FOR MANUFACTURERS ABOUT SUBCONTRACTORS
July 2018
INDUSTRY NEWS | FORMING & FABRICATION | COMPOSITES | CASTINGS
COMPOSITES: Metal composites for landing gear
www.engineeringcapacity.com
10
th
ANNIVERSARY ANNIVERSAR YEAR
The UK’s largest annual gathering of OEMs and engineering supply chain professionals AERO ENGINEERING COMPOSITES ENGINEERING AUTOMOTIVE ENGINEERING PERFORMANCE METALS ENGINEERING
REGISTER
FOR FREE TTODAY ODAY
CONNECTED MANUFACTURING NUCLEAR ENGINEERING NEW FOR 2018
Register your interest to visit the UK’s largest engineering event, giving you access to: 9 600+ exhibiting suppliers and partners 9 200+ *VU[PU\PUN 7YVMLZZPVUHS +L]LSVWTLU[ JLY[PÄLK WYLZLU[H[PVUZ HUK JHZL Z[\KPLZ from OEMs, industry experts and government 9 Innovative and exciting feature exhibits showing the latest technologies in action 9 Enabling Innovation zone for SMEs and start-ups to present new inventions and idea
Register your interest to attend at:
www.advancedengineeringuk.com
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 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 2018 ISSUE Machined Components, Waterjet & Laser Cutting, Automotive, Moulding, Advanced Engineering 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 It is sometimes all too easy to get depressed by the current political news and start to despair of the future. But it can be just as easy to look above the daily turmoil and see pointers to a much brighter future. And, of course, if you want to tap into optimism, idealism and a desire to make the world a better place then you have to look to young people. At the start of July students from across the UK came to Yamazaki Mazak’s European Headquarters in Worcester for the finals of the Manufacturing Technology Association’s (MTA) Technology, Design and Innovation (TDI) Challenge. This exists to to help teachers and lecturers to promote the great work of their D&T and Engineering students and to celebrate their creativity and innovation. Creativity and innovation were certainly on show – with projects ranging from a new blowpipe for bagpipes that reduces moisture build-up in the bag to a smartphone-controlled Internet of Things pet feeder. What, for me, was even more impressive was the fact that so many of the projects sprang from a desire to make the world a better place. One of the runners-up had designed an adjustable support that was intended to improve the comfort of children with cerebral palsy in primary school classes, while two of the winners had come up with devices for cyclists promoting safety and sustainability. Vivika Martini won the 14 to 16 category with a wind-turbine powered charger that cyclists could use to power up their phones in remote areas while the group prize went to a team from Sutton Grammar School who had used smart materials to make illuminated cycle clothing. The MTA is able to fund this type of activity for young people thanks to an educational trust it set up using profits from the MACH exhibition, so it is nice to see that MACH 2018 has just won the Exhibition of the Year category at the Trade Association Forum Best Practice Awards. The show organised by the industry, for the industry and giving back to the industry. Andy Sandford, Editor
Member of the Engineering Industries Association
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 2018
Email: info@dkwengineering.co.uk
1969 - 2014
45 years
www.dkwengineering.co.uk
www.engineeringcapacity.com
3
Contents July 2018
11 INDUSTRY NEWS
News
Features
06 ÂŁ530k for biggest ever machine 06 MGS adds 900t injection moulder
13 Composites 06 Cover Story: New metal composite applications Composites bring fusion power closer Electric dream machine
06 Measuring up for Bowers 06 Mekall's panels are intrinsic to metrology tools
09 Full steam ahead for Force of Nature 06 Graham Sykes and his
17 TURNED PARTS
Speeding plastics production
23 Casting & Forging 06 UK powers Swiss nuclear restart
steam-powered bike
Adding value on diecastings
10 Three is the magic number 06 Third UK-made 3D printer installed
26 Forming & Fabrication 06 Fabrication challenge
11 Steel support for STEM 06 Barrett provides material for
for green energy Testing for endurance
school projects
28 FORMING & FABRICATION 4
www.engineeringcapacity.com
17 Turned parts 06 Busy making parts for Sir Nigel
31 Aerospace 06 SW aerospace heroes
JULY 2018
Engineering Capacity | INDUSTRY NEWS ICEE Managed Services is using waterjet cutting to produce a range of commemorative World War 1 ‘Tommy Soldier’ profiles and outlines from acrylic plastic and mild steel materials. The work is being done for ICEE’s customer Littlehampton Welding, a leading maker and installer of architectural metalwork and public realm artworks. Littlehampton Welding’s customer is in turn Remembered, a new charity currently running a major nationwide campaign called ‘There But Not There’, featuring the evocative profiles. ICEE used its Bystronic CNC waterjet machine to cut both plastic and metal versions, and the parts produced for Littlehampton Welding include several 1.83m high solid profiles, cut from 25mm thick clear acrylic plastic, and a 2.8m high linear outline cut in one piece from 20mm thick mild steel plate. Remembered’s campaign is designed to support the commemoration marking the armistice period and the end of WW1 centenary in November this year. As a striking way to publicise the campaign and raise money for beneficiary charities, life-size and larger Tommy Soldier profiles and outlines, cut by ICEE, are being finished and installed by Littlehampton Welding for Remembered, across the United Kingdom in prominent public spaces. The Tommy Soldier profiles and outlines represent a rifle-bearing WW1 soldier, standing in contemplation. The silhouette is JULY 2018
Waterjet cuts Tommy memorials
based on the graphic part of Remembered’s logo, which was itself inspired by a contemporary photograph taken by a pioneering war photographer, Horace Nicholls. To cut out Tommy Soldier profiles from clear acrylic plastic, Littlehampton Welding decided the waterjet method was best suited because it is a cold-cutting process and it cuts cleanly, accurately and rapidly. The cut surface has a fine quality matt appearance that requires no fettling and gives no clue as to the production process. Additionally, without any compromises, the same machine will also cut mild steel sheet and plate. As one of several subcontractors approached, ICEE was given the job because, as Littlehampton Welding’s Technical Director Martin Norrell says: “We have worked with ICEE before and tend to prefer them for finer quality projects. We know their waterjet equipment is modern and appropriate and they also possess the right expertise.
“What’s more, we like their approach because they listen carefully and are willing to persist with the development process. They will readily make samples and prove-out ideas. This has resulted in right-first-time, reliable and cost-effective production. Additionally, ICEE being relatively close means we can drop in anytime to discuss ideas and progress. Transport costs are less and delivery time is minimised,” he says. With little or no heat produced during the process, ICEE’s waterjet machine will cut a variety of ferrous and non-ferrous materials, including mild steel, Corten weathering steel and stainless steel up to 25mm thick (a greater thickness for aluminium). Titanium plate may also be cut and stone materials including granite up to 230mm thick, plus concrete (with or without reinforcing bar), carbon fibre composite materials and plastics. While the Tommy Soldier plastic profiles and metal outlines are processed with the waterjet machine cutting in twodimensional (2D) mode, ICEE’s machine will also cut in 3D. Thanks to 5-axis CNC movements, 3D cutting offers great potential for producing a variety of imaginative, threedimensional forms from thick materials. The 3D process often offers a less costly alternative to milling, grinding or casting. 8 therebutnotthere.org.uk icee.co.uk/waterjet-cutting www.engineeringcapacity.com
5
INDUSTRY NEWS | Engineering Capacity
£530k for biggest ever machine MGS Technical Plastics has invested £530,000 in its biggest machine to date. The KraussMaffei KM900 is a dual platen machine with a 900-tonne capacity, allowing the Blackburn-based plastic injection moulding specialist to work with bigger parts than ever before. The new purchase is scheduled for delivery in August. It replaces MGS's 800 tonne model, bringing increased capacity, efficiency and quality levels. The KM900 is more efficient than previous equipment, with a short dry cycle time of just 2.3 seconds. In the last decade, the firm has invested almost £2m more on property, machinery, staff and training. Mark Boardman, quality manager, said: "We chose the KM900 as the next piece of our continuous improvement strategy as it will immediately assist our delivery of a largescale project we are currently undertaking for a tier one automotive supplier. "This addition to our factory gives us extra capacity and a shorter turnaround. The KM900 is ideal for our needs as it helps meet critical lead time challenges, and it also gives us the ability to manufacture larger parts than before." 8 mgsplastics.co.uk
6
www.engineeringcapacity.com
Measuring up for Bowers
Specialist subcontractor Mekall produces a variety of panels, labels and graphic overlays for one of the world’s leading metrology specialists. Bowers Group manufactures a wide range of precision measuring instruments, including its range of XT digital bore gauges. As part of the Spear and Jackson group, Bowers Group has worked with specialist engineering subcontractor Mekall for the past 20 years. The Glasgow-based company supplies a wide range of labels for various products within the Bowers Group portfolio. A senior member of the Bowers Group design team said: "The look of the instrument is intrinsic to the quality, therefore labelling is an important part of the overall product design. We work with Mekall because they provide consistently good quality products at competitive prices, and they always deliver on time. Moreover, they always listen carefully to our requirements and come up with a label which meets the specification exactly. "I would say a key benefit of working with Mekall is care and
attention to detail. The labels must fit exactly into the product mouldings therefore precision cutting is vital. Mekall has invested in specialist equipment which cuts the label to the finest tolerances, so the fit is perfect." Mekall, part of the Rainbow Technology Systems group of companies, is a precision engineering subcontractor with a particular focus in membrane switch panels, graphic overlays, fascia panels, and labels.
I would say a key benefit of working with Mekall is care and attention to detail. The labels must fit exactly into the product mouldings therefore precision cutting is vital. Mekall has invested in specialist equipment which cuts the label to the finest tolerances, so the fit is perfect
‘‘
David Westwood, sales and marketing manager at Rainbow Technology Systems, said: "Mekall continues to build on its reputation gained over 25 years JULY 2018
Engineering Capacity | INDUSTRY NEWS for consistently meeting quality and delivery expectations, which are fundamental prerequisites for survival and growth in a competitive market. We continue to manufacture all products inhouse in the UK and are currently expanding our product offering to include screen-printing for biosensor technology, fine-line printed electronics and LEDs." He added: We continue to make substantial investments in technology and skilled personnel
throughout all areas of the business to aid our capability and capacity, and we are actively forming partnerships with likeminded companies both nationally and offshore thus ensuring we are at the forefront of modern subcontract manufacturing. Our mission will always be the provision of superb quality and delivery and value at highly competitive prices." He added: “We continue to make substantial investments in
technology and skilled personnel throughout all areas of the business to aid our capability and capacity, and we are actively forming partnerships with likeminded companies both nationally and offshore thus ensuring we are at the forefront of modern subcontract manufacturing. Our mission will always be the provision of superb quality and delivery and value at highly competitive prices." 8 rainbow-technology.com
APT Leicester, Leicester, the artt of precision precision.. ar
CNC Milled Components
JULY 2018
|
Subcontract Turned Turned Parts Parts
www.engineeringcapacity.com
7
INDUSTRY NEWS | Engineering Capacity Leicester-based Nylacast, a manufacturer of engineered polymers and products, has been ranked for a third consecutive year as one of the top companies in the region, alongside Next, Walkers, Caterpillar and Leicester City Football Club. Established in Leicester for over 50 years, Nylacast, recently invested in 120,000 square foot of premises and now operates from two sites in Thurmaston. The engineering firm also has manufacturing and distribution facilities located in key locations to service a worldwide market place, this includes USA, South Africa and China. Employing over 430 members of staff, Nylacast has a focus on the development of its technology, people and communities. The engineering company runs a dedicated training academy delivering award winning apprenticeship and graduate programmes, nurturing talent from local schools and colleges and taking students on a journey to becoming qualified, graduated engineers. The global demand for d
ite
d re cc
ow
Top 200 in Leicestershire
Leicester is a high achieving city. Being listed amongst the top 200 companies in the region makes us very proud of our Leicestershire heritage when it has never been a better time to promote local trade and British export
‘‘
Nylacast’s materials technology sees the company working on projects ranging from the Queensferry Crossing to the world’s largest ship, Shell Prelude,
to
D
A
N
FM10101
Manufacturers of High Quality Mill-Turned Parts
8
www.engineeringcapacity.com
in addition to providing safety critical components for over 70 million vehicles worldwide. Over 70% of product manufactured in Leicester, UK, is exported to over 47 countries. Nylacast group CEO Mussa Mahomed commented: "Leicester is a high achieving city. Being listed amongst the top 200 companies in the region makes us very proud of our Leicestershire heritage when it has never been a better time to promote local trade and British export. We look forward to further excelling our performance and operations both in the city and the global marketplace." The Leicestershire Top 200 List was compiled by a team of academics at De Montfort University's Business School which took into account both the financial facts and numbers of the companies along with their local operations or presence in Leicester. 8 nylacast.com JULY 2018
Engineering Capacity | INDUSTRY NEWS The owner of a subcontractor and race component manufacturer has given a preview of his new steam-powered rocket bike named Force of Nature. Motorsport and drag racing enthusiast Graham Sykes showed off the culmination of six years’ work at the recent Fluid Power & Systems 2018. He designed and then produced all of the prismatic parts on a Hurco vertical machining centre, mostly from DXF files output from AutoCad and input directly into the machine's proprietary Ultimax CNC system. A holder of five motorcycle land speed records on his V8 powered drag bike, The Syko, Graham's top speed was 181.39 mph. Dynamic testing of Force of Nature on the track will commence following further satisfactory static tests. They have already seen 600 kgf of peak thrust over six seconds, which should allow acceleration to a speed of over 200 mph in a quarter mile. A public launch
Full steam ahead for Force of Nature
Fibrax Limited, which manufactures rubber, TPE and plastic components, has extended its global manufacturing capabilities by establishing an operational facility in Morocco. The new manufacturing plant will trade as Morocco Precision Moulding and form part of the Fibrax Group of Companies, which also has established operational facilities in Wrexham, UK and Sanok, Poland. Specialising in the design, development and manufacture of high performance
Moulders make it in Morocco
JULY 2018
will take place later this year when all tests are complete. In preparation for a test run, a 60kW bio-fuel burner will be attached to the bike to heat 50 litres of water in the pressure vessel to 250°C and 40 bar via a flame holder tube running through the centre.
Meanwhile, Graham Sykes Performance Engineering Ltd continues to design and manufacture components for other race teams, as well as customers in the food industry, from its workshop in North Yorkshire. 8 sykoracing.com
custom rubber mouldings and plastic components, Fibrax supports many of the most strictly regulated sectors worldwide. The demand for quality automotive components has significantly increased in North Africa and this investment will ensure the Fibrax Group is well placed to provide outstanding technical support and a responsive service delivery to companies operating in the region. 8 fibrax.com www.engineeringcapacity.com
9
INDUSTRY NEWS | Engineering Capacity Dalau, a specialist supplier and machinist of plastics, has installed a sixth 5-axis machining centre as part of a £1m spend in new machine tools at its Clactonon-Sea factory. The new Hermle C 250 machining centre has been modified to accept vacuum workholding fixtures and was supplied by the German manufacturer's UK sales and service agent, Geo Kingsbury, which also carried out the customisation. The Hermle installation is part of a £1 million spend on machine tools at the Clacton factory within the past year to cope with a steep increase in demand for Dalau's machined components across numerous industries. They include automotive and medical as well as the semiconductor sector, particularly in the US and Germany. The expansion has seen the number of 5-axis machining centres increase to six, the appointment of two extra Darlington-based 3D print specialists Paragon Rapid Technologies believes it is the only service provider in the World to have three NEO800 3D printers from UK manufacturer, RP Support. Using the Stereolithography (SLA) process, all three machines are running WaterShed® 11122 material to produce clear, durable, waterresistant components with high dimensional stability. The NEO800’s variable laser technology offers printed parts
10
www.engineeringcapacity.com
5-axis is fantastic for plastic
programmers and a move to double-shift operation. Production manager Ben Bonds explains that there is no machining centres of this size specifically for milling and drilling plastics as the market would not be large enough to make such a machine commercially viable. So Dalau has to rely on production centres designed for cutting metal, which for processing plastics tend to be unnecessarily large for a given working volume. They are also far too powerful; in the 5-axis shop at Clacton, the load drawn by the spindle motors never exceeds 5 per cent.
The new C 250 is currently devoted to finish-machining a family of PTFE pump bodies that have been roughed on another of the 5-axis machines. Four or five operations are required to complete the machining operations in total cycle times of between three and four hours. An airconditioned environment held at 21°C ensures that tolerances down to ± 0.05 mm can be held easily, despite the tendency for plastics to distort during machining. The four-part assemblies into which these components go are delivered to a US customer specialising in manufacturing equipment for the semiconductor industry. Indeed, four-fifths of the shop's output is exported to long-standing customers in the US, where Dalau has had a sales subsidiary since 1990 in New Hampshire. 8 dalau.com
Three is the magic number with superior side wall quality and an unrivalled build definition to reduce the need for surface finishing. Alongside a larger build platform of 800mm x 800mm x 600mm for bigger 1-piece models, an optimised build speed now means that Paragon customers are also benefitting from improved lead times and lower costs. This growth in capacity in response to increasing demand for high definition SLA models is indicative of Paragon’s ongoing
commitment to producing superior parts through its growing Additive Manufacturing suite. “The industry is constantly pushing the boundaries of 3D print performance, with users looking for more economical ways of producing their parts and products. We’ve found that our NEO800 machines are far exceeding expectations.” said Phil Adamson, Managing Director at Paragon. 8 paragon-rt.com
JULY 2018
Engineering Capacity | INDUSTRY NEWS
Talisman rebrand welcomed
Steel support for STEM Following an approach from a secondary school asking for steel to use in lessons, Barrett Steel was pleased be asked to get involved and is keen to support the education of young people nationwide. Donating excess product to help with the education of the future engineers seemed like an excellent idea, and a way in which this long-established family company could have a positive impact on their local communities. Mr Jason Brister, Head of Art, Design and Technology at Sir John Nelthorpe School in Brigg, North Lincolnshire, was the one to first make the approach: “Starting in September 2018 we are introducing a new Engineering course for our GCSE students and I reached out to local companies that may be able to support our faculty with charitable donations of steel, copper, brass or aluminium offcuts.” Barrett Steel’s depot in Scunthorpe, Kass Steel Stockholders were put in touch and invited school staff to visit and examine some suitable pieces for their project needs. JULY 2018
We were delighted to be put in touch with Kass and are confident that their input will have a positive impact on our students’ learning. We have fought for two years for Engineering to be included in the curriculum, so this support is invaluable to help our engineers of the future
‘‘
“We were delighted to be put in touch with Kass,” said Mr Brister, “and are confident that their input will have a positive impact on our students’ learning. We have fought for two years for Engineering to be included in the curriculum, so this support is invaluable to help our engineers of the future.” Tom Barrett, Commercial Director of Barrett Steel, said, “STEM (Science, Technology, Engineering and Maths) subjects are the core of our business and our customers’. Anything we can do to assist the skillset of our local communities is fundamental to the industry’s advancement.” 8 barrettsteel.com
Customers and suppliers have welcomed the rebrand of one of the UK's oldest and leading precision plastics injection moulding specialists. LGG Charlesworth, a company synonymous with the plastics industry for nearly 100 years, became Talisman Plastics on 1 June. Attending Subcon 2018 at the NEC, Birmingham earlier this month, managing director, Shaun Champion, said feedback to the rebrand had been extremely positive. The event also saw the Malvern-based company generate many quality enquiries from new customers. "Having undertaken the rebrand last month, we wanted to use the exhibition to promote our new brand to existing customers and suppliers, as well as potential new ones," said Mr Champion. "It's important for us to demonstrate our long pedigree in the plastics industry and the exciting future we have under this new brand." 8 talismanplastics.co.uk
www.engineeringcapacity.com
11
Trade Leads from the EIA
PEOPLE | Engineering Capacity
The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk Partnering – electric bicycle drive A young German SME has developed an electric drive, which fits to most bicycles on the market without any needed adaption of the bicycle. The company is interested in long-term European partnerships Reference: JV1226 Closing Date: 24/04/2019 Israel - Oil valves and fittings An energy company is looking for an equipment supplier or manufacturer Reference: 31226 Closing Date: 30/11/2018 Turkey - Steel hollow sections A company is looking for a supplier of various types of steel hollow sections Reference: 31264 Closing Date: 01/11/2018
Mark Poole has been appointed Quality Engineer at precision fabrication and welding specialist LTi Metaltech. His background in oil and gas gives him experience of ensuring compliance to strict safety regulations and compliance standards.
Teresa Blackman has been appointed to help oversee the Customer Care team at Worthing-based plastic injection moulding and extrusion company Nordell, which is celebrating its 50th year in business. She has 17 years’ experience in the industry.
Mike Sprague has joined contract electronics manufacturer Esprit Electronics as Senior Account Manager in its customer service team. He was previously Operations Manager at a specialist in load cells and load monitoring equipment.
Michael Emmott has retired after 49 years’ service at Keighley Laboratories. He started as a trainee inspector and retired as Heat Treatment Commercial Director. His humour and knowledge will be missed say his former employers.
Brazil - Automatic tilt tooling machines A major aerospace company wants to represent a company that can supply tilt tooling machines Reference: 31504 Closing Date: 07/08/2018 Brazil - Automatic drilling machines A major company is looking to represent an aerospace automation company Reference: 31502 Closing Date: 07/08/2018 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.
12
www.engineeringcapacity.com
JULY 2018
Engineering Capacity | COMPOSITES
New metal composite applications A new name in light, stiff and strong aluminium matrix composite (AMC) materials says they are set to be used in new demanding aerospace, automotive and consumer applications. Alvant, formerly known as Composite Metal Technology (CMT), says that AMC material is being specified in an increasing number of demanding applications in aerospace, defence, automotive, consumer and industrial sectors, including a Safran landing gear project. The new name comes with a new management team and follows a series of new contracts. In parallel, Alvant has just been selected by Safran Landing Systems to participate in the £28 m ‘Large Landing Gear of the Future’ R&D project. The company has also received orders to supply the ‘Breakthrough Aerospace Materials’ project with Rolls Royce, and an R&D project with Ford investigating the application of hybrid-AMC components for high-performance production cars. More contracts are expected to be announced shortly. The Basingstoke-based company manufactures AMCs using a proprietary Advanced Liquid Pressure Forming (ALPF) process. The core technology is based on continuous ceramic fibres embedded into an aluminium matrix to give unique properties, which can be tailored according to the application. Within the past 12 months, JULY 2018
commercial demand has increased significantly for the advanced composite material due to its greater strength, higher stiffness, lower weight and superior wear resistance, as well as lower coefficients of thermal and electrical conductivity. Alvant’s new management team has focused on responding to and shaping these commercial opportunities. “Commercial readiness of AMCs comes at a time of increasing demand for strong, yet lightweight, components in transport and defence, industrial processes and high-end consumer products,” explains John Bonas, managing director of Alvant. “Today’s design teams are looking for ways to increase product capabilities and performance while simultaneously meeting ambitious goals for fuel efficiency
and sustainability. These are often conflicting challenges for which AMCs can be a solution. “AMCs provide the strength and stiffness of steel at less than half the weight. They also offer advantages over carbon composite material, including higher transverse strength and stiffness, superior damage tolerance, and a higher thermal operating range. AMCs can be used to engineer more durable lightweight components for harsh environments,” says Bonas. Alvant owns the proprietary rights to the ALPF AMC manufacturing process and has full-service capability, offering engineering consultancy, concept development and component design through to prototype manufacture, low-volume production, and the sale of licensing for higher-volume production. 8 alvant.com www.engineeringcapacity.com
13
COMPOSITES | Engineering Capacity Rockwood Composites has used composites to successfully assemble the central core for the UK’s newest fusion device, Tokamak Energy’s ST40. The ST40 is the first world-class tokamak controlled fusion device to have been designed, built and operated by a private venture. It is designed to show that fusion temperatures – 100 million degrees C – are possible in compact, costeffective devices. This has the potential to allow fusion power to be developed for commercial deployment in years, not decades. Constructing the core involved the very precise application of a glass-fibre/Kapton®/glass-fibre insulation layer to each of the core elements. The whole assembly was then bonded together with precise control of the bond line thickness. The central core is made of 24 inner elements of toroidal field coils which each needed to be insulated. This was achieved by applying a glass-fibre pre-preg/Kapton®/ glass-fibre pre-preg insulating layer to each of the core elements. Rockwood used a silicon intensifier consolidation system to accurately control the position and pressure during the cure. This enabled air and resin to be progressively squeezed out from under the Kapton® film and ensure that the Kapton® tightly bonded to the toroidal field coil to give a very uniform and consistent insulation layer. The next challenge was to bond all the insulated column component together with extreme accuracy. This was achieved by using a dry glass-fibre fabric to 14
www.engineeringcapacity.com
Composites bring fusion power closer
control the bond line thickness and a dispersed adhesive system, which provided a consistent 0.1mm bonded joint. Rockwood applied the same insulation approach to the solenoid winding, which creates one of the many huge magnetic fields in ST40. Again, glass-fibre pre-preg and Kapton® was applied this time in a helical overlapping manner during the winding process and applied between each of the coils. Finally, the whole solenoid was overwrapped with glass pre-preg. The Newton Abbot based composites specialist developed this project from first principles, as no off-the-shelf solution was available. They also supplied the entire cryogenic suspension system for the ST40 system, comprising a large number of bespoke carbon fibre bands. The technology is also being used in ITER, the world’s
largest fusion experiment in France involving engineers and scientists from 35 countries. Rockwood established this process as a means of bonding large structures together very accurately over large distances. It is now developing processing solutions for high temperature super conductors, which is an important element in the challenging work of small scale tokamaks. Mark Crouchen, Managing Director of Rockwood Composites, said: “Fusion devices are built to create one of the most extreme environments you can get – more extreme temperatures than anywhere in the solar system! The properties of composites are instrumental in enabling the ST40 to achieve these extremely high temperatures – hotter than the centre of the Sun.” Graham Dunbar, ST40 Project Manager, said: “We were faced with a real problem in the manufacture of the central core of our high magnetic field tokamak. We approached Rockwood Composites and their fantastic team of engineers were able to find the best solution through an innovative use of composites. I am enjoying working with the team as we develop the technology further.” Tokamak Energy’s aim is to put fusion power into the grid by 2030. 8 rockwoodcomposites.com JULY 2018
Engineering Capacity | COMPOSITES Italian composites and 3D printing know-how were in pole position when an all-electric superbike prototype was unveiled for on-track testing at the French MotoGP in Le Mans. The Energica Ego Corsa MotoE all-electric bike was developed in conjunction with CRP Meccanica and CRP Technology. CRP Technology, which is the CRP Group’s specialist in laser sintering, is 3D printing aerodynamic parts in professional 3D printing with using CRP’s Windform composite materials. Sister company CRP Meccanica, which has worked for more than 45 years alongside F1 teams as a strategic partner for hi-tech mechanical components, is working on the development of the braking and suspension system. The know-how of the two companies is also supporting the development of the new battery. All these elements have improved the general performance of the superbike, bringing it closer its target figures. The next stop on the road to the 2019 FIM Enel MotoE World Cup will be at CRP and Energica’s home GP in Mugello, with a very special rider for the demo lap: the four-time World Champion Max Biaggi. The demo lap will begin on Sunday at 13:20 local time (GMT +2) in front of the traditionally passionate and vocal Italian crowd at the Mugello Circuit and will be live on motogp.com. The testing at the French GP was carried out by both Loris JULY 2018
Electric dream machine
Capirossi and the Energica official test rider Alessandro Brannetti. “We are happy about the test performed at Le Mans with the new prototype”, said Brannetti.
“Energica with CRP’s support is definitely heading in the right direction and I’m excited to see what’s in store next.” 8 crp-group.com
www.engineeringcapacity.com
15
COMPOSITES | Engineering Capacity
IATF 16949 for composites
Prodrive Composites has become the first UK carbon composites business to attain full certification against the newly released IATF 16949:2016 automotive standard. IATF 16949 is the internationally recognised standard for quality in the automotive industry, developed by the International Automotive Task Force (IATF), which is made up of the world’s leading automotive manufacturers. Prodrive has also achieved ISO 9001:2015, a technical specification for automotive sector quality management systems, which has become one of the most widely used international standards in the automotive industry, harmonizing the different assessment and
Visit our website or contact us for a quote or advice
16
www.engineeringcapacity.com
certification systems in the global automotive supply chain. Warren Roberts, Prodrive Composites, chief executive, said: “Accreditation to these new standards will eventually become a pre-requisite for all suppliers to the automotive sector. Now, as the UK’s largest composite supplier outside the aerospace sector, it is a significant
achievement to be the first to achieve IATF 16949 and I would urge all composites business to look to reach these standards.” Prodrive supplies structural and visual composites to most of the UK’s leading premium vehicle manufacturers including, Bentley, JLR, McLaren, Aston Martin and Lotus. 8 prodrive.com/composites
Targeting UK rail and transport With a new UK business development manager on board, Compotech is showcasing its rail industry composites expertise at three key shows. Following its participation at RAIL LIVE at Long Marston in June it will now be exhibiting at RVE Modern Railways exhibition Derby in October and INNOTRANS in Berlin in September, with multiple SMC presses – with the largest ones supporting up to 2,000 tonnes – Compotech is further developing their capabilities across Europe with the appointment of Peter Rawson as UK business
development manager for segments serving Transportation and machine building. Peter will be these exhibitions with examples of Compotech’s full range of capabilities. Producing a wide range of high quality FRP composite parts for the rail and transport industries, Compotech has wide ranging in-house capability for full finishing including CNC machining, painting and assembly of parts. 8 compotech.ch JULY 2018
The workshops of the Llangollen Railway are using a new lathe from XYZ to machine parts for the iconic streamlined steam locomotive Sir Nigel Gresley. The workshops provide maintenance for the Llangollen Railway’s own rolling stock as well as supporting other heritage railways around the UK and building brand new steam locomotives to order. Like many such organisations it relies on donations, not only of cash and time, but also machine tools. However, when one particular project came up the decision was taken to invest in new machinery in the form of an XYZ SLX 425 ProTURN lathe. The project in question was the restoration of the iconic streamlined A4 Class locomotive Sir Nigel Gresley. Built in 1937, the Sir Nigel Gresley holds the post-war steam speed record of 112 mph (180 km/h) which it achieved on 23 May 1959 while hauling a full train of passengers. In its life it has had many overhauls, and the latest is taking place in full public view at the National Railway Museum in York by the Sir Nigel Gresley Locomotive Company Volunteers, except for its boiler, which has been stripped of its streamlining and transferred to Llangollen for refurbishment and re-certification. As part of this boiler restoration the boiler stays must be replaced, these threaded shafts support and brace the metal walls of the firebox against the pressure (up to 250 psi) and are an important safety feature. As the boiler on the JULY 2018
Photo courtesy of the Sir Nigel Gresley Locomotive Trust
Engineering Capacity | TURNED PARTS
Busy making parts for Nigel Sir Nigel Gresley requires 296 of these stays of various lengths with Whitworth threads on either end an upgrade from manual turning was deemed wise. Llangollen Railway therefore took the decision to invest in an XYZ SLX 425 Proturn lathe with a 1.25 m between centre distanced length. A decision that is paying dividends as each boiler stay can now be machined complete in half the time that they previously took on a manual lathe. “The ProtoTRAK control makes life very easy as it guides you through everything, the TRAKing feature is
very handy and the Do-One canned cycle feature in the control is extremely useful for machining features such as radii and chamfers. In addition to the easy conversational programming, we always use the Verify graphical system for added reassurance,” says machinist Michael O’Toole. The ‘Do-One feature in the ProtoTRAK SLX control used on ProTURN lathes allows the operator to combine manual and CNC operation to create radii, tapers, fillets and repair threads. The operator simply inputs the angle or radii into the control and then by using the electronic handwheels can manually create the shape or form required. For one-off and low-volume batches this can generate significant time savings. 8 xyzmachinetools.com llangollen-railway.co.uk/ sirnigelgresley.org.uk www.engineeringcapacity.com
17
Manufacturing buyer? We can help you find quality, approved suppliers. IIndustries: ndustries:
IIndustrial ndustrial Machinery Machinery Elec Electronics tronics Defence D effe ence / Military Military C Construction onstruction Oil/Chemical/Ener Oil/Chemical/Energy gy A Automotive utomotive Consumer C onsumer Products Products FFurniture urniture A Aerospace erospace Marine M arine
Services: Services:
A dditive M anufacturing Additive Manufacturing C asting Casting D esign & Development Development Design Electronics Elec tronics FFabrication abrication FFinishing inishing Machining M achining Plastic P lastic & Rubber TTool ool M o Making aking Woodworking Woodworking
Approvals: A pprovals: AS 9000 AS 9100 ASME BAE CAA C AA CE M arking Marking C oded W elding Coded Welding EN 1090 FA A FAA FFDA DA FFord ord Q1 FR2000 IPC Approved Approved ISO 13485 ISO 14001
ISO 15085-1 ISO 3834-2 ISO 9000 ISO 9001 ISO 9002 ISO 9003 Llo yds R egistered Lloyds Registered MIL -SPEC MIL-SPEC MOD NADC AP NADCAP OHSAS 18001 QS 9000 SC21 TTSS 16949 UL Approved Approved
F ind y our Find your E lectronics, Machining, Machining, Fabrication, Fabrication, Tool Tool Making, Making, Casting, Casting, Plastic or Finishing Finishing Electronics, sub contractors at: at: subcontractors w ww.qimtek.co.uk/buyers www.qimtek.co.uk/buyers www.qimtek.co.uk. 01256 394500 www.qimtek.co.uk.
Drag, Drop, rop, Source Source Post your ur project project Upload your our drawings, dr d awings, ma materials, terials, ba batch tch siz sizes, es, frequency, y, rrequired equired appr approvals ovals and mor more. e.
Receive e quotes quotes dir directly ectly Suppliers who match match yyour our rrequirements equirements will contact you ou dir directly ectly with quot quotes time.. es and lead time
Review sub subcontractors contractors View supplier plier profiles, profiles, track track your your project, project, award work rk and review review subcontract subcontract par partners. tners.
1 100% FREE
£
This service i e is fr free ee fr from om star startt tto o finish. We are entirely funded ed db byy our supplier net network. work.
Q Qimtek
““Qimtek Qimtek for me is not just a ser service vice pro provider, viderr, but a pa p partner!" rtner!" 20 Dec December ember 2017 C Charter harter G Global lobal
TURNED PARTS | Engineering Capacity
Speeding plastics production A versatile new turn-mill centre allows Colpa Precision to slash lead times and material costs on plastic components. The ability to change its recently installed Citizen Cincom A20-VII sliding head turn-mill centre into a non-guidebush variant for applications on plastic components and shorter length parts while retaining the guidebush assembly for longer parts, has enabled Colpa Precision Engineering to slash weeks from its lead time with significantly reduced material costs plus the ability to obtain greater number of parts from a bar. Said General Manager Martin Branch: “The removable guide bush feature on the Cincom A20 has increased our competitiveness in a tight market as we no longer have to order preground bar for plastics components which has not only reduced material cost, but also saved four weeks on our lead time to customers and has enabled us to pick-up new business.” He also confirmed that by replacing an aging Citizen Cincom C16 with the new A20, Colpa is slightly reducing cycle times, but more important to customers, improving productivity, consistency, uptime and machining accuracy, which is again helping to lower delivery lead times. Colpa Precision Engineering was set up in 1946 and has had the current directors / proprietors Dave Fry and Steve Low running 20
www.engineeringcapacity.com
the firm for the last 25 years. Investment has been consistent with some £560,000 spent over the last three years and in addition to machining centres and fixed head lathes, some six Citizen sliding head machines are installed. On the Watford site, 10 people are employed and production batches vary between prototype and customer development parts to continuous production runs such as involving the supply of 32,000 parts a month. The recent Cincom A20-VII installation is now mainly used for plastic parts and some aluminium to which Mr Branch said: “We run our first production batch with the guidebush installed and then removed it in less than 45 minutes. So far we have never used it again due to the advantages we have gained without it on smaller parts.” He also added that a Cincom A32-VII installed two years ago has now been dedicated to mild steel and stainless steel part
production which uses a permanent guidebush. Colpa’s customer base covers a wide field including optical, electronic, audio, music, pneumatics, commercial air conditioning and certain aircraft industry companies producing parts from brass, mild and stainless steel, aluminium, titanium and a wide range of plastics including PEEK and acetal. Cycle times tend to generally vary between 45 secs and 2 mins. Mr Branch describes two typical parts produced on the new A20-VII, one a micro cable clamp produced in 1,000 batches in white acetal to +/-0.05 tolerances and a black acetal intricate, multi-featured anti-skate dial which is machined in cycle times of under 2 minutes in batch quantities of 500. The cable clamp is 9.5 mm in diameter by 6 mm long and is turned on the outside diameter, JULY 2018
Engineering Capacity | TURNED PARTS spot drilled, drilled and tapped followed by use of a slitting saw to cut a slot along the length of the OD into the drilled hole. It is then picked-up by the sub-spindle which has a pre-set tension so as not to collapse the part, to produce a cross hole dimple, the bore chamfered and the part deburred in cycle. Meanwhile, the anti-skate dial has a cycle time of under 2 minutes and was transferred to
the new machine from the existing A32 in order to free up its capacity for larger work and maximise the use of unground bar. The component is 14 mm diameter by 14.75 mm long with key features that include the head of the part with 12 milled slots each having 1 mm radius at the bottom of the slot set on a 15 mm tool PCD. A spigot diameter has a waist, the head undercut with a cross hole 1 mm diameter which
breaks into the 2 mm through bore. 8 colpa.co.uk
Wealdpark Limited Stand number 5126
Subcontract Capacity #.# MILL TURN FACILITIES USING SLIDING AND FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER -IYANO FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER (URCO VERTICAL MACHING CENTRE 03, $ATATRACK MANAGEMENT SOFTWARE
BS EN ISO 9001:2008. Approved by BSI since 1991.
Company Contact Details Phil Smith, Director, Wealdpark Limited Sutton Road, St. Helens, Merseyside, WA9 3DJ Tel. 01744 22567 / 732083 Fax. 01744 451339 E: sales@wealdpark.co.uk www.wealdpark.co.uk
JULY 2018
www.engineeringcapacity.com
21
TURNED PARTS | Engineering Capacity
Doubling up speeds turnaround Peter Day Precision Engineers has invested in twin-spindle, twin-turret turn-mill capacity to speed order turnaround. The Christchurch-based subcontract machinist has invested in a Nakamura WY150, supplied by The Engineering Technology Group, so help it cope with a 20% growth in orders. The twin-spindle, twin turret configuration gives the company the ability to remove a lot of secondary operations making the overall machining process quicker for customers. “Our work is very much around manufacturing complex machined components that have to perform in demanding environments. Whether that is for aerospace, oil & gas or the medical sector,” explained Pete Makosa, General Manager for Peter Day Precision& Hightown Engineering. “Over the last twelve months we have seen a 20% increase in orders, which will see the wider VPEG group (Peter Day’s parent company) break through £10m turnover this year. This, combined with a strong pipeline of future orders, means we need additional CNC turning capabilities.” 8 peterday.co.uk
22
www.engineeringcapacity.com
Funding for extra capacity County Durham precision engineering firm Ronco Engineering has received the first investment from a new £120m North East Fund to invest in new staff and machine tools. The North East Fund is supported by the European Regional Development Fund. Ronco Engineering has worked with NEL Fund Managers to secure a £250,000 investment from the North East Growth Capital Fund which will help it build the extra capacity required to successfully manage its growing order book. Six new skilled posts are being created within the specialist production team at the Tanfield Lea-based business, taking the total workforce to 38. Three new turning centres and new grinding equipment are being added to the factory floor, while premises improvements will ensure that enough power is available to service the extra equipment. The Ronco management team is now aiming to use the extra capacity to win more new contracts and hopes to almost
double the firm's turnover within the next three years. Ronco Engineering offers the full spectrum of engineering services, from prototype design and CAD modelling through to final testing and manufacturing, and includes household names such as Caterpillar and JCB. David Steel, managing director at Ronco Engineering, says: "Over the last couple of years, we've spent a lot of time on business development activities which are now really bearing fruit with both existing and new clients. "This investment will give Ronco a real shot in the arm and enables us to build the capacity needed to capitalise on the many interesting opportunities we've created with customers in the UK and Europe.” The North East Growth Capital Fund has been designed to create over 800 jobs in more than 70 regional firms over the next five years and offers unsecured investments of up to £500,000 to established businesses looking to realise their growth potential. 8 ronco-engineering.co.uk JULY 2018
Engineering Capacity | CASTING & FORGING Sheffield Forgemasters, which manufactures components for civil nuclear power, has completed manufacturing, research and consultancy work to allow the world's oldest working nuclear reactor to restart. It was contracted by plant operator, AXPO, to investigate the origin of ultrasonic indications which were detected in the Reactor Pressure Vessel (RPV) of Unit 1 of the Beznau nuclear power plant (KKB) in Switzerland, which was taken offline for two years until confirmed to be safe by the Swiss Federal Nuclear Safety Inspectorate (ENSI). Forgemasters manufactured a large cylindrical forging, identical to the body of the RPV, using techniques employed in the original 1960s manufacture and also acted as engineering and metallurgical consultants, establishing a root cause analysis and delivering detailed reports to support the safety case which permitted the reactor to restart. Professor Jesus TalamantesSilva, group design and technology director at Sheffield Forgemasters International, said: “This detailed body of work provided both AXPO and ENSI with critical pieces of information, allowing them to assess the current and on-going safety of the RPV. “Fundamental to the project was the recreation of the ultrasonic indications in the full-scale replica; this was only possible by mimicking the original manufacturing route as faithfully as possible. Using material from the replica, the response to JULY 2018
UK powers Swiss nuclear restart
ultrasonic inspection – which was almost identical in both forgings, was attributed to non-metallic inclusions. “This finding then allowed the replica to act as a surrogate for the Beznau RPV, permitting destructive and non-destructive tests to be carried out, which are impossible to do on the irradiated RPV. This testing established that the nonmetallic inclusions were aluminium oxide and their presence did not have a negative influence on the mechanical properties and therefore safety of the RPV.” As an engineering consultant for the project, Sheffield Forgemasters was responsible for the entire process of recreating the RPV section, conducting materials testing and establishing a root cause analysis. The root cause analysis ruled out a significant number of potential origins of the ultrasonic indications – many of these could have curtailed/ended the operating life of the reactor. This, coupled with the
replica, provided compelling evidence to ENSI and AXPO that the reactor was safe to restart. Professor Talamantes-Silva added: “There are few companies in the world with our capacity to deliver this kind of civil nuclear materials consultancy, which is crucially relevant to the inaccessible RPVs of older power plants and offers the chance to identify manufacturing and age issues before they become critical.“This project has enabled the Beznau reactor to restart after a very costly two-year hiatus and ensures that the operational requirements of the power plant are met for the future of the reactor's life.” It has produced energy since September 1969 and is the world's oldest nuclear power plant still in commercial operation. Sheffield Forgemasters is a global supplier of components for civil nuclear power and specialises in the casting and forging of ultra-large components required in the heart of a nuclear power plant. The company is now a world leader in the delivery of technology enabling it to tap into markets including Small Modular Reactor and pressure vessel development and has recently partnered with a Canadian company on the design of one of the world's first fusion nuclear reactors. 8 sheffieldforgemasters.com www.engineeringcapacity.com
23
CASTING & FORGING | Engineering Capacity Dyson Diecastings has enhanced its CNC machining capabilities with the addition of a new FANUC machining centre. Founded almost 100 years ago, the Milton Keynes based company initially started as a casting business before moving into adding simple operations such as drilling and tapping holes in its castings. Paul Savage of Dyson Diecastings says: “As technology has evolved, so have customer demands and the capabilities of our company. We have moved from just drilling and tapping to adding a CNC machining department and we now conduct profile milling, facing and much more. In terms of value adding processes, we do painting, plating, polishing and more to offer a ‘fully finished’ product.” As a business, the Buckinghamshire manufacturer also undertakes design for manufacture, project management, design optimisation, high pressure die-casting and CNC machining for high-profile brands such as Aston Investacast has increased its workforce by 40% to support new business and has started a £500k investment programme with the backing of its new owners Expromet Technologies Group. The investment casting specialist company has increased the number of employees based at its manufacturing site at Ilfracombe, North Devon from 65 people, when it was acquired last year, to the current level of
24
www.engineeringcapacity.com
Adding value on diecastings
Martin, Jaguar, Siemens, TRW, Vent Axia, Turner Powertrain, Honeywell and many others. Dyson Diecastings has two sites totalling 200,000sq/ft where work can range from 10-20 off components for prestige automotive customers through to a weekly output of 10,000+ on large volume projects such as automotive centre consoles, air and oil cooling assemblies, engine brackets and valve bodies through to hi-fi speakers and hand dryers for public conveniences. The latest investment is a FANUC ROBODRILL B-Series D21LiB5 with an extended bed
length that accommodates the variety of components that pass through the machine shop. As Mr Savage continues: “Usually, we would go for a 1m bed length machine and also have a 600mm FANUC machine alongside, but this 800mm bed length FANUC is ideal for what we need. “We purchased three machines last April and the order is already in for another three that will arrive in a matter of weeks.” “We cut a lot of aluminium and only take cuts that can be as little as 0.2mm, the more we take off the more it costs us. We have one part on the machine that has been running for 12 years and it requires some long series drills and taps to avoid key features in the component. Additionally, we do some milling with 120mm diameter face mills, so machine tool rigidity is as critical as performance and precision.” 8 dysondiecastings.co.uk
New owners back casting expansion 90. Investacast hopes to create up to a further 10 new jobs over the remainder of this year, taking its team to approximately 100 employees. Alistair Schofield, CEO of Expromet, commented: “It’s been an exciting start to 2018. When we acquired the business, we set out ambitious growth plans for the future. We've seen a considerable increase in orders from both
existing and new customers across many industrial segments over the last 12 months, which has translated into increased recruitment requirements to help us grow the business.” Looking to the future, Investacast is substantially strengthening its engineering and management team in 2018. 8 investacast.com haworthcastings.co.uk
JULY 2018
Engineering Capacity | CASTING & FORGING Midlands-based, lightweight casting company Sarginsons is set to start on a new programme of work on parts for the next generation of Jaguar Land Rover vehicles. The company, which is based in Coventry, has invested to upgrade its sand foundry which will see the firm making new components for the aluminium chassis of future vehicles for the global automotive giant. Work is set to start in June after the company invested in new process controls and mixing equipment at its manufacturing facility in Torrington Avenue. Sarginsons will provide the parts to two tier one suppliers to Jaguar Land Rover, which will form part of the company’s next generation of vehicles. Anthony Evans, the managing director of Sarginsons, said: “We continue to invest to ensure that we are able to bid for and land new contracts with major manufacturers. “We don’t supply Jaguar Land Rover directly but our components have to meet the very stringent standards set by the world’s biggest OEMs. “The programme of work will start in June and we are very excited to be part of this next generation of vehicles. “As well investing in our equipment and processes, we also continue to invest in our staff and training to ensure we can deliver major contracts and programmes such as this.” Mr Evans added: “The mood in the industry is positive. We are JULY 2018
Revving up for JLR castings
working on several automotive programmes and some nonautomotive contracts too.
“There is a great deal of uncertainty around what Brexit will mean but we are seeing no let-up in orders and, also, we are seeing some of our clients looking to open bases in the UK – and in this region – to ensure there is no issue when it comes to supplying some of the major manufacturers in our area.” 8 sarginsons.com
>ccdkVi^kZ > c c dkV i ^ kZ BVcj[VXijg^c\ B V c j [ V X i j g ^ c \ Hdaji^dch H daji^dch
BGI 8Vhi^c\h A^b^iZY B G I 8 V hi ^ c \ h A ^ b ^ i Z Y Hdji] LVn! LValdgi] 7jh^cZhh EVg`! Hdji] LVn! LValdgi] 7jh^cZhh EVg`! 6cYdkZg! =Vbeh]^gZ! HE&% *?I! J@ 6cYdkZg! =Vbeh]^gZ! HE&% *?I! J@
lll#bgi"XVhi^c\h#Xd#j` lll#bgi"XVhi^c\h#Xd#j`
I/ I/ ) )) % &'+) (')%'& ) % &'+) (')%'&
www.engineeringcapacity.com
25
FORMING & FABRICATION | Engineering Capacity Precision fabrication specialist LTi Metaltech’s skills and experience were crucial in the manufacture of a pressure vessel for a large green ammonia energy project. Precision fabrication and welding can be extremely challenging, particularly when the manufactured components need to withstand some of the highest temperatures and pressures. This was certainly the case when Siemens CT tasked the LTi Metaltech with the manufacturing of pressure vessels involved in ammonia capture, for a large Government funded green ammonia energy project. On receiving the original specifications, LTi immediately identified that the components’ design geometrics would have made them extremely difficult to test and meet the necessary regulatory compliance. This was critical, as they needed to withstand immense internal pressures of over 500 bar, whilst also having an elevated working temperature. Other challenges included the additional factors of safety built into the original specified design, which were beyond the current industry standards normally used. The factor of safety ratio is important as it tests and certifies the load carrying capacity of a structure beyond its expected or actual loads during its normal operation. It also ensures a structure is always much stronger than required for its intended load, to help safeguard safety and performance. Working to EN 13445 European Pressure Vessel Standards, which 26
www.engineeringcapacity.com
Fabrication challenge for green energy
sets the required minimum standards in the design, fabrication and inspection of vessels, LTi took the following steps to resolve these challenges. Following consultation with its client LTi manufactured a new sphere to replace the original square design – eliminating any potential weaknesses and high fatigue areas within the design. Next, LTi utilised its experience of pressure and vacuum vessels to investigate how applied stresses could potentially harm the material and design, so it could ensure the necessary factor of safety was built in and the quality and performance of the material was maintained. Following reviews, LTi was able to fabricate the components from
thinner material, which were lighter, more cost effective to produce and yet still fit for purpose. To demonstrate regulatory compliance, components need to undergo 100% ultrasonic nondestructive testing; involving the use of high-frequency sound waves to locate cracks and other internal weld or parent material defects in the component. However, this was challenging due to the original design’s geometrics. To overcome this, LTi worked closely with the British Standards Institute (BSI), conducting intermediate testing of various elements during the manufacture, to satisfy the BSI that sound engineering practices were employed throughout and ensure the regulatory compliance of these components. LTi also employed optimised welding processes using MIG (metal inert gas) rather than TIG (tungsten inert gas) welding, to help reduce distortion, whilst improving the overall welding speed and weld filler material deposition. MIG welding achieves this, as a metal electrode wire is also continuously fed into the weld being made. By removing weight from the original design and reducing cost in the process, LTi’s client gained a new design that was compliant, stronger and more cost effective. 8 lti-metaltech.com JULY 2018
Engineering Capacity | FORMING & FABRICATION Baylis Automotive, a West Midlands manufacturer of metal pressings and welded assemblies is celebrating after securing a clutch of new orders, helping it achieve 25% annual growth in the process. Baylis Automotive, which employs 60 people at its 65,000 sq ft facility in Smethwick, has won a number of contracts to supply seating and HVAC components for the agricultural sector, taking turnover to £5m. The company is now targeting further expansion and has joined forces with Control Energy Costs (CEC) to help it manage its energy more efficiently as it looks to increase capacity. It is an approach that is already reaping dividends, with the firm saving in excess of £25,000 by renegotiating its current supply contract and securing Climate Change Levy (CCL) tax relief for the first time. “We supply over 172,000 pressings every week and these range from small HVAC nozzles to large heavy duty side members for coolant systems - all manufactured to the highest possible quality,” explained Raj Desai, Managing Director of Baylis Automotive. “This year will see us smash £5m in turnover and, with the increase in work, comes an increase in costs through new machinery and more energy. We don’t have the time to monitor usage or look at ways where we could be more cost effective, so thought we would bring in external specialists.” He continued: “CEC were JULY 2018
Ploughing ahead in agriculture introduced to us through a mutual business partner and we were immediately impressed with its transparency and the desire to understand our issues. “Technical Analyst Rebecca Capon quickly got to the bottom of things and spent a lot of time negotiating a new provider for our electricity needs and explained to us that we could be eligible for financial relief through the Climate Change Levy. We didn’t even know that existed.” Control Energy Costs, which is one of the UK’s leading specialists in utility management, managed to secure Baylis Automotive a £15,000 refund from CCL and ongoing savings through the new provider could work out to as much as £4,000 per month. It is also currently in the process of assisting the company with increasing its power supply so its growth and subsequent rise in energy usage doesn’t result in excessive charges. “A lot of manufacturers in the Black Country are growing and
with that growth comes escalating energy costs,” added Rebecca. “There’s lot of examples where firms just pay the increase without investigating as it’s seen as a noncore part of their business. This is where we come in. All of our analysts have extensive experience of forensically examining usage, identifying new supply contracts and tapping into any subsidies companies are eligible for. “So far, we have generated Baylis Automotive over £25,000 in relief and monthly savings and this figure could increase as we look at new energy saving measures the company could introduce.” Control Energy Costs work with more than 900 retained clients across the UK, with its team of analysts providing an initial, no-obligation audit and then working with the customer to identify existing issues and opportunities to reduce bills, whilst advising on improving future procurement strategies. 8 baylisautomotive.co.uk cec.uk.com www.engineeringcapacity.com
27
FORMING & FABRICATION | Engineering Capacity Sheffield specialist engineering firm SCX Special Projects has opened the door on a stunning articulated steel façade at a high-profile office and residential development in central London. It supplied the façade and designed, built and installed the mechanism that allows two huge decorative portcullis panels to open or close in just 15 seconds. The company worked closely with MAX Architects and Kier Construction as part of a regeneration project for Royal London Asset Management at 25 Wilton Road - opposite Victoria Station in one of the most desirable and visible locations in the capital. Kier, renowned for delivering high profile property redevelopment projects, sought SCX’s expertise and flair in mechanical handling and lifting solutions to enable the portcullis doors to be lifted and lowered whilst remaining in full view. The two panels on the building’s distinctive front elevation are predominantly polished stainless steel and have a stunning stencillike design by artist Chloe Steele. SCX Special Projects supplied the panels, cut to the artist’s design using high pressure water jets. They are 15mm thick, measure 3m by 2m, and weigh over 800 kg each. The company, which is based in Wincobank, Sheffield, was also responsible for the mechanism for the façade. The engineering challenge went further than mechanical, including electrical systems and ensuring safety controls. 28
www.engineeringcapacity.com
Doors to automatic
Using hand-power alone, the panels can be lifted or lowered in just 15 seconds, safely held by mechanical locks whilst in the raised position. The doors function as security shutters when closed, and when raised they remain in full view above the entrance. SCX’s innovative design cleverly integrates into the slim metal framework, while the innovative counterweight mechanism is on display in the building’s foyer, behind polycarbonate panels. Max Titchmarsh, founder of MAX Architects, adds: “The Portico at the main entrance to this significant development was crucial to creating a buffer from the busy street and delivering the impact the entrance required. The design of the Portcullis doors exposes the mechanism and frames the artwork in way which adds real interest to the principal interest. It is unique and we’re very pleased with the result.”
Kier Construction’s senior quantity surveyor, Martin Melges, said: “The articulated panels add both form and function to the front elevation of the building. SCX’s mastery over moving structures combines effortlessly with Chloe’s striking design to make the steel doors look as graceful as the architect intended.” Danny Pickard, lead engineer at SCX Special Projects, comments: “Clients such as Kier look to us to solve unique mechanical engineering problems. The articulated façade at 25 Wilton Road is no exception. “We are seeing a trend towards more moving structures in architecture. It’s a new route for architects to take – no longer do buildings have to be rigid and static. The façade looks fantastic, and it was a pleasure to work with everyone involved.” 8 scxspecialprojects.co.uk JULY 2018
Engineering Capacity | FORMING & FABRICATION William Hughes has increased its component endurance testing capabilities with the acquisition of two new compression spring fatigue testing machines from Italian test equipment specialist Micro Studio. With the investment in these new machines William Hughes can test fatigue on compression, tension and some torsion springs. There are also facilities for endurance testing of torsion bars and seat mats. This enables the company to guarantee its springs will meet customer requirements for a minimum number of cycles without breaking. Springs in different applications are subject to different levels of usage – from modest usage in an automotive seat mechanism to much more demanding duties in typical aeronautical applications – and it can be important to have data for spring fatigue in these real-world tasks. “Fatigue is not just a body function for athletes,” says William Hughes technical director Emma Burgon. “Any component working in a dynamic application is prone to fatigue. We can – and do – model theoretical lifespan, and that’s useful information, but practice can differ from theory so the only way to guarantee lifespan is to test in real life.” The new machines enable William Hughes to test large numbers of cycles on compression springs very quickly, establishing the minimum number of operations a component or assembly can achieve. “More and more JULY 2018
Testing for endurance customers are demanding within their production specification that a certain component must be able to achieve a given number of operations,” explains Burgon.
Any component working in a dynamic application is prone to fatigue. We can – and do – model theoretical lifespan, and that’s useful information, but practice can differ from theory so the only way to guarantee lifespan is to test in real life
‘‘
“If a main assembly has to meet, say, 20,000 cycles, then all of the components within that assembly must be able to meet that cycle requirement, under stress conditions, even if they’re not involved in all actions. Knowing that a particular spring will not fail during those 20,000 operations gives the customer confidence, and means he can in turn guarantee the safety of the whole assembly.”
With two machines, William Hughes can test up to 24 springs simultaneously, with the machines ensuring accurate strain tests of compression springs even at the highest speeds. The equipment gives William Hughes the capability to test springs up to a load of 30kN as standard, and the machines can be equipped to test springs up to a load of 40kN. The company can fatigue springs to specified numbers of cycles without breaking, or until the spring breaks. When a spring does finally break, the machines record the number of cycles achieved at that point. “It’s not unusual for us to be asked to produce springs that will offer spring lifecycles of tens of thousands or even tens of millions of operations without breaking,” says Ms Burgon. “With these new machines, we can back up spring theory with real world testing and offer the guarantees that give our customers the highest levels of confidence.” 8 wmhughes.co.uk www.engineeringcapacity.com
29
FORMING & FABRICATION | Engineering Capacity New investments at Harlow-based Gratnells in moulding, coating and laser cutting will cut lead times for subcontract customers. Gratnells Engineering has been providing engineering solutions for nearly 130 years. Historically known as the leading name in school storage in over 68 countries of the world (and the producer of the iconic Gratnells Tray) Gratnells Engineering has developed into a multi-sector manufacturer capable of providing high-volume laser cutting, powder coating and bespoke metal solutions to a wide range of customers.
Gratnells Engineering decided to invest in state-of-the-art laser technology to enable us to offer fast production runs with the best quality finish, to our customer base
‘‘
The Harlow-based manufacturer specialises in short run, quick turnaround projects, Malton Laser has produced a series of stainless steel trophies for the podium finishers in the Ginetta racing championships. The trophies, manufactured from stainless steel, have all been laser cut and welded by the company’s metal fabrication experts. Cut utilising Malton Laser’s laser cutting technology, the trophies depict the routes of the tracks on which the races take place, as well as highlighting the finishing position of the recipient.
30
www.engineeringcapacity.com
Short run, fast turnaround giving customers shorter lead times, high precision and quality customer service. Powder coating, injection moulding and laser cutting are just some of the areas where investment has been made this year, including a new SpraylinePlant machine, IM machine number 8 and a BLM LT Fibertube cutting machine. In particular, the BLM LT Fiber tube cutting machine has helped increase efficiency, benefitting both the company and their customers with a fast and highly precise process. Designed to cut from small to medium diameters and thicknesses of metal tubular sections, the LT Fiber allows tubes of any shape to be cut, process of special sections and even open shapes without any additional special equipment required. The laser cutting range boasts an automated unloading and support system for pre-cut lengths up to 6100mm, automatic
weld seam detection, and a module that maintains the cleanliness of the internal tube surface whilst machining. Anticrush technology makes the machine capable of processing even the lightest of tubes without deforming the walls. This hightech equipment is also great for scrap reduction by setting the sequence of parts to be cut and minimising end of bar scrap; meaning less overall waste, which is good for the company and for the environment too. Loic Jones, Operations Director, says “Gratnells Engineering decided to invest in state-of-theart laser technology to enable us to offer fast production runs with the best quality finish, to our customer base. This substantial investment will allow us to continually support the everdemanding needs of modern manufacturing clients”. 8 gratnells.com
Cut out for racing success
After being cut, each trophy was welded by expert engineers, before being powder coated to create a smooth, robust finish. To date, trophies manufactured
by Malton Laser have been awarded at the opening six events on the calendar, including Oulton Park, Brands Hatch, Donington Park, Thruxton, Rockingham and Snetterton. Malton Laser will continue to provide trophies for the remainder of the Ginetta Championships season, which support the British GT and British Touring Car Championship packages. 8 maltonlaser.com
JULY 2018
Engineering Capacity | AEROSPACE Stars of the South West aerospace and defence sector were celebrated last month at the second WEAF Aerospace Ambassadors Awards under the wings of Concorde at Aerospace Bristol. Organised by the West of England Aerospace Forum (WEAF), the annual awards focus on the cream of the industry and shine a spotlight on their outstanding achievements. Backed by headline sponsors Safran and SKF Aerospace, the awards attracted scores of entries, which presented the judging panel of independent and recognised experts with a challenge to find the most deserving winners. The SME Star Award went to Bowmill Engineering of Poole. Bowmill’s Nick Epps said: “Thank you so much. I feel so honoured to receive this award. I am privileged to be working with a team of people so passionate about the growth and development of Bowmill. I’d like to thank all of Bowmill’s colleagues and clients who have supported not just me, but the business itself.” Other award winners were: Ben Smith, Rolls Royce – Filton, Bristol, Best Aerospace Engineer; Liam Towills, RPI UK – Bath, Best Young Aerospace Entrant; Frank Bamford, Semper Aero - Weston Super Mare who won a lifetime achievement award; Paolo Zanotto, Leonardo MW – Yeovil, Customer Service Award; and Linda Coode, Aerospace Bristol, Best Aerospace Media Ambassador. A final Award was made to JULY 2018
SW aerospace heroes
honour the legacy of Trevor Eggington of Westland Helicopters (now Leonardo Helicopters). His daughter Jane Egginton said: ‘Trevor was incredibly passionate about pushing technology to the next level throughout his career and the fact that this has been recognised by his peers in industry today makes me incredibly proud of his achievements. This award will be cherished by myself and Trevor’s family for many years to come.” The South West has one of the largest concentrations of
Jane Eggington collects the Legacy Award on behalf of her father Trevor from Adrian Harding
aerospace and defence capabilities in Europe, and is the largest aerospace cluster in the UK, worth more than £7 billion per annum. Adrian Harding, Business Development Manager of WEAF, the leading membership trade organisation for aerospace and defence companies in the South West, said: “Congratulations to all the winners of the second Aerospace Ambassador Awards – the brightest and best in the South West’s aerospace and defence sectors! And a well done to all the individuals who were shortlisted – the judges had an extremely difficult job, such was the quality of nominations. The South West is a nest of innovation in engineering and manufacturing, and the individuals who have won these awards demonstrate this perfectly.” Individual award sponsors are Airbus, Castlemead Insurance, Bridgwater & Taunton College, Trowers and Hamlins LLP and Aro PR and Marketing. 8 weaf.co.uk/ www.engineeringcapacity.com
31
AEROSPACE | Engineering Capacity The demand for lightweight aluminium and titanium etched parts has helped Advanced Chemical Etching (A.C.E.) win new orders and create 15 jobs. The company, which is located on Hortonwood in Telford, has seen sales soar by 20% over the last twelve months, with new contracts secured across the aerospace, F1 and automotive sectors. It now looks set to smash the £5m barrier for the first time in its history. The firm’s ACmE™ and TiME™ processes have generated significant demand from a global customer base that is committed to sourcing lightweight components. The growth has necessitated the need for 15 new jobs and there could be more recruitment plans on the horizon if plans to hit £8m by 2020 are realised. “When etching aluminium it generates its own heat, causing the standard etching solution to go out of control…our ACmE™ process negates this by allowing more machine etching time instead of waiting for the solution to cool down back into controllable limits,” explained Ian Whateley, Managing Director of Advanced Chemical Etching. “TiME™ is similar and much safer than the conventional HF/Nitric mix and results in very clean etched profiles. The ability to develop these new technologies has seen us add hundreds of new clients to our books and we are looking to capitalise on this by continued investment in new machinery and capacity.” He continued: “Our expertise is 32
www.engineeringcapacity.com
Light parts spur jobs boom
going all over the world too. Current export levels are at 30%, but with the increase in demand for titanium medical parts supplied into Europe and USA, we are expecting this to be closer to 50% by 2020.” A.C.E. specialises in development of prototype components, pre-production and volume fulfillment to customers in aero, automotive, electronics, medical, telecoms and renewables. The scope of its activities is far and wide and can include anything from safety critical components for aircraft and F1 cars to meshes and electronic connectors and even frames for designer glasses. All parts are developed and manufactured at its main site in Telford or at the company’s dedicated sister business, ACE Forming Limited, in Kingswinford. Latest production machinery, a dedicated laboratory and state-of-the-art measuring capability ensures it works to the
most exacting tolerances and can manufacture components in materials, such as stainless steel, nickel alloys, copper, beryllium copper, phosphor bronze, brass and, thanks to groundbreaking new processes, aluminum, molybdenum, titanium, nitinol and elgiloy. Ian went on to add: “The big investment to date in 2018 has been the installation of three new LED exposure print frames, which give us the ability to image up to 1500mm x 600mm sheets. “We have further equipment planned for later this year, with several new production machines being added to our already impressive equipment list.” He concluded: “All of this investment will increase throughput and improve our fine line technology for thinner materials. It’s all about making sure we are ahead of what the market wants.” 8 ace-uk.net JULY 2018
Engineering Capacity | AEROSPACE A trio of major new orders to supply into the aerospace, petrochemical and nuclear sectors have helped Alloy Wire International smash the £10m barrier for the first time in its 72-year history. The company, which supplies more than 60 different ‘High Performance’ alloys, has seen sales increase by £3m since 2016 and puts the sustained expansion down to its ability to offer 3-week lead times and the growing demand for its Emergency Manufacturing Service. The company has also invested heavily in its stock, with 200 tonnes now available at any one time – the largest holding it has ever held. Mark Venables, Managing Director, commented: “The recovery in oil and gas has certainly been one of the highlights of recent months and interest for our material has come from every corner of the globe…I think at the last count we were exporting to 55 countries. “In order to cope with the increase in volumes we have taken on three new people in
JULY 2018
Pushing through £10m sales and in the dry drawing department, whilst investment in bespoke machinery and an ever-growing international list of sales offices gives us an ideal platform to grow sales even further at our sites in Brierley Hill and in Yorkshire.” He continued: “We have a fantastic team who all know our strategy and work very hard to continually maintain the high standards the AWI name has become synonymous with. Whilst
wire may be our core offer, it’s our people that deliver the biggest competitive advantage.” Alloy Wire International makes round, flat and shaped wire in a range of material that is growing by the month, with more than 60 currently available to choose from. The firm stocks in excess of 200 tonnes of material, which allows it to offer unrivalled lead times of three weeks from the order being placed. It has also recently invested in an additional 4,000 sq ft of production space and launched its own ‘Wire Finder App’ as part of a marketing drive to help customers find the right wire for their applications. Mark concluded: “It frequently amazes the team how far our products go and we have found out in the last year that our wire is used in space programmes, in nuclear reactors and in some of the world’s fastest car engines. UK manufacturing at its very best!” 8 alloywire.com www.engineeringcapacity.com
33
Qualiturn are a very modern subcontract machining service. We offer CNC precision Turned and Milled components to your specifications and quantities. We work with all sizes of customers, offering the same service to all. Supplying various market sectors across the world. 18 Merchant Drive Mead Lane Industrial Estate Hertford, Hertfordshire SG13 7AY Tel. +44 (0) 1992 584499 www.qualiturn.co.uk
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. Royd Way, Keighley, West Yorkshire BD21 3LG Tel: 01535 602587 www.hewitt-topham.co.uk
34
www.engineeringcapacity.com
MACHINE TOOL MANUALS 8
Qualiturn Products Limited
PRECISION ENGINEERING 8
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.
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
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
Dawson Precision Components 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. Greenfield Lane, Shaw, Oldham, Lancashire OL2 8QP Tel: 01706 842311 www.dpc.co.uk
Shorter Works, Bailey Lane Sheffield S1 3BL Tel: 0114 276 8167 www.flamehardeners.co.uk/
MACHINING (5 AXIS) 8
GEAR CUTTING – GENERAL 8
CNC PRECISION COMPONENTS 8
Unit 2, Deethe Farm Industrial Est, Cranfield Rd, Woburn Sands, Milton Keynes, Bucks MK17 8UR Tel: 01908 585103 www.jflbroaches.co.uk
Flame Hardeners Ltd
PRECISION ENGINEERING 8
JFL are broach and broaching specialists with amost 40 years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms.
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. Quartremaine Road, Airport Service Estate, Portsmouth PO3 5RD Tel: 023 9267 7747 www.dkwengineering.co.uk
PRECISION ENGINEERING 8
JFL Broaches and Broaching
HEAT TREATMENT 8
BROACHING 8
DIRECTORY | Engineering Capacity
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. Sutton Road, St. Helens Merseyside WA9 3DJ Tel: 01744 22567 www.wealdpark.co.uk
JULY 2018
Accredited to AS9100 Rev D
Parts Assembly Parts Subcontract Machining ts g suppor Mill-turnin oach lean appr
AS AS 9100 & ISO 9001
year half of this In the first has committed to ing Roscomatic investment, includ More than Engineering of 1000 latest Capacity | £750,000 medium-size small to INDUSTRY ation of the axis NEWS the install (SMEs) have d manufacturers 1MSY multibeen given Miyano BNE-5 . business a centre boost turn-mill ing-based months thanks over the last ten company The Worth to a new £9.7m nist business machi suppor million parts subcontract The Manufa t initiative. some 1.5 cturing Growth completed dispatches from Progra g mme (MGP), ssemblies a year – rangin funded European and sub-a Regional Develo by the assemblies ned castings and Fund (ERDF) pment machi is to large Economic and delivered by parts – and Growth Solutio small turned ing a record has helped achiev companies ns (EGS), 98%. currently the UK to across 13 mins to just ry rate of grow, Martello from on-time delive products and develop been cut new r complex director Joe is driven overcomemins. A furthe nent which ny Managing Keet says: the compa r Seanproduc tion ity 2.5 issues steel compo taking flexibil explains that of constant Cell Leade that ional sly previou weress stainle g ions phy of operat d us them holding by a philoso of lean manufacturin three operat reduced to a “The levels o BNE has hadback. Thisenable has ning now developmentsupported by machialready led tominutes is in the Miyan reduce jobs, with new inute cycle. ent an additio 11 400, four-m ing £1 techniques, significantly positio 359 important, -on-investm to often exceed liaison’ to ns expected nalsingle most ent and investm tivity.” to be Further return setters an ‘opentimes once l produc ongoinne year and the has s createdfrom freeing-up from the g project million a improve overalcomple are and comes y which keeps new machi ted.machi By thenes other tasks for each m people strategto date on the He says the£1.6m end of perfor July, time up of grant ium existing 3-axis arising. ion of lost reducing the workforce replaced beenofmade, utions 10 alumincontrib reduct have and any issuesin tion, four family withedmoney errors We’ve company requir so that a to suppor first-off inspec reloca gottion “We invest ass. te in place andstill previouslyt anothe lot of grants He says: deliver a separa r 2200 firms parts that betwee to and we want risk of setting and the latest n and leadership nownow work in progre g operations 1MSY andbeMarch which manuf automation and manag acturer and cutting Lorrain 2019. of turnin operat ion can technology of the BNE-5 ge ement, R&D, lean ity le e cycle. ction come Holme and see howassitto capabforwar illing produ s, Chief manufacturin The flexibil me the shorta er, milling Execut d s theyiscan e productivity in oneiveturn-m g, Officer its succes take helps to overco require. Howev ofaverag EGS, produced and capacit is that with three age explain is key toadvant of the would cutting ed: “We systems and ve bonus at y, quality assista cycle has pped we still need massi are offer. nce skills we A way part single that It’s never on targets of above the tant sly overla we per times beenateasier, development.supply chain have set for the as the procesaneou it is so imporown engineers total cycle s isworkp proving that ourselves,tools simult quickiece by and the Martin Coats, there is a suppor up toscope to grow our ends oftacan support and our bar real from nt both Operations appetit using SMEs for Director at and be tailored to the of e exact time, through consta to maximise EGS, continu needs ofter. support that targeted business same in order firms come ed: “When diame the busine can barManufa and so training, The to us they “The differen help them grow. 51 mm 15 kW mainss.” vestment and what cturing ead receive strateg -on-in rt ic review from Progra a return kW The fixed-h mme programme ce with our is 7.5Growth we suppo was set one MGMs that two-ax is upwith the void e and improve how customers.” to fill determines of our spindl by manufacturinthat it is delivered left e, both by the o r to barriers are what spindl Manufacturing Advice dary g we delive n to the new Miyan d experts in the way secon Service (MAS) understand s of 5,000 of support is and what the challen who y ordere In additio by tage um speed advan providi needed to maximng companies ges access to ny has alread help them reach their are facing. special in, have the assista the compa CNC sliding head isted potenti impos revs/m nce They understand to d / super “Since Octobe al. manufacturer the langua nes. The to synch ronisehelp two Citizen grow and ge improv12-station, s centre machi L20-VIII MDs are talking highest barrier r 2016, the l for both e. Ideal for turn-mill and can guide This contro is being with 15% . nes, a Citizenfrequency them on making was ‘Contin achieve ven turrets an 18-stro d through two machi low uous Improv of clients all-dring adecisions, before the right featuring followed by ement’, logy) and experienced network of LFV (LFV bringing in ‘Environment specialists BER 2017 manufacturin cutting techno will bring ‘Marke on al’ on SEPTEM and specifi ting growth vibrati g and Market c issues are facing managers ange M16-V 14. Knowledge’ (MGM) ations to they’re or opportunities they to industr top-of-the-r (12% each). y specialists , access Citizen install looking initial stage Once the and the opportunity the total has She continu to explore.” to we then bring been completed, ed: “1000 m average grant apply for an acity.co benefic ringcap of £1400, rising iaries is just works with in an expert who maximum the manag the start. www.enginee to a to £3,500 14 ement team address these Support can . be used for 8 manufacturin issues.” SEPTEM BER 2017 programme.c ggrowth o.uk
Growth su helps 1000pport SMEs
MACHINED COMPONENTS: Prismatic parts from bar
www.engineeringcapacity.com
Call 01737 270648
Batchflow Engineering Ltd CNC turning capacity from 2mm200mm using high precision Fixed and Sliding Head CNC Lathes. Experience in machining a range of materials, from Low to Medium volumes, to customers specifications. Budbrooke Road, Warwick, Warwickshire CV34 5XH Tel: 01926 492889 www.batchflow.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. Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk
WATERJET CUTTING 8
September 2017
INDUSTRY NEWS | MACHINING | AUTOMOTIVE | SHOW PREVIEWS
JULY 2018
Design & Engineering Support Service
5
Get your company noticed with an Engineering Capacity classified profile advert FOR MANUFACTURERS ABOUT SUBCONTRACTORS
Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk
Precision Turned Turned P Parts arts
ity eering Capac TS | Engin COMPONEN MACHINED
Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts
CNC Milled Components
www.engineerin gcapacity.com
TURNED PARTS 8
APT Leicester, Leicester, the ar artt of precision precision..
TURNING (CNC) 8
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
SUBCONTRACT CNC TURNING 8
Kirkham Engineering Co Ltd
SPRING MAKING 8
REPETITION TURNED PARTS 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
“I can’t speak highly enough of URICA, It’s the way forward.� - Stuart Townley, Managing Director, Flying Intelligence
FORGET ABOUT BANKS
WE CAN FUND YOUR EXPORT ORDERS IN DAYS Get 100% cash upfront from your export customers, minus a fee, which completely covers FX, credit and non-payment risks. Non-debt funding without personal guarantee or security Remove FX, credit and non-payment risks Open account credit and credit terms up to 120 days We credit-insure invoices, so we will never ask for the money back Global coverage $u-7; bm lÂ†Ń´ŕŚž rŃ´; 1†uu;m1b;v Ĺ?bm1Ѵ†7bm] &" ġ &! -m7 Ĺ‘
CONTACT US
POWERED BY
W: www.urica.com T: 0207 193 7616 Ě bm=oŠ†ub1-ĺ1ol
u;; |o fobm o†u omѴbm; rѴ- oul Ň ƑƓ _o†uv |o v;| †r Ň o Ѵom] |;ul 1om|u-1|