptional for such a low-cost machine and greatly helps to reduce cycle times and improve surface finish

‘‘

package and use the DXF facility in the Hurco control to generate the cutter paths automatically.

Mr Dunn added: “Besides its compactness, another benefit of the Hurco machine is the high level of technology built into its control software. In addition to having the option of a module that allows native handling of DXF

files, it can accept externally written G-code for milling 3D freeform surfaces.

“Ultimotion software was supplied as part of the package, giving fast, smooth, dynamic motion that is exceptional for such a low-cost machine and greatly helps to reduce cycle times and improve surface finish.”

Overstone Engineering's target market is the design, production and assembly of items that disrupt activities on other manufacturers' shop floors.

Typically, they include machining of prototypes in ones and twos, small-volume milling and turning and electro-mechanical assembly.

8 overstone-eng.com www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity UK-owned Brompton Bicycle has partnered with specialist coatings supplier Surface Technology for the second time to produce 1,300 of its special Nickel Edition bikes.

This follows last year's instant sell-out of the bikes, which are electroless nickel plated by Surface Technology, part of Norman Hay plc, at Brompton's Leeds facility.

Mo Rahnama, design operations manager at Brompton, said: “Brompton had talked for some years about creating a specialist nickel version but came up against a number of technical challenges postponing the development. Surface Technology was the obvious partner for the project due to their extensive knowledge and understanding of industrial coatings and their ability to research and test a unique solution for our product.”

This year, the two companies have worked together to increase efficiencies in the manufacturing process, meaning Brompton Bicycle has been able to extend the range, offering varying heights of handle bars for different riding styles.

Second plating cycle for Brompton bikes The technical teams at Surface Technology and Brompton identified ways to reduce the amount of masking time required, while ensuring the tolerances of the various component mounting points within the frame were maintained. As a result, Brompton ensured mounting point holes were machined larger in the fabrication process to allow correct assembly from the plated parts.

To enhance the quality of output

the Brompton bikes were salt spray tested. The frames were placed in a secure chamber and sprayed in a climatic environment for more than 200 hours to accelerate the corrosion process.

Brompton stated they were checked and photographed every day and at the end of the testing the frames were cleaned back to their original nickel coating with no sign of corrosion damage.

9 surfacetechnology.co.uk

MIDEST on the move

DIT funding for ASEAN shows

The French subcontracting show MIDEST has moved from its traditional Autumn slot and now has new owners. GL Events Exhibitions has acquired the show from previous owner Reed Expositions and will run it alongside the Industrie, Smart Industries and Tolexpo exhibitions at Paris Nord Villepinte from 27 to 30 March 2018. The entire Midest team will be joining GL Events.

The new owner’s aim is to create a French global industrial trade show dedicated to manufacturing tools and technologies and industrial know-how.

9 midest.com

The Engineering Industries Association can provide Government funding for UK SME companies to exhibit at the METALEX machine tool, sheet metal working, wire, tube and welding show in Bangkok from 22 to 25 November 2017 and at Manufacturing Indonesia in Jakarta from 6 to 9 December 2017. A 9m2 stand, including space, construction, furniture and GB graphic will be £2,297 at METALEX and £812 at Manufacturing Indonesia. For further information please contact Karen Finegold on 01923 828 991 karen.finegold@eia.co.uk 9 eia.co.uk

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JULY 2017

Engineering Capacity | INDUSTRY NEWS Building on strong figures for the first quarter of 2017, the subcontract manufacturing market edged ahead another 6.7% in the second quarter, with strong demand for machining in June offsetting a dip in May. According to the latest Qimtek Contract Manufacturing Index (CMI) figures, the index for the second quarter stood at 174, compared to 163 for the first quarter, although it was 8% down on the corresponding quarter of 2016 when demand was particularly strong and the index stood at 188.

The base line figure of 100 represents the average value of the subcontracting market during 2014.

On a process-by-process basis,

Subcontract market making steady progress

WEC Group’s engineering apprentices have put their new fabrication and machining skills to the test in order to manufacture major parts for a research space rocket.

Within just four weeks, WEC Group Training Academy apprentices fabricated a rocket propulsion system and fitted the rocket’s fin brackets which were cut at the company’s in-house waterjet division.

The 8.3m Skybolt 2 rocket, created by Starchaser Industries, is set to launch later this year as a way of engaging young people and inspiring them to pursue science technology, engineering and mathematics as part of their education.

Expected to reach 4000 feet in just 17 seconds, the carbon fibre rocket will contain and test an

It is rocket science

JULY 2017

machining was up by 6.7% on the first quarter, the same as the overall index, despite the poor figures for May. Fabrication nudged up slightly by 3.4% on the quarter despite tailing off from a high point in March.

Other processes including electronics and plastic moulding were up by 24%, but from a low base compared with the same period in 2016.

Commenting on the latest CMI figures, Karl Wigart, owner of Qimtek, said: “Despite all the uncertainty for the economy

array of electronic instruments which could potentially be used in future flights, and will test fly a number of experiments from the University of Chester, Manchester, Leicester, Sheffield Hallam and other UK educational institutes.

The rocket boosters are now being fitted in Cheshire before

resulting from the General Election and the Brexit negotiations, the contract manufacturing market remains resilient.

Indeed, it could be that this uncertainty is leading manufacturers to turn to subcontractors to hedge against volatile demand.

“Progress is definitely bumpy, but the long-term trend, particularly in machining, is upwards and this is borne out by what we are hearing from our members.”

9 qimtek.co.uk

coming back to WEC in two weeks’ time when the apprentices will manufacture the launch pad to prepare for lift off. This is the first time WEC has built a rocket, but the company has assisted with the manufacture of launch pads and parts before.

9 wec-group.com www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity

Foreign companies put 10% more into UK auto Figures released by automotive inward investment body Drive Midlands show that the region's automotive sector secured 58 new foreign direct investment (FDI) deals during 2016/17, a 10% increase on the previous year.

These new projects, which involved investors from the US, India and China, helped to generate almost 3,000 new jobs across the Midlands.

David Shepherd, senior business development manager (automotive) at the West Midlands Growth Company, which oversees the Drive Midlands initiative, said: “The fact that the Midlands continues to attract foreign investors is proof of its resilience and ability to deliver a 'business as usual' perspective.

As we wait for the Brexit situation to unfold, automotive businesses from OEMs right through to large manufacturers are pulling together to make sure this region remains a safe and attractive bet for investors.”

The Midlands currently accounts for 50% of the UK's automotive activity and is home to seven high-volume car manufacturers.

9 drivemidlands.co.uk

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R & D grants jump-start new alloys

Thanks to £100,000 of R & D tax relief a North Staffordshire manufacturer has developed new alloys that have generated £1m of new orders for complex forgings and machined components.

Copper Alloys Ltd, which employs 30 people at its facility in Burslem, has secured a string of contracts over the last twelve months with customers in the aerospace, defence, marine and petrochemical sectors.

This expansion has been supported by Jumpstart, who has worked with the company to generate more than £100,000 of R&D tax relief over the last three years…all of which has been directed into the development of new alloys for applications as

diverse as ice cream machines and nuclear submarines.

Jumpstart’s John Thomson said: “On the surface, Copper Alloys operates in a very traditional industry, but it doesn’t take you long to realise how innovative and technologically advanced it is.

“The company undertakes lots of R&D in testing out new processes and new equipment so it was just a case of extracting the information from Ivan and then packaging it in a way that would support its claim. I’m delighted we’ve had such a good result so far and it has been fantastic to see the money ploughed back into helping the company grow to £6m.”

9 copperalloys.net jumpstartuk.co.uk JULY 2017

The world of metalworking

More innovations are unveiled at EMO than at any other trade fair in the industry.

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The full range of state-of-the-art metalworking technology will be showcased with an HPSKDVLV RQ PHWDO FXWWLQJ DQG PHWDO IRUPLQJ PDFKLQH WRROV PDQXIDFWXULQJ V\VWHPV SUHFLVLRQ WRROV DXWRPDWHG PDWHULDO Ă RZ FRPSXWHU WHFKQRORJ\ LQGXVWULDO HOHFWURQLFV and accessories.

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INDUSTRY NEWS | Engineering Capacity

Environmentally responsible engineering British Metal Treatments (BMT) is offering an environmentally responsible material reclaim service to help companies repair and reconfigure engineering components.

The highly skilled workforce at BMT can carry out the highest quality reclamation work on everything from mandrels and sleeves to actuator cylinders, valves and couplings.

Kenneth Gauld, managing director of parent company AJT Engineering, said: “Through reclamation, we can prevent the need for complete manufacture which in turn lessens the environmental impact.”

“We are something of a onestop shop and are able to carry out tailored, turnkey projects, in addition, we provide unrivalled technical support throughout the

surface treatment sector, and can assist with any environmental or health and safety concerns at project inception.”

The company recently completed an extensive and complex reclamation project to repair and reclaim a cylinder clamp body which was traditionally discarded following use. Before machining work was carried out and a hard chrome plating applied, the team had to isolate the area to be treated with 0.070” nickel.

To ensure that its customers receive the very best quality products, BMT's workforce has undergone extensive training both “in-house” and externally through the Institute of Materials Finishing to perfect its skills in areas such as electroplating, correct current calculation, deposition applications

Blackhill Engineering has won its first contract for the manufacture of equipment to support nuclear decommissioning work at Magnox's Winfrith site in Dorset.

The contract marks a further breakthrough into the nuclear sector for Exeter-based heavy engineering company Blackhill, part of SC Group, the Devonheadquartered engineering services business, which is actively targeting the nuclear and energy sectors as part of its long-term growth and diversification strategy.

Nick Ames, chief executive of SC Group, said: “Magnox is a prestigious new customer for

Magnox contract win

10

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Blackhill which is ideally placed in terms of its heavy engineering capacity and local geography to

and the unique process routes for specific substrates.

The BMT plant is based at Port Glasgow and specialises in electro-chemical deposition techniques, particularly with chromium, nickel as well as electroless nickel plating (ENP). It also offers in-house machining and grinding and carries out all surface work for both before and after the plating processing.

9 bmtgalv.co.uk

provide the South West's fabrication services required by the nuclear sector.”

Magnox, owned by Cavendish Fluor Partnership, holds a Nuclear Decommissioning Authority (NDA) contract to safely manage 12 nuclear sites and one hydroelectric plant in the UK. Blackhill specialises in machining large fabrications and complex assemblies, and boasts a 60-tonne lifting capability in the South West of England.

9 blackhillengineering.co.uk JULY 2017

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INDUSTRY NEWS | Engineering Capacity

Industrial prospects for USA and Mexico A special seminar at the EMO machine tool event in Hannover will analyse the direction of travel for US manufacturing and the effect of that on Mexico.

Running from 18 to 23 September, EMO Hannover 2017 is the world's premier trade fair for the metalworking industry with over 2,000 exhibitors from 45 countries.

Last year the USA was the second-biggest market for machine tools worldwide, with Mexico ranking number 7, but now the organiser of the event, the VDW (German Machine Tool Builders’ Association) is asking what will happen next.

The two nations had been beacons of hope for international manufacturers of production technology: the USA with its reindustrialisation programme, and Mexico, which had evolved into one of the world’s most important automaking locations, but the events of the past year make the future less certain.

The outlook will be investigated as part of the VDW’s Metalworking Growth seminar on 21 September at EMO Hannover, which is being delivered in partnership with Gardner Business Media, publisher of Modern Machine Shop Magazine.

Dr. Wilfried Schäfer, Executive Director of VDW says: “Soundly based expert information is 12

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indispensable for every corporate leader from the manufacturing sector doing business with these two countries. It’s all the more valuable when the experts

concerned are able to base their assessments and appraisals on how the situation is actually viewed from within these two markets.”

Travis Egan, the publisher of the Modern Machine Shop trade periodical, takes an optimistic stance. He perceives a highly upbeat mood among the manufacturers in both these countries, and promises good business opportunities for every vendor able to utilise this optimistic atmosphere in his favour. The figures issued for the German machine tool industry’s first quarter, for example, prove him right: German exports to the USA have increased by 16 per cent, with exports to Mexico even up by more than one third.

8 emo-hannover.de JULY 2017

Engineering Capacity | PEOPLE

Trade Leads from the EIA The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk

David Searle has been appointed South East Project Manager by ECS Engineering Services. A civil engineer with 15 years’ experience predominantly in the rivers, costal and hydrology sector, he has worked with numerous public and private sector clients.

Gareth Higgins managing director of precision sheet metal fabrication specialist KMF, has been awarded an MBE in the Queen's Birthday Honours list. Mr Higgins, who has helped steer KMF through 25 years of growth, is honoured for services to apprenticeships.

Microfluidic control valve A Swiss medical systems SME has developed a passive flow control valve using microelectromechanical systems (MEMS) and is looking for partners to license and apply the technology.

Reference: JV1162 Closing Date: 13/09/2017 Mirror polished stainless A Scottish SME which designs and produces men's luxury accessories, including stainless steel hip flasks, is seeking automated or robotic technology which will enable them to finish their flasks in-house.

Reference: JV1165 Closing Date: 27/09/2017 Romania – plastic welding A Romanian welding service company wants to work with British suppliers of polyethylene welding equipment.

Reference: 29189 Closing Date: 23/12/2017 Turkey - Scrap steel Turkish iron and steel company wants to buy steel scrap Reference: 29513 Closing Date: 31/12/2017

Richard Halstead is the new EEF Director for Membership Engagement across the North West, North East and Yorkshire & Humber Regions.

This new post recognises the importance of the North of England as a growth area and the impact of continued devolution.

JULY 2017

Mark Titterington has been named as Is the new Chief Executive of Engineering UK, an independent organisation that works to inspire tomorrow’s engineers. He has held various business leadership roles throughout his career and joins from Syngenta.

Brazil - Power line products Materials needed to renovate power transmission lines.

Reference: 29581 Closing Date: 30/08/2017 For more information please email head.office@eia.co.uk quoting reference number.

Please remember to use due diligence in responding to Trade Leads. Engineering Capacity provides you with the above information in good faith, but is unable to accept any responsibility or legal liability arising from any use of these leads.

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TURNED PARTS | Engineering Capacity Subcontract machinist JC Precision Engineering, has more than one string to its bow, as it earns 70% of its turnover from producing a wide range of components for racing go-carts, a business that has grown progressively from the race track participation of the Munday family led by father Vincent who set up the firm 36 years ago and is now run on a day-by-day basis by his two sons Dan and Chris.

Production at the Market Overton factory in Rutland is steeped in CNC machining centres and fixed head lathes for turning, for which around ÂŁ1 million has been invested over the last five years, usually buying one machine a year.

The family had long considered investing in CNC sliding head turnmill technology for producing smaller precision parts, and following a visit to MACH 2016 decided to order a Citizen Cincom L32-VIII with removable guide bush.

This was installed last July and the company is already considering a second machine as it is concerned it will run out of capacity.

Since July, apart from more

On track for growth

Chris Munday (left) and his brother Dan (right) are now planning a second Citizen order due to immediate success of first installation.

effectively switching work from other machines, the firm has won new contracts that they could never have dreamed of producing before.

The directors have already noted how they have increased not only profitability, but also throughput, with cycles now being clocked twothirds faster than before. For example one part taking 50 plus seconds on a fixed head machine is now produced in just 17 secs.

However, most important to them is that lead times are being slashed compared to previous methods which involved separate

fixed head turning and often further milling and drilling set ups as well as manual finishing.

Indeed, further benefits are also being accrued from the ability to achieve total consistency enabling ‘through-the-night’ running and the ability to maintain tolerances as tight as 10 micron when needed.

As a result, previous production methods involving four or five set ups have been reduced to one including in-cycle deburring.

Batches as small as 20 have proven to be economical especially when planned with other work with the machine already either set with or without the guide bush in place or having no need for a bar change. This economic capability for small quantities has also encouraged Stub axle shaft made from 31mm EN8 is machined with single cut to 17mm diameter and 0.025 tolerance on Citizen L32.Vlll at JC Precision Engineering.

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JULY 2017

Engineering Capacity | TURNED PARTS design input for certain key customers as well as development and providing a prototype service.

In ordering the Cincom L32-VIII the Munday’s elected to specify the detachable guide bush. Said Dan Munday: “We have considerable demands for special sizes of short length parts such as spacers and even washers where we can save on bar end material and it takes less than 30 minutes

to change over to a guide bush when needed.”

He describes how they are running a wide range of parts in materials including EN24, 316 stainless steel, plastics, aluminium and brass. These include special bolts and pins, master cylinder brake pistons, brass fuel fittings and stub axles. Indeed, a further point of disbelief in the capability of sliding head machining has also been dispelled in producing the

stub axle out of 31 mm diameter EN8 when in a single cut of 7 mm, the part was taken down to 17 mm diameter and held to a 0.025 mm tolerance. The part was then threaded each end from the main and sub-spindle and within the cycle, a hexagon was milled adjacent to a flange.

JC Precision Engineering is now planning to add more space and invest in another Citizen.

8 jcengineering.co.uk

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TURNED PARTS | Engineering Capacity One of the UK’s leading subcontract machinists is celebrating its 90th birthday in style after securing a string of new contracts and creating 15 jobs.

Muller Holdings, which has sites in Cleobury Mortimer, Redditch, South Wales and Wednesbury, has landed an additional £500,000 of sales to mark its big anniversary, including work for automotive, smart gas meters and producing parts for the ‘GripIt’ building product.

The company has withstood a number of recessions over the last nine decades and was a key supplier to the Second World War effort, where it relocated from London to Shropshire to avoid further air strikes during the Blitz.

Today, it specialises in CNC milling, turning, multi-spindle and CNC conventional and Escomatic manufacturing services, with its components ending up in the best selling cars in the world, in dental products and appliances that keep homes and factories warm.

“90 years of manufacturing is some achievement and we have a colourful history, from starting life owned by the Swiss and supplying the Ministry of Defence, to becoming Cleobury Mortimer’s largest employer and forging an exciting joint venture in India,” explained Paul Bethell, Managing Director and one of the key people behind the MBO in 1993.

“Our business has been based on technical excellence and providing precision machining solutions and these two attributes have remained constant despite 16

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Muller still on form at 90 the changing economic and industrial picture.”

He added: “Whilst we are very proud of our history, the focus now is on the next nine decades and the first half of 2017 have been very good for all of our four sites in the UK. Turnover has

Second World War, Muller Holdings became a significant presence in high volume turned parts for the automotive, defence and medical sectors, using a range of multi-spindle automatics, rotary transfer machines and fixed head

Our workforce stands at 150, but we expect this to grow by about 10% between now and the end of the year. These positions will be experienced manufacturing professionals and the possibility of employing more apprentices

‘‘

increased across our key markets and our pipeline of enquiries has definitely received a boost from the drop in the price of Sterling.

“Our workforce stands at 150, but we expect this to grow by about 10% between now and the end of the year. These positions will be experienced manufacturing professionals and the possibility of employing more apprentices.”

Following the end of the

Escomatics for miniature turned parts supply.

By the early 1980s, the first investments in CNC lathes and machining centres were made and ten years later this was followed by the introduction of multi-axis lathes with power tooling and magazine bar-feeds… this gave it the opportunity to offer complicated machining at competitive rates.

JULY 2017

Engineering Capacity | TURNED PARTS Over the course of the next twenty years, a number of strategic acquisitions were made, setting up dedicated facilities in the Black Country, Redditch, Llandovery in South Wales and a joint venture in Haryana in India. “The last two years have seen more than ÂŁ850,000 of investment in new machinery, a sort of early birthday present to ourselves,â€? continued Adam Cunningham, Director at Muller Redditch.

“As part of this, we have increased our escomatic and multi-spindle capacity by 10% and we will shortly be installing highspeed visual inspection equipment

to ensure we offer world class quality to our customers. “This is designed to give us the necessary capacity and competitive advantage to go after our 3 yearplan to be at ÂŁ16m by 2020.â€?

Muller Holdings is part of the Midlands Assembly Network, a nine-strong group of sub-contract manufacturers who work together to win orders and share best practice and resource.

8 muller-england.co.uk

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JULY 2017

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TURNED PARTS | Engineering Capacity

Optimas cements its JLR supply role Optimas Solutions has formalised a continuation of its contract with Jaguar Land Rover (JLR) for fastener supply to JLR's Castle Bromwich and Solihull manufacturing facilities.

The announcement comes as JLR continues to invest in its UK manufacturing, having shown strong growth in the domestic and export markets over recent years.

David Harvey, VP automotive for Optimas, commented: “In 1998 we opened a purpose built facility next to the JLR Castle Bromwich plant. We use a private road which is used to deliver parts via electric vehicles every two hours; all day every day.

“The service has continued to grow and we now supply over 1 billion fasteners to thousands of 'points of fit' within the JLR UK manufacturing network our components are found on every Jaguar and Land Rover in production today.”

Optimas began its relationship with JLR in 1993 as a supplier of fastener solutions for a single production line, going on to provide c-class components and becoming the first full service provider to the company.

8 optimas.com

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Hague Fasteners wins multiple contracts

A UK manufacturer of nonstandard fasteners has celebrated moving into its new home by securing a string of new contracts.

Hague Fasteners, which has recently been awarded ISO9001:2015, has won £300,000 of work to supply specialist products to the oil and gas, petrochemical and growing construction sectors.

The 25% surge in orders comes after the business completed a move to a larger factory in Willenhall, West Midlands that enables it to triple its production capacity to 8,500 sq ft.

“We had reached bursting point at our old site so knew 2017 was always going to be the year we made a move,” explained CEO Jon Hague, who runs the firm with his wife Claire.

“It took us over six months to

find the right place, but as soon as we saw it we knew the location was ideal, giving us more space to take on new clients and the ability to plan the layout down to the finest detail.

“Our factory now boasts more CNC machines and is laid out in cells to help improve efficiency.

This is just the start, we've got exciting plans to add further new technology to the shopfloor and expect to take on six new people between now and the end of the year - some of whom could be apprentices.”

Hague Fasteners supplies products in small to medium batch quantities, from single prototypes through to 5, 10, 25 and 50-part runs. It provides technical fasteners in sizes from 3mm to 200mm in diameter.

8 haguefasteners.co.uk JULY 2017

Engineering Capacity | AEROSPACE & DEFENCE JJ Churchill has added two more Makino 5-axis machining centres to its machining cell, which is now up to four Makinos, in order to meet niche orders in the aerospace industry.

JJ Churchill’s four Makino VIPER grinding centres have been positioned so that they are ready to accept automation and are also ready for the addition of a further three Makino grinders in the future.

Andrew Churchill, managing director, JJ Churchill, said: “The work we are most interested in carrying out is always a challenge and often one where our customers have found it difficult to find the capability.”

“We like to push the boundaries of grinding, milling and turning, in the most difficult materials, geometries and dimensions, that’s why we have reorganised our factory around the Makino cell, in order to constantly achieve the high expectations which our customers require.”

Mr Churchill added that robotic loading of the new machines is key in enabling JJ Churchill to achieving global cost

ADS show hits the road The ADS Defence & Aerospace Technology Roadshow takes place once again in September 2017 visiting Major Defence & Aerospace Sites across the UK on its 3-week tour.

This gives participating companies the opportunity to

JULY 2017

More Makinos for JJ Churchill

competitiveness. The investment completes a £2.3m investment in new technology, people and systems to meet new orders from existing and new customers in the aerospace industry.

JJ Churchill is focused on ‘sticky niches’ within the aerospace market, niches which require a high degree of technical and organisational skill, including work involving difficult geometries, difficult dimensions and challenging materials.

This new investment in Makino 5-axis VIPER CNC grinding capacity, linked to advanced information-management systems, enables the machining of complex, precision components in advanced nickel-based alloys and single crystal components.

The company’s aerospace sales have increased by more than 60% in the past year and the sector now contributes two thirds of the company’s total sales.

8 jjchurchill.com

come and present their products, services and technologies on board a unique exhibition vehicle directly inside the customers' premises.

Multiple sites of Rolls-Royce, Leonardo, Thales, GE Aviation, Cobham, Qinetiq, Goodrich, Agusta Westland are BAE Systems are all on the proposed tour list for 2017.

The organiser, Dream Marketing International provides

you with your Exhibition stand with graphic display, power, lighting and cupboard storage and the opportunity to have two of your personnel on the vehicle at each location on the route.

Contact john@dreammarketing.co.uk or phone 01189 886 823 and you will receive a full information pack by return.

8 dream-marketing.co.uk

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AEROSPACE & DEFENCE | Engineering Capacity

EL

Kenard chosen for growth initiative

for Manufacturing, Deloitte, Industry Forum and the National Physical Laboratory.

Kernard Group, which has manufacturing divisions in Dartford and Tewkesbury, said that engaging with SiG through an intense diagnostic phase helped its management team to develop a vision and strategy for the future.

Sharing in Growth CEO, Andy

E BR AT I N

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Kenard Engineering Group has been selected for Sharing in Growth (SiG), the governmentbacked supply chain competitiveness programme to help take advantage of aerospace growth opportunities.

The initial focus of the four-year programme will be to drive operational excellence, business development, people development and management control and reporting.

Kenard Group managing director, Keith Ellis, said: “We see this as a fantastic opportunity to invest in our ability to deliver globally cost competitive performance, with thought leadership on the latest best practice and applications in manufacturing at its core. We expect SiG to help unlock the full potential of our business, to the benefit of all our stakeholders and industry.”

The training and development programme, funded by the Regional Growth Fund, will be delivered by SiG’s own 120-strong team of coaches as well as a bank of experts including The University of Cambridge’s Institute

Years 19

74 - 2014

FM10101

Manufactur Manufacturers ers of High Quality Mill-Turned Mill-Turned Parts

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Page, said: “We are already working with 55 companies, so they can fulfil their world-class manufacturing and business ambitions. With our support, the first 43 companies on the programme have secured around £2 billion in contracts to date – almost 20% of which is for direct export. Consequently, we are well on target to hit our ultimate objective of safeguarding 10,000 UK jobs by 2022.”

SiG is currently recruiting companies with similar growth ambitions to Kenard to fill the remaining funded places.

Established in 2013, the SiG programme is endorsed by Airbus, BAE Systems, Boeing, Bombardier, GE, GKN, Leonardo, Lockheed Martin, MBDA, RollsRoyce, Safran and Thales.

8 kenard.com JULY 2017

Engineering Capacity | AEROSPACE & DEFENCE

AE Aerospace expansion on the cards

Double accreditation The heat treatment division of Keighley Laboratories Limited has received two accreditations in two weeks.

Not only has been awarded Nadcap (Heat Treating) accreditation for its Nitriding process, which it delivers to the aerospace industry, it has also recently undergone a successful annual BSI reassessment for BSI BS EN 9100:2009; AS 9100 rev C accreditation.

“Congratulations to Keighley Laboratories on successfully passing what may be the aerospace industry’s most stringent process capability assessment audit,” said Joe Pinto, executive vice president and chief operating officer at the Performance Review Institute.

“Nadcap audit criteria are widely acknowledged to be hard to meet and companies like Keighley Labs, who succeed at doing so, rightfully deserve recognition.”

Debbie Mellor, managing director, commented: “The range JULY 2017

Congratulations to Keighley Laboratories on successfully passing what may be the aerospace industry’s most stringent process capability assessment audit

‘‘

and number of accreditations held

by Keighley Laboratories builds the support and confidence of our customers. They highlight the company’s achievements and strengths, particularly important in our competitive market. This confidence is demonstrated by customer interest in our new Gaseous Nitrocarburising process which is now up and running.

“As part of our continuing strategy to increase business with the aerospace sector the Technical Services division at Keighley Laboratories plans to extend existing Nadcap (Material Testing Laboratory) scope to include chemical analysis.”

8 keighleylabs.co.uk

A West Midlands Aerospace company is looking to expand into new premises in the region to cope with further increases in sales and a growth in staff numbers.

AE Aerospace has already enjoyed a 500% increase in sales following a ten-fold increase in orders and is continuing to grow.

Peter Bruch, managing director of AE Aerospace said: “We have simply run out of space. When we completed a management buy-out three years ago, we had 24 members of staff. We now have 63 and expect to reach 100 by the end of next year.”

“We believe that we win orders because of our focus on safety, quality, delivery and cost and our expertise and knowledge. We have a good range of products. And we know our sectors very well.”

Mr Bruch hopes to find a site with enough space to construct a purpose-built new factory that will provide the company with room for more machining capacity..

The move to the new site will take place in stages over the next 12 months, with the factory being fully open by September 2018.

8 aerospace.com

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AEROSPACE & DEFENCE | Engineering Capacity Hardide Coatings has gained Nadcap accreditation, enabling it to provide its advanced tungsten carbide-based coatings to any aerospace prime contractor or their supply chains worldwide.

Hardide Coatings developed Hardide-A for the aerospace and defence industry as a replacement for hard chrome plating, shortly to be banned under EU REACH regulations, and provide an alternative to HVOF, cadmium plating and other coating processes.

Philip Kirkham, CEO of Hardide Coatings, commented: “Aerospace is a key growth market for Hardide and this is a significant achievement and milestone toward realising the clear potential for our coating technology in this

Hardide Coatings awarded Nadcap accreditation

sector. An increasing number of aerospace companies require their suppliers to be Nadcap accredited so to be fully approved opens up the market to us.”

“Congratulations to Hardide Coatings Ltd on successfully passing what may be the aerospace industry's most

stringent process capability assessment audit,” said Joe Pinto, executive vice president and chief operating officer at the Performance Review Institute.

“Nadcap audit criteria are widely acknowledged to be hard to meet and companies like Hardide Coatings, who succeed at doing so, rightfully deserve recognition.”

Hardide Coatings, which has manufacturing facilities in Oxfordshire and Virginia, US, confirmed its Hardide-A coating was also approved by Airbus in March this year.

8 hardide.com

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JULY 2017

Engineering Capacity | AEROSPACE & DEFENCE Staffordshire Precision Engineering has purchased a VTC-800/20SR vertical travelling column 5-axis machining centre from Worcester-based machine tool manufacturer, Yamazaki Mazak UK. The investment will enable the £3m turnover company to begin manufacturing larger, high precision components for the automotive and aerospace industries, as well as the medical and scientific instrument markets.

Gary Smith, director at Staffordshire Precision Engineering, commented: “The last 18 months have been a very exciting period for the businesses and we believe our recent purchase of a Mazak VTC800/20SR will allow us to meet growing customer demand for larger and more complex parts which, up until now, were beyond our capabilities.

“We've already won new business off the back of the purchase. We can now also machine bigger parts, such as housings, to go alongside the medical and scientific instrumentation components we manufacture for existing

Search and rescue business Arlington Aerospace division North West Precision Ltd (NWP) has been boosted with the award of a search and rescue contract for a special operations aircraft.

The award of the cover assembly contract for the

JULY 2017

Staffs targets aerospace contracts

customers, which means customers can consolidate their subcontract work into one supplier.”

This is the fourth Mazak machine Staffordshire Precision Engineering has invested in, having purchased two QUICK TURN SMART 250M lathes and one VARIAXIS i-500 5-axis multi-tasking machining center in 2016 as part of its expansion.

Mr Smith added: “We like the fact that we can go to one supplier and source multiple machining solutions. The two lathes were needed to service an aerospace contract, and the

VARIAXIS has been a huge asset to us as well. We have paired it with a pallet loader to increase production efficiency and it has already generated a lot of enquiries for highly complex aerospace parts.

“The fact that Mazak is another Midlands manufacturer, and that they offer robust after-sales support, is one of the reasons we purchased the VTC-800/20SR. Our relationship with them goes above and beyond purchasing machines and our Mazaks are central to our plans for future growth.”

8 staffsprecision.co.uk

Hawker U125A was made up of 30 aircraft sets.

Mark Franckel, Group CEO of NWP, said: “NWP continues to go from strength to strength. We’re not just delighted with this contract, but also that our manufacturing is being used to help save people’s lives.”

The current aluminium frames and hatch covers of the aircraft

are being used for spares as part of NWP customers’ on going, long-term ‘life of aircraft’ contracts.

The Hawker is a special mission aircraft for search and rescue and maritime patrol missions and is used by the militaries of Japan, USA and their allies.

8 arlingtonindustriesgroup.com

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AEROSPACE & DEFENCE | Engineering Capacity Produmax has purchased a Jones & Shipman (J&S) Ultramat 1000 CNC B universal grinder to give it new grinding options and reduce manufacturing cycle times on wing flap actuator components.

The acquisition of the Ultramat, which replaces three older J&S machines, plays a significant role in the delivery of one of Produmax’s larger contracts - the manufacture and assembly of wing flap actuators for Bombardier. The actuator assembly contains a number of components where concentricity and a good seal between surfaces is essential for unblemished operation and, West Yorkshirebased Produmax says the Ultramat has reduced the cycle times from 25 minutes to around five.

Produmax operations director, Paul Birtles, commented: “Having a machine with such capability and capacity means the technical team are continually finding new projects for it in addition to those we had initially allocated on its installation. This has given us greater flexibility when reviewing methods of manufacture.

Boeing ups forecast Boeing has raised its forecast for new aeroplane demand, projecting the need for 41,030 new aeroplanes over the next 20 years valued at USD$6.1 trillion dollars.

The US-headquartered company's annual Current

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Grinder for flap actuators

“Also, while the 1000mm grinding length capacity is more than adequate, with new applications coming in all the time, having a ‘future proofed’ machine is a real bonus.”

The grinder is highly specialised with a variable rotating B axis, Renishaw probing, Heidenhain ‘Absolute’ linear scales, a full Fanuc 0i CNC and J&S’s own software to minimise set up times and maximise output.

Workpiece materials vary but are aligned within the grinder’s capabilities, as Mr Birtles

explains: “Our expertise in high precision engineering and knowledge of machining processes embraces hardened and PH steels, titanium, Inconel and aircraft grade aluminium alloys as well as heat treated and hard chromed materials and this enables us to manufacture difficult to make components with volumes ranging from small batch work to large multiples.”

Produmax is also producing significant numbers of components destined for installation on the latest C series aircraft which is being assembled

by Bombardier factories around the world; quite a few of these components are hard chromed and ground using the grinder.

Produmax Limited has recently become the first company outside of the USA to achieve the latest AS 9100 revision D quality standard and the first company globally to be accredited to prEN 9100:2016.

8 produmax.co.uk

Market Outlook (CMO) was released at the Paris Air Show, with total aeroplane demand rising 3.6% over last year's forecast.

"Passenger traffic has been very strong so far this year, and we expect to see it grow 4.7% each year over the next two decades," said Randy Tinseth, vice president of marketing at Boeing Commercial Aeroplanes. "The market is especially hungry for

single-aisle aeroplanes as more people start traveling by air.”

According to the report, the single-aisle segment will see the most growth over the forecast, fuelled by low-cost carriers and emerging markets. 29,530 new aeroplanes will be needed in this segment, an increase of almost 5% over last year.

8 boeing.com

JULY 2017

Engineering Capacity | FORMING & FABRICATION Following the acquisition of deep-drawing specialist Fourjay, West Bromwich-based manufacturer, Berck Limited will be supplying the MoD with pressed components for fighter jets.

Berck, which manufacture metal pressings and metal subassemblies for the world's leading automotive, electronic and medical industries will now be supplying fuses for the Eurofighter and F-16.

Managing Director of Berck Limited, Darren Yates explained: “Fourjay were specialists in deep drawing which is something that we have been unable to do until now. They supply into the Ministry of Defence and they are a large worldwide supplier of fuses. Some of Fourjay's fuses and connectors are used in the Eurofighter and the F-16's which is fantastic news enabling us to move forwards.”

The family-owned business utilises cutting-edge technology, and its production facilities are equipped with versatile roll feed and multislide presses to ensure efficient production and consistent quality in all of its precision components.

Ongoing investment in manufacturing processes has provided Berck with cutting edge Enterprise Resource Planning (ERP) software for optimising production control and collecting real-time shop-floor data.

Berck has also acquired the staff from Fourjay and re-assured their future as a part of Berck's growing operation. Mr Yates explained: “It was excellent news JULY 2017

Fuses for fighter jets for their staff and us. We can already add to our skilled workforce with people that are coming over with a variety of new skills. They will have an opportunity to train our people and vice versa. We have already presented Berck to them and they all seem to be very excited.

We are a bigger operation and we have an infrastructure in place in a different way. We will be able to demonstrate our modern manufacturing techniques and practises

‘‘

“We are a bigger operation and we have an infrastructure in place in a different way. We will be able to demonstrate our modern manufacturing techniques and practises. There was no computer system at Fourjay, now all of the work orders will be processed in the MRP system and they will be trained to use that. It's good news all around that they will be working in a more modern company.”

Berck's precision components are already found in nearly every car manufacturing operation in the UK and overseas.

With a rich history dating back to 1947, Berck have gained a global reputation now the company aims to acquire more companies in the future, as Yates concluded: “One of the best ways to develop your business is through acquisition. We have done it with Fourjay and we are looking to do it again in the future. We believe it will take six months to absorb what Fourjay have got and then it will be onto the next one.

“It is brilliant that we can now offer a new process in deep drawing and it only adds to our portfolio, it is a very exciting time here at Berck. We have communicated what is happening to our staff as well. With a family run business it is very important to add the right sort of people, but I think the new Fourjay staff will only improve the Berck team.”

8 bercklimited.co.uk www.engineeringcapacity.com

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FORMING & FABRICATION | Engineering Capacity

FC Laser boosts productivity Precision laser cutting specialist FC Laser has installed a new 10kW Bystronic fibre optic laser centre to help boost productivity and edge ahead of the competition.

The new machine is capable of cutting materials as thick as 30mm with incredible accuracy and because it's 40% more energy efficient than its predecessor, FC Laser will be able to boost its productivity while reducing its energy costs.

Steve Connolly, general manager, FC Laser: "Speed,

accuracy, quality and maximum uptime - the new Bystronic machine is literally at the cutting edge of laser technology and it is so easy to use."

He adds: "When the other two machines are installed we will be in our best position yet to meet the requirements and demands of

our expanding customer base."

In order to fulfil this increased productivity, the company, which celebrated its fifth birthday in early June, has taken on an undergraduate on a 12-month internship.

Swarrendeep Samr's main responsibility will be to get the absolute best productivity levels out of the Swiss-made machine and the two more that will follow.

As an in-house specialist capable of maximising what the fibre optic lasers can achieve, FC Laser intends to edge even further ahead of its nearest competitors.

FC Laser recently announced a record year with 30% growth in 12 months and a move planned for 2018 to a new 20,000 sq ft factory.

8 fclaser.co.uk

Pressworking company launch

West Midlands based Moseley Brothers, press tooling production specialist, has launched a new company to focus on its expanding metal pressing and assembly element of the business.

MB Presswork will run alongside sister companies Moseley Brothers and GF Laser at the firm’s centrally located West Midlands facility.

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John Hickman, managing director, said: “Our move to larger premises in 2015 ensured we could update our press capability and continue to carry out efficient production to meet our customers increasing demands. After the installation of new presses it was a natural move to launch MB Presswork as part of the groups expansion plans.”

Mr Hickman added that the firm has already forged some strong relationships in the automotive market and is looking to grow and add to these partnerships in 2017.

“We have a robust staff structure with dedicated personnel in order that our exceptional service levels are upheld,” he said.

The company’s growth has meant that MB Presswork has needed to employ an additional sales representative to drive new business for the company.

“It’s vital that we communicate to our customers, existing and new, our updated trading style for the metal pressing and assembly element of Moseley Brothers,” Mr Hickman added.

“With this in mind we have committed to a schedule of trade shows which will place us at the best industry events where we can discuss further our full range of services and introduce our new branding into the marketplace”.

8 mbpresswork.co.uk JULY 2017

Engineering Capacity | FORMING & FABRICATION

School gets cutting edge entrance

Barnsley-based laser cutting specialist Cutting Technologies has teamed up with local sculptor Michael Johnson to create a decorative screen for Herringthorpe Junior School, located in Rotherham.

Herringthorpe Junior School commissioned Mr Johnson to create the Wind in the Willows-themed screen to cover the junior school's entrance as part of a literacy trail project.

Mr Johnson, who contacted Cutting Technologies to intricately laser cut the designs using stainless steel, said: “The safety of the children was of utmost importance during the process and so to avoid little fingers being caught, a ½ inch of acrylic was placed between the screen as protection.

“The process included ideas from teachers and children at the school and is perfect for making the walk in to school much brighter and engaging.”

The screen focussed around a quote from Wind in the Willows; JULY 2017

“Here today, up and off to somewhere else tomorrow!

Travel, change, interest, excitement! The whole world before you, and a horizon that's always changing!” It also included stream bank images such as weeds, mosses and nettles.

Jane Robinson, director at Cutting Technologies, added: “This project was perfect for us - it combines manufacturing with wider school subjects brilliantly and is a fantastic showcase for STEM within schools. We're really pleased we were able to help.”

Since 1989, Michael Johnson has created more than 180 sculptures across the UK with clients including community groups, local authorities, property developers and national institutions.

Cutting Technologies cut and engrave in a variety of materials from wood and plastics to metal and fabric, using technologically advanced laser engraving equipment.

8 cut-tec.co.uk

Metalcraft contract extension with Sellafield Avingtrans plc's subsidiary Stainless Metalcraft (Chatteris) Ltd, part of the group's energy and medical division, has secured an additional £11m contract option with Sellafield.

The contract extension for an additional quantity of containers builds on Metalcraft's May 2015 contract for the supply of waste containers over 10 years, worth up to £47m. From the initial contract award in 2015, Metalcraft has cleared the prototype development phase of the contract and established a dedicated manufacturing facility, which is now engaged in pre-production trials.

Austen Adams, managing director of Metalcraft and Avingtrans plc's energy and medical division, said: “This is another significant step forward for Metalcraft in this market.

“Over the last two years, the company has demonstrated its capability to produce these demanding ILW (Intermediate Level Waste) containers. The Metalcraft team, working closely with Sellafield, has established a great platform for the provision of these containers for years to come.”

8 metalcraft.co.uk

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FORMING & FABRICATION | Engineering Capacity Engineering and fabrication specialist, WEC Group Ltd, has manufactured a range of Overhead Line Electrification (OLE) structures for Network Rail/ABC’s £100m Walsall to Rugeley Trent Valley railway electrification project.

The group fabricated a range of steel Single Track Cantilevers, Two Track Cantilevers, Portals and Anchor Portals in-house as well as four angle-fabricated TTC bridges for the 15-mile project.

WEC Group is heavily involved with rail electrification contracts and is a leading manufacturer of overhead steel poles for light rail transit systems and overhead line electrification.

Rail electrification fabrications In addition to this latest contract, recent projects include the Manchester Metrolink Light Rail project, Sheffield Tram Lines and LRT projects in Hong Kong and Istanbul.

As an approved aluminium

welding supplier to Bombardier Transportation and accredited to EN 15085-2, BS EN 1090 and RISQS, the group also specialises in the manufacture of undercarriage and interior parts.

8 wec-group.com

High quality manufacturing services for a range of industries Including: 5 Design for manufacturing 5 Fabrication including 5 2D and 3D waterjet cutting 5 Fibre laser cutting 5 Welding 5 Metal forming, coating and assembly

Plus, where required, a range of related services including warehousing, installation, commissioning, life-time maintenance and decommissioning ICEE will process ferrous, non-ferrous and exotic metals, plastics, composites and stone materials Stuart Hendry, ICEE Managed Services Ltd 20 Arnside Road, Waterlooville, Hampshire PO7 7UP Tel: 023 9223 0604 Email: stuart.hendry@icee.co.uk Web: www.icee.co.uk/

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JULY 2017

Engineering Capacity | FORMING & FABRICATION

Wimbledon Court 1 roof on track Sheffield-based SCX Special Projects has completed the first year of a three-year project to construct a retractable roof for No.1 Court at the All England Lawn Tennis Club (AELTC).

The folding roof over No.1 Court is part of a redevelopment designed to increase seating capacity and transform the grass court arena into one capable of guaranteed play in all weather conditions.

The mechanical handling solutions specialist, part of the SCX Group, was awarded the contract after successfully designing, manufacturing and installing a similar retractable roof over Wimbledon’s Centre Court in 2009.

SCX Group managing director, Simon Eastwood, said: “We are very proud to have built the original retractable roof on Centre Court, and subsequently to have been chosen by the AELTC to work on No.1 Court.”

The new roof has already used more than 3,500 tonnes of steel, The University of Strathclyde’s Advanced Forming Research Centre (AFRC) will run the Scottish Government’s new £8.9m Lightweight Manufacturing Centre.

The specialist centre will develop new manufacturing processes for lightweight materials, such as titanium and carbon fibre, and will be the first step towards creating a National Manufacturing Institute

JULY 2017

the equivalent of 295 buses or six Airbus aeroplanes.

SCX Special Projects has again devised a concertina design using transparent Gore Tenara (a type of Gore-Tex fabric), which is stretched between 11 steel trusses, with two main sections that meet in the middle. It can be deployed or retracted in around eight minutes.

SCX is responsible for the design and supply of all the mechanical and electrical equipment for the

roof, and for the construction of the components that make up the moving sections of the roof.

In a comment to The Times, Philip Brook, chairman of the AELTC, said: “It’s a very complicated project. It took three years to put a roof on Centre Court and it’s much the same this time around.”

Work is on schedule for completion in time for the 2019 tournament.

8 scxspecialprojects.co.uk

£8.9m Lightweight Manufacturing Centre for Scotland. The centre will support highly-skilled jobs and help place Scotland at the forefront of lightweight manufacturing.

Executive Chairman of the Advanced Forming Research Centre, Professor Keith Ridgway CBE, said: “We are delighted to be in a position to be able to use the capability and knowledge here at the AFRC, and within the wider

Strathclyde community, to drive the development of the Lightweight Manufacturing Centre alongside the Scottish Government and Scottish Enterprise.

“Since opening in 2009 the AFRC has developed a trackrecord for world-class research and innovation in manufacturing and materials science . . .”

8 hvm.catapult.org.uk

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CASTINGS & FORGINGS | Engineering Capacity Sheffield Forgemasters has won a £5.5m contract with Samsung Heavy Industries (SHI) for the first major offshore oil industry development in two years.

The company’s offshore oil & gas specialist, Vulcan SFM, secured the contract to supply 73 steel castings ranging from 0.5 tonnes to 19.5 tonnes, for a semisubmersible oil platform, the hull of which is being built in Korea by SHI for operation in a Gulf of Mexico oilfield.

Following a global cessation of offshore oil and gas developments in 2015 the project is the first major offshore development to be sanctioned and will see a second oil platform installed at an undisclosed, established oilfield, to increase overall production capacity.

Paul Mockford, Design Director at Vulcan SFM, Forgemasters' offshore division, said: “It is a testament to Sheffield Forgemasters' standing in the offshore oil and gas sector that we should win this contract for the first major offshore development since 2015.

“We have a long-standing relationship with SHI and our track record in delivering robust cast engineering solutions for use in offshore oil and gas developments is unparalleled.

“The contract is for a range of components, 20 of which are module support castings which allow the topside modules to sit on the hull of semi-submersible platform - the remaining castings are structural components within the hull.

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Forgemasters back in offshore business

We have a longstanding relationship with SHI and our track record in delivering robust cast engineering solutions for use in offshore oil and gas developments is unparalleled

‘‘

“These hull castings are complex shapes and will reproduce the intersection of multiple plates of steel which would otherwise be welded together. Castings provide a more fatigue resistant solution in these highly loaded locations.

“One of the key benefits of using a cast solution for complex joints is that they can be designed to reduce the effect of fatigue loading.

Thicker sections can be used in areas of high stress and smooth radii introduced to give reduced stress-concentration factors.”

Sheffield Forgemasters will manufacture the castings to the client's design. Delivery of the components is expected to start in late 2017/early 2018, running through to mid-2018.

The new floating production platform will have the capacity to produce up to 140,000 gross barrels of crude oil per day from up to 14 production wells. Oil production is expected to begin in late 2021.

The platform will operate in the Green Canyon region of the Gulf of Mexico, roughly 200 miles (320km) south of New Orleans, Louisiana, US. It lies in approximately 5,100ft (1,550m) of water.

Forgemasters employs 650 staff across its 64-acre Brightside Lane site and serves industries including defence, civil nuclear power, materials processing, offshore and power generation.

8 sheffieldforgemasters.com JULY 2017

Engineering Capacity | CASTINGS & FORGINGS A £1.8m investment in a custom-built finish machining facility will enable a West Midlands company to become a fully integrated supplier of grey iron bearing housings for engine turbochargers.

The investment at Chamberlin & Hill Castings Ltd will see the installation of three high specification Chiron Scherer Feinbau automated mill/turn centres supplied by the Wellesbourne based Engineering Technology Group (ETG).

“Without investing in machining capacity, the customer made it clear that it would have to review Chamberlin & Hill's position as a supplier,” said Kevin Nolan, chief executive, Chamberlin & Hill Castings Ltd. “In contrast, if we did make the investment, we were probably going to become the most significant supplier of turbo bearing housings in Europe.”

Sheffield heavy engineering specialist DavyMarkham has secured a £20m contract with sister company Amber Precast to help with the safe decommissioning of nuclear facilities.

Up to 50 jobs are being created at the historic firm as part of the four-year joint venture with Amber Precast to design, test and construct six cubic metre reinforced steel and concrete containers.

The contract with Magnox Ltd, which is responsible for managing 12 nuclear sites in the

JULY 2017

Machining for turbochargers

Chamberlin & Hill has many years' experience as a specialist supplier of light and medium castings to the automotive industry, but in recent times has embarked on repositioning itself to become an assembly ready Tier 1 component supplier to the automotive turbocharger sector.

A major, long standing customer is Borg Warner who had

earlier advised Chamberlin & Hill they were seeking an “integrated supply” in order to streamline its supply chain.

Three Chiron machining cells were ordered, two of which were commissioned in February 2017, with a third scheduled to arrive in November this year. The capacity provided by these three machines has already been sold, bringing about additional revenue worth several million pounds per year.

The company is currently machining one turbo bearing housing every 81 seconds per cell floor-to-floor time.

Ultimately, the investment in Chiron technology is set to facilitate growth from the foundry of 30% in 2017/18, and, when the three machining cells are fully utilised, an additional £3 million of business from the machining facility.

8 chamberlin.co.uk

Nuclear boost for DavyMarkham UK, will see DavyMarkham creating a dedicated plant and team of workers at its factory in Prince of Wales Road, Darnall, for the construction of the robust transportable cast concrete containers.

DavyMarkham's expertise is being harnessed to ensure the highest quality steel components, such as container casings and handling features, are used alongside the experience and know-how of sister company, Amber Precast, in the

manufacture of the six-cubicmetre cast concrete boxes.

Once the final design and manufacturing methodology have been approved, it is calculated that Magnox will require more than 1,000 of these boxes to store various types of intermediate level waste (ILW) generated during the operational and early decommissioning phases of its UK power stations.

8 davymarkham.com

www.engineeringcapacity.com

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COMPOSITES| Engineering Capacity

Composite pipes become reality Sigma Components says that innovations from its SigmaLite range of lightweight aerospace components are moving from concept to reality as several R&D projects for aero-engine and airframe applications move into test phases with OEM support.

COMPipe - a composite aero-engine pipe that delivers weight savings of 50% over traditionallymanufactured pipes - has attracted considerable interest since the results of the CleanSky-funded R&D programme were announced at Farnborough Air Show in 2014.

Lab tests demonstrated that the thermoplastic composite pipe is capable of withstanding operating temperatures of up to 165°C, operating pressures of up to 450 psi and a typical engine operating environment, including fireproof requirements.

The flagship technology is now undergoing application-specific testing, with results expected towards the end of the year.

The Sigma Lite range includes new products and works in progress from Sigma's ongoing R&D programmes.

8 sigmacomponents.com

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www.engineeringcapacity.com

Boeing helicopter composites German-owned COTESA GmbH will produce complex composite parts for the Boeing H-47 Chinook heavy-lift helicopter in a five-year first-time contract.

COTESA will manufacture portions of the Chinook tunnel cover section – a honeycomb-like core that makes up parts of the helicopter’s external skin – for the global Chinook fleet.

Sir Michael Arthur, president of Boeing Europe, commented: “The contract award to COTESA is a testament to the technology potential we see in Germany and another important milestone in our partnership with German industry.”

Jörg Hüsken, chief executive officer of COTESA, said: “We are excited to join the Boeing supplier team. This contract award provides an opportunity for COTESA and our employees to demonstrate our expertise in highperformance composite parts.”

Michael Hostetter, defense, space & security director of

Vertical Lift Programs, Germany, added: “We are committed to bringing opportunities to German companies from across the Boeing enterprise and will continue to strive to bring the best of Boeing to industry and the best of industry back i nto Boeing.

“As a leading production facility for specialty composite parts, COTESA’s expertise will support our efforts to enhance the Chinook helicopter and deliver top-quality, cost-effective solutions to our customers.”

To date, Boeing has delivered more than 900 H-47 Chinook helicopters that are in operation in 19 countries, including eight NATO nations: Canada, Greece, Italy, Netherlands, Spain, Turkey, United Kingdom and the US, allowing for increased interoperability between NATO nations during joint training and deployment operations worldwide.

8 cotesa.de JULY 2017

Engineering Capacity | COMPOSITES UK manufacturer of lightweight composite structures and GRP mouldings Norco Holdings will promote its services to the defence sector at the Defence and Security Equipment International (DSEI) event in September.

The company said it has chosen to exhibit at DSEI for the first time as a result of significant growth in its activities within the defence and security sector.

Mark Northey, managing director of Norco Holdings, said: “We fully understand the importance of having a presence at DSEI, with many of our current and potential customers either exhibiting or planning on visiting the event. The defence and security sector offers us significant opportunities as key properties of reduced weight and lower cost impact on buyer decisions. Our recent experience on diverse projects including UAV's, Naval work boats and simulators ensure we can offer customers world-class expertise in their

Lightweight defence structures

composite requirements and we look forward to demonstrating this at DSEI this year.”

Norco manufactures satellite dishes and radomes using prepreg materials, combining low loss skin and core materials with its manufacturing and painting techniques developed in-house, to help minimise transmission losses.

Norco has also pioneered in-

mould surfacing solutions to improve reflectivity at frequencies above 8GHz and manufactures UAV's and flight simulators for the aerospace industry.

DSEI runs from 12-15 September at ExCel London.

The show will have five key sector-focused zones: air, land, naval, security and joint.

8 norco.co.uk

Coventry manufacturer set for expansion Coventry-based manufacturer, the Penso Group, is to continue its rapid development having secured an £11m funding package.

The new funding package from Clydesdale and Yorkshire Banks will be used to develop the company's technologies, along with helping to build a new factory which the company plans to build on its present Coventry site this year.

Chris Buckenham, group finance director, Penso, said: “With the understanding of JULY 2017

Clydesdale and Yorkshire Banks, we have a partner who can support us in our ambitious development plans.”

“We are delighted to be working with a partner who are aligned with the ethos of Penso Group, itself a very dynamic and fastmoving business. Clydesdale and Yorkshire Bank have demonstrated the ability and desire to offer finance solutions that meet our requirements, which is exactly what we are looking for.”

Penso was established in 2000 and now employs over 200 workers.

The composite manufacturing specialist provides a complete turnkey engineering service to customers from prototyping to manufacturing in the automotive, aerospace, defence and rail sectors.

It has recently been awarded a government grant to be the lead partner on Project Flexible Lightweight Architectures for Vehicle Applications (FLAVA).

8 penso.co.uk www.engineeringcapacity.com

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JFL are broach and broaching specialists with amost 40 years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms.

Ecopare Ltd Ecopare provides practical solutions for energy management that make a difference. We maximise energy savings by offering installation and implementation services in addition to our core expertise in energy analysis, strategy, and planning.

23 Frederick Sanger Road, Surrey Research Pk, Surrey GU2 7YD Tel: 01483 688170 www.ecopare.energy/

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www.engineeringcapacity.com

HEAT TREATMENT 8

ENERGY MANAGEMENT 8

Unit 2, Deethe Farm Industrial Est, Cranfield Rd, Woburn Sands, Milton Keynes, Bucks MK17 8UR Tel: 01908 585103 www.jflbroaches.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

Flame Hardeners Ltd Bespoke surface heat treatment processors. Gears up to 4.5m dia.

Shafts or rollers up to 1.5m dia. and 7.5m in length. Machine beds up to 6m lengths. Wheels up to 2.3m dia.

We have over 75 years of experience.

Shorter Works, Bailey Lane Sheffield S1 3BL Tel: 0114 276 8167 www.flamehardeners.co.uk/

LASER CUTTING 8

Laser Process Ltd Premier Laser Cutting Subcontractor. Continual investment in the latest technology to provide our customers with the service they deserve.

Upper Keys, Keys Park, Cannock, Staffordshire WS12 5GE Tel: 01543 495000 www.laserprocess.co.uk MACHINING (5 AXIS) 8

JFL Broaches and Broaching

Royd Way, Keighley, West Yorkshire BD21 3LG Tel: 01535 602587 www.hewitt-topham.co.uk GRINDING CENTRELESS 8

BROACHING 8

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

Hewitt & Topham Ltd Precision gear cutters since 1938.

Standard and non standard cutter pitches and pressure angles. Gears from 2.5-6mm diameter. Northern England leading gear specialist through quality and commitment.

Mini Gears (Stockport) Ltd Mini Gears is a subcontract manufacturer of machined components, gears and racks.

Winner of 17 Industry Awards, it has a global customer base, 35,000 sq. ft. facility and over 100 machines.

Top Gear House, Bletchley Road Heaton Mersey Industrial Estate Stockport SK4 3ED Tel: 0161 432 0222 www.minigears.co.uk

MANAGEMENT SYSTEMS 8

Wealdpark Ltd CNC mill-turn facility using Star sliding head lathes with bar capacity up to 32mm diameter.

Miyano and Doosan fixed head lathes with bar capacity up to 65mm.

Hurco vertical machining centre.

GEAR CUTTING – GENERAL 8

AUTO REPETITION WORK 8

DIRECTORY | Engineering Capacity

PSL Datatrack PSL Datatrack, a flexible production management system for small/ medium size manufacturing businesses, helps to manufacture quality parts, on time and at the right price. PSL Datatrack provides vital information to management and shop floor.

Lily Hill House, Lily Hill Road, Bracknell, Berkshire RG12 2SJ Tel: 08456 345931 www.psldatatrack.com

JULY 2017

PRECISION ENGINEERING 8

Greenfield Lane, Shaw, Oldham, Lancashire OL2 8QP Tel: 01706 842311 www.dpc.co.uk

• • • • • •

DKW Precision Engineering Celebrating our 47th year supplying CNC Turned and Milled Components to all Sectors in both UK and Export markets. From 1 off to Volume, 1-450mm diameter turning, 1x1mtr milling, fast turnaround.

•

Precision T Turned urned P Parts arts Subcontract Machining Surface T Treatment reatment CNC Machined Components Parts P arts Assembly Design & Engineering Support Service A AS S 9100 & ISO 9001

SPRING MAKING 8

You Y ou o dream it it,, we mak make e it it..

JULY 2017

Batchflow Engineering Ltd

Rotatech Ltd Specialists in reconditioning and rebuilding of all makes of precision machine tool spindles.

Spindles rebuilt in purpose built clean room. On-site removal and re-installation available.

20 Cavans Way, Binley Industrial Est, Binley, Coventry, W. Midlands CV3 2SF Tel: 02476 452600 www.rotatech.com

WATERJET CUTTING 8

Budbrooke Road, Warwick, Warwickshire CV34 5XH Tel: 01926 492889 www.batchflow.co.uk SPINDLE REBUILD 8

SAWING MACHINERY 8

Saws (UK) 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.

CNC turning capacity from 2mm200mm using high precision Fixed and Sliding Head CNC Lathes.

Experience in machining a range of materials, from Low to Medium volumes, to customers specifications.

Quartremaine Road, Airport Service Estate, Portsmouth PO3 5RD Tel: 023 9267 7747 www.dkwengineering.co.uk

South Easts leading specialist metal cutting machinery and blade supplier. Agents for Fabris, Pilous, Alligator, Comet, Forestor, Carif and many more.

Unit 8, Wealden Business Park, Farningham Road, Crowborough, East Sussex TN6 2JR Tel: 0844 8804511 www.sawsuk.com

Simpson Springs & Pressings Ltd

Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk TURNING (CNC) 8

Dawson Precision Ltd Precision CNC milling and turning.

Machining centres, CNC Turning centre and multi-axis sliding head machines. Full in-house machining service with additional laser marking and kitting capabilities.

SUBCONTRACT CNC TURNING 8

PRECISION ENGINEERING 8

Engineering Capacity | DIRECTORY

ICEE Comprehensive fabrication facilities offering complete turnkey solution.

Design, Precision Engineering, Sheet Metal Fabrication and Welding.

Prototypes, one off or batch work.

Waterjet Capacity: 4m x 2.25m & dash; materials up to 230mm depth.

Aluminium Alloy Specialists.

20 Arnside Road, Waterlooville, Hampshire PO7 7UP Tel: 023 9223 0604 www.icee.co.uk

www.engineeringcapacity.com

35

ADVANCED ENGINEERING2017

1 & 2 November 2017, NEC, Birmingham The UK’s largest annual gathering of advanced engineering professionals Advanced Engineering is the industry event where high-technology manufacturing sectors converge under one roof to meet and do business.

Join us where the familiar and the unfamiliar collide to provide new opportunities across the engineering supply chain.

AERO ENGINEERING COMPOSITES ENGINEERING AUTOMOTIVE ENGINEERING PERFORMANCE METALS ENGINEERING NEW FOR 2017 2017

Contact us about exhibiting today mm

+44 (0)20 8843 8800 or visit www.advancedengineeringuk.com www www..advancedengineeringuk.com .advancedengine