Engineering Capacity July 2021 digital edition

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

July 2021

INDUSTRY NEWS | OIL & GAS | TURNED PARTS | SUBCON SHOW

AEROSPACE: Advanced ceramics for space

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FOR BUYERS OF CONTRACT MANUFACTURING SERVICES Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Commercial Director: Arfan Qureshi sales@engineeringcapacity.com Tel: 0207 241 4627 Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services.

For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company no. 10567217 ISSN 0306-0179 COMING UP IN OUR SEPTEMBER 2021 ISSUE Machined Components, Waterjet & Laser Cutting, Automotive, Subcon Show Issue,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

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JULY 2021

Editor’s View Football may not be coming home just yet, but the signs are that manufacturing industry is, as global automotive companies make major commitments and investments in the UK. Nissan, in partnership with the Chinese manufacturer Envision has announced it is to build a £1bn battery plant – a so-called ‘gigafactory’ – in Sunderland.

The company says the Nissan EV36Zero, a £1 billion flagship Electric Vehicle Hub, will create a ‘world-first EV manufacturing ecosystem’, which I think is a fancy way of saying that it will attract a cluster of closely-linked supply chain companies. It says that this will create 6,200 green jobs at Nissan and in the UK supply base.

Nissan's COO, Ashwani Gupta, said: “Nissan EV36Zero will transform the idea of what is possible for our industry and set a roadmap for the future for all.”

The future of the former Vauxhall plant in Ellesmere Port was itself secured with the announcement by Stellantis that it will be the automotive multinational’s first manufacturing site dedicated to battery electric LCV and passenger car models for Vauxhall, Opel, Peugeot and Citroën.

Production of the first all-electric vehicle will start next year.

Research by Protolabs shows that as the UK drives to become a world leader in electrification this will create a major reshoring opportunity.

The survey of senior executives from the European battery industry showed that 84% of UK companies are looking to bring parts of their supply chain closer to their manufacturing base over the next twelve months.

77% of UK respondents are also looking to outsource component production to specialist manufacturers, whilst 86% are planning on launching a new battery product or storage system during the next 12 months.

Inward investment and reshoring are only part of the good news story though. Research by Make UK and BDO shows that UK manufacturing is set to recover a significant amount of last year’s 10% decline in output in 2021 and will grow faster than the economy as a whole.

Andy Sandford, Editor

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Contents July 2021

31 COMPOSITES

News

Features

06 Welsh Apprentice award 06 Compact Orbital gears

14 Oil & Gas 06 3D print DNV certified Green use for offshore pipelines

recognised

08 New era for the EIA 06 Association teams up with MTA

19 Aerospace & Defence 06 Advanced ceramics for space Airbus site approval

09 Electronics manufacturer goes digital 06 Real time software for Jaltek 10 Manufacturing recovery accelerates 06 Good news from

22 Turned Parts 06 Thread rolling capabilities

16 OIL & GAS 25 Forming & Fabrication 06 Multi-million Hinkley

Make UK survey

Point C win

31 Composites 06 Underground escape route 32 Subcon Show preview

27 FORMING & FABRICATION 4

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Engineering Capacity | INDUSTRY NEWS Contract manufacturing specialist Prima Electronic Services is producing biometric sensor modules to support healthcare work in the developing world.

Cambridge-based start-up Simprints supplies fingerprint sensor modules to countries like Tanzania, Ethiopia and Bangladesh. These provide the means to accurately identify people in places where the forms of documentation which are commonplace in high-income economies are simply not available. In such situations, biometrics offer an effective alternative.

When plans were formulated by Simprints’ engineering team to produce the Vero 2, an upgraded version of its existing fingerprint sensing solution, the decision was made to engage with Prima as a contract manufacturing partner.

Prima and Simprints worked on rapidly finalising a fully functioning prototype. Together, the two companies established a highly efficient automated test process with a bespoke, configurable test rig being constructed for this purpose. Once samples using the initial design had been made and tested, Prima implemented the required iterative changes. As Simprints’ operation is relatively small, most of the project’s main activities had to be outsourced.

Prima therefore organised all the procurement, sourcing the complete bill of materials. In addition, Prima provided Simprints with useful guidance on potential supply chain issues, and helped to JULY 2021

Supporting global health

address these by suggesting modification to the design.

Powered by a Li-Ion battery, the Vero 2 is a compact portable unit.

With a 1700DPI resolution imaging array, this module conforms to ISO 19794-2, INCITS 378-2004, NIST SP 800-76 and FBI biometric standards. It provides a method for hospitals, clinics and pharmacies to maintain continuity of patient treatment. With limited Internet connectivity in these locations, the Vero 2 needs to be able to work offline. Therefore, transfer of acquired biometric data is done by interfacing with an Android-based smartphone via Bluetooth connectivity. CE and FCC approved, the module exhibits the high degrees of robustness necessary for field deployment.

It can deal with 90% relative humidity levels and operate in high ambient temperatures that can reach 45°C. An IP65 compliant enclosure prevents ingress of water and dust. In

addition, the design has undergone extensive drop testing to ensure long-term reliability.

“At least a billion people around the world don’t have any documentation to prove their identity, so access to biometric data is vital,” says Alexandra Grigore, Chief Product Officer at Simprints.

“Our next generation Vero solution had to incorporate various enhancements. The most important of these was the ability to transfer images in full, rather than approximations made on an alphanumeric template. This will give much greater scope for our data to interoperate with algorithms employed by other organisations. Further key aspects were improvements to the battery technology to extend operational lifespan, and use of RGB LEDs to enable better cultural acceptance.

The advice and assistance we received from Prima was invaluable in meeting all our objectives.”

8 primagroup.co.uk www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity Compact Orbital Gears, which has a workforce of 43 based in Rhayader, was named the Small Employer of the Year at the Apprenticeship Awards Cymru 2021 virtual ceremony.

The company designs, manufactures and develops bespoke gear solutions for aerospace, automotive and clean energy customers. This ability to offer bespoke solutions is key to the company’s success.

Tricia Evans, Compact Orbital Gears’ financial controller, said the company was delighted to be recognised for its commitment to providing quality apprenticeships.

“We ae thrilled to have won the award because it recognises the dedication of all those involved in the Apprenticeship Programme at the company,” she added.

“It’s a huge achievement for a small, Mid Wales company to be recognised as a top employer of apprentices within the community and testament to everybody involved in the programme, including Myrick Training and NPTC Group of Colleges.

“Apprentices are absolutely essential to our business. We have to grow our own skilled employees here in Mid Wales which supports the local community.”

Celebrating outstanding achievement in training and apprenticeships, the awards saw 35 finalists compete in 12 categories on June 17.

Highlight of the work-based learning calendar, the awards showcased businesses and individuals who have excelled on the Welsh Government’s 6

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Welsh apprentice award

Apprenticeship and Traineeship Programmes and gone the extra mile to achieve success during these unprecedented times.

Jointly organised by the Welsh Government and the National Training Federation for Wales (NTfW), the awards had Openreach, the UK’s digital network business and passionate supporter of apprenticeships, as the headline sponsor.

Established in the 1960s, Compact Orbital Gears is proud of its highly skilled workforce, family ethos and long history of recruiting apprentices from within Mid Wales.

The company currently has three apprentices and five other young employees working towards Further Education qualifications.

Myrick Training and NPTC Group of Colleges Newtown Campus deliver engineering and business and administration qualifications.

A focus on growing its own pool of skilled engineers is paying off for Compact Orbital Gears at a time when there is a UK shortage. Its Apprenticeship Programme

provides technical training, supported by in-house specialist instruction with experienced employees sharing their skills and knowledge with apprentices.

Providing opportunities for development ensures that staff turnover at Compact Orbital Gears is very low and the company’s long term aim is to introduce state-of the art, computer aided machinery which is ideally suited to apprentice development.

Believing that organic growth is key to the success of the business, the company also provides work placements for university graduates and budding engineers in local schools.

Congratulating Compact Orbital Gears, Minister for the Economy, Vaughan Gething, said: “Our award winners have excelled via the Welsh Government’s Apprenticeship and Traineeship programmes and gone the extra mile to achieve success during unprecedented and extremely challenging times.

8 compactorbitalgears.com/ JULY 2021

INDUSTRY NEWS | Engineering Capacity The Engineering Industries Association (EIA) promises new opportunities for members as it comes under the umbrella of the Manufacturing Technologies Association (MTA).

CEO of the MTA James Selka said; “This is an exciting opportunity for both associations and I am very pleased to be able to welcome the EIA into the MTA family.

“Now in its 80th year, the EIA has a proud history of working hard to represent and support its members.

On-boarding into the MTA family will help ensure the EIA’s longer-term sustainability and by bringing key elements of the engineering and manufacturing community closer together, also ensure member businesses receive enhanced support and enjoy a stronger, more influential voice into Government.”

The Engineering Industries Association has announced the death of its President, Sir Ronald Halstead CBE, MA, Hon. DSc, FRSC. He died on Friday 18th June 2021 at the age of 94.

Sir Ronald led the EIA for over 25 years and had a very distinguished career. He was appointed a Commander of the Order of the British Empire for services to the food industry in the Queen’s Birthday Honours in 1976 and knighted in the Queens’ Birthday Honours in 1985.

Sir Ronald joined the Beecham Group in 1954, and following appointments in the

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New era for EIA

Karen Finegold, previously Executive Director of the EIA has been appointed as the EIA’s Head of the Association.

She said: “I’m delighted that we have been able to join with the MTA as part of their family and I believe EIA members will experience a huge benefit with this development. The services offered by the EIA will be

enhanced by joining an allied association and the close links with the MTA have made this a natural progression.”

She continued: “As we announce this development today, I would like to pay tribute to the fine work of Sir Ronald Halstead in leading the EIA in supporting and representing its members for over 25 years.”

Sir Ronald has sadly since passed away – see obituary on this page.

The Engineering Industries Association is an organisation with over 80 years’ experience in promoting trade and representing the interests and aspirations of the UK engineering manufacturing sector, particularly SMEs. 8 mta.org.uk eia.co.uk

Sir Ronald Halstead UK and US, became Managing Director (Consumer Products) and then Chairman and Chief Executive in 1984–1985.

Sir Ronald joined the Board of British Steel in 1979 and was Deputy Chairman from 1986 to 1994.

At the time of his death his current appointments included: President of the Engineering Industries Association; Patron, President and Chairman for over 20 years of the Conservative

Foreign and Commonwealth Council; Council member of the European Policy Forum.

He also sat on the advisory panel of APPG for Trade & Investment Sir Ronald was a stalwart supporter of UK manufacturing and a strong advocate SME companies in the engineering industry sector. He will be greatly missed by all that knew him.

8 EIA.co.uk

JULY 2021

Engineering Capacity | INDUSTRY NEWS

Electronics manufacture goes digital

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FactoryLogix helps with this allowing us to offer enhanced PCBA and box-build capability for customers.”

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In turn we can support our customers better from NPI to Production.”

He added: “Our manufacturing philosophy is ‘right first time’.

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Electronics manufacturing company Jaltek has invested in a digital Manufacturing Execution System for real time materials tracking and traceability.

The Aegis Software Factory Logics MES platform will support all aspects of production at Jaltek's facility in Luton.

With Aegis’ v7 MES software already an integral part of Jaltek’s manufacturing technology, FactoryLogix was the natural progression for the business to move to Industry 4.0. The upgrade to Jaltek’s digital factory aligned with enterprise supply-chain tools adds to material management and traceability.

FactoryLogix provides real time tracking of materials throughout the factory, along with full material traceability.

Jaltek’s continued investment enhances agility and further supports demand for the highest quality of products and manufacturing resilience.

Steve Pittom, Managing Director, said: “Our business continues to grow, we are investing in our people, equipment and our digital factory, which further expands our manufacturing capacity.

FactoryLogix gives access to real-time data and insights we need to make smarter, faster business decisions. The technology also enables us to accurately and securely source the required materials.

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INDUSTRY NEWS | Engineering Capacity

Manufacturing recovery accelerates Industry surges as accelerating recovery takes hold – with UK orders leaping and exports bouncing back.

Britain’s manufacturers are accelerating as growth prospects become significantly more positive for the rest of the year, according to a major survey published by Make UK and business advisory firm BDO. Having seen a brutal 10% decline in output in 2020, the sector is now set to recover a significant amount of that loss in 2021 and outpace the growth of the economy overall. This growth is based on a surge in both domestic and overseas orders which is translating into strong hiring intentions.

Investment intentions have also turned positive for the first since the first quarter of 2020, suggesting that the introduction of the temporary super-deduction tax’ in the Budget is having some impact together with improved growth prospects.

However, Make UK stressed that the figures are reflecting a recovery from a very low base with balances last year reaching record lows worse than those seen during the financial crisis. Between 2019 and 2020 the manufacturing sector lost approximately £18bn in value which will take more than a short-term boost of pent-up demand to return the sector to its pre-pandemic size.

Yet, Make UK forecasts do suggest, assuming vaccine 10

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effectiveness is strong, that manufacturing output levels will return to pre-pandemic levels by the end of 2022. That is earlier than previous forecasts had suggested.

Fhaheen Khan, Senior Economist at Make UK, said: “Manufacturing growth is now firmly accelerating as restrictions have been eased and economies around the globe have started to open up. Looking forward there seems no reason to believe that this will not continue, assuming the shackles come off firmly in the second half of the year.

“However, given we are coming from a very low base, worse than during the financial crisis, we have to bear in mind that there was bound to be a rubber band impact this year. Furthermore, for some sectors such as Aerospace the limited prospects for international travel in the near future means they may struggle to return to normal trading for some time.”

Richard Austin, Head of Manufacturing at BDO, added: “Manufacturers have fought hard to recover from the brutal impact of the pandemic and have made great strides since the start of the year.

“With investment intentions having turned positive for the first time since the first quarter of 2020, it appears the government’s introduction of the temporary super-deduction tax has provided the incentive manufacturers needed to bring forward their investment plans.

“We know targeted tax policies can have a huge impact but, with the melting pot of challenges ahead around supply chains, availability of basic commodities and rising inflation, we need the government to look at longerterm strategies to allow the sector to build back better and confidently invest over the next 10-15 years.”

8 makeuk.org JULY 2021

Engineering Capacity | INDUSTRY NEWS

Spreading the word for 10 years

Advanced Engineering is back for 2021 Advanced Engineering will return to the NEC, Birmingham on November 3 and 4, 2021 for the first time in two years.

The event provides an opportunity for the whole UK manufacturing supply chain to source innovation and technology across multiple sectors, including aerospace, automotive, rail, marine, space & satellite, medical, renewables, and more. Exhibitor space is already 90% sold out.

At its last outing in 2019 the show attracted over 10,000 visitors.

Over the last twelve years, Advanced Engineering has gained the support of some of industry associations such as The Institution of Engineering and Technology (IET), Composites UK, JEC, ADS, The Society of Motor Manufacturers (SMMT), The Society for the Advancement of Material and Process Engineering (SAMPE), GTMA, The Aluminium JULY 2021

Federation (ALFED), The Surface Engineering Association (SEA), The Confederation of British Metalforming (CBM), Make UK, the Institution of Mechanical Engineers (IMECHE), GAMBICA, The UK Space Agency, The Department of International Trade, KTN and Innovate UK. Engineering Capacity is an official media partner of Advanced Engineering.

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Aro PR and Marketing is celebrating its tenth anniversary with new staff and more clients than ever before.

The team of journalists, marketing experts and science writers has created a niche role helping small and medium sized high-tech engineering, composites and scientific companies raise their profiles, increase sales, and generate leads within weeks.

Aro covers the full range of advanced engineering industries, including aerospace, automotive, oil and gas, med tech, power generation, motorsport, energy, marine, and science sectors.

The company has recently recruited two new staff members in response to increasing activity.

8 aroprandmarketing.co.uk

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FM10101

Manufacturers of High Quality Mill-Turned Parts

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Hear panel discussions and keynote addresses from key names in manufacturing including Make UK CEO Stephen Phipson, Made in Britain CEO John Pearce and many more!

Over 200 exhibitors will be at this year’s show.

This a must-attend event for UK manufacturers looking to meet and source new solutions from the very best of British manufacturing and world-class suppliers.

The Launchpad is back giving engineering startups a free platform to showcase their innovations and be in with the chance of winning a free stand at our 2022 show! Find out more on the show’s website (including how to enter).

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The long-term global demand for die cast parts, of all types and sizes, continues on an upward trend with more and more parts being re-designed for diecasting. The much talked about ‘circular’ economy and the move away from plastics to more recyclable, natural materials such as die cast alloys is also driving that demand.

This creates a problem (albeit a good problem!) for a die casting plants who find themselves now needing to recruit a new generation of technicians to increase and upskill their current workforce.

A growing list of companies have found a new way to solve these problem. They are hiring suitable new people, many of them young and enthusiastic but with no foundry experience as they have worked in completely different industries, then enrolling them in a new online training program in Die Casting Technology.

The programme enables new recruits to quickly learn all the important

technical aspects of the process without excessive pressure being put on existing staff. Combining this structured learning with the practical skills and experience they learn in the plant, enables them to become highly productive in a much shorter period of time. The course has several modules available making it suitable for machine operators and technicians, as well as tool designers and quality engineers. It will supplement and add to those with existing professional qualifications, in addition to being a valuable support for many new apprenticeship roles.

Right First Time Success By quickly increasing the knowledge of new staff and enabling them to participate fully in their new roles, not

only encourages them but also enables the company to benefit from new and valuable input throughout the production process. By being Right First Time and quicker to market, from initial design through to volume and series production, can save significant time and money for the company.

Completing this specialised course in die casting ensures that there are no gaps in their technical knowledge of employees and can help to avoid bad habits being learned, greatly improving their performance, and reducing the incidence of costly ‘out of spec’ castings being produced.

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OIL & GAS | Engineering Capacity MNB Precision has installed new mill-turning and machining capacity as part of its long-term growth strategy.

Established over 40 years ago MNB Precision is a family-owned business providing manufacturing and precision engineering services to a growing number of OEM and Tier One companies operating primarily, but not exclusively, in the oil and gas sector. Other sectors served

by MNB include power generation, rail, defence, nuclear, automotive etc.

The two new machines, supplied by Mills CNC, were a large-capacity Doosan SMX 3100 multi-tasking mill-turn machine and a Doosan DNM 6700 vertical machining centre.

The machines were installed at MNB’s 36,000sq. ft. facility in May 2021 and their arrival is part of a larger new technology investment package that, over the next seven months, will see MNB take ownership of four more advanced Doosan machines – two lathes, a vertical machining centre and a mill-turn machine.

Elliot Benton, Commercial Director, said: “We are committed to continuous improvement and, as such, are no strangers to making strategic and prudent investments in advanced manufacturing and machining technologies.

“The sectors where we operate are ultra-competitive and the investments we make are all intended to help us improve our quality, productivity and operational efficiencies.”

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Machines for long-term growth

The Doosan SMX 3100 is a highproductivity, multi-tasking millturn machine equipped with a 12” chuck and features a 30kW/4000rpm spindle, a B-axis milling spindle, a 40 tool magazine, a servo-driven tailstock, linear scales and the latest Fanuc 31iB5 control.

As part of the investment package the machine was supplied with a SLU-X4 steady rest, which in conjunction with the tailstock, enables the reliable and high-accuracy machining of long workpieces.

The SMX 3100 is the first Doosan mill-turn machine acquired by MNB but the company is no stranger to the technology itself.

Elliot Benton said: “Mill-turn technology enables us to machine complex, high-precision parts in one hit. The technology can make jobs, previously considered unprofitable, a more attractive proposition and helps

significantly reduce job set-up and part cycle times.

“The investment in the SMX 3100 has been made specifically to machine high-precision, low alloy steel, oil and gas plug-type components, required in large volumes, for a customer in Norway.

“We invested in a Doosan DNM 5700 vertical machining centre in 2017 and can vouch for the machine’s accuracy, speed and reliability. Our latest investment provides us with a larger travels and a bigger working table.

“The DNM 6700 increases the machining capacity of i8 Ltd - a new, precision engineering subsidiary we created and absorbed into MNB in 2019, following the purchase of the assets of Integr8 - a local engineering subcontractor. The machine was acquired to initially machine complex parts for a water treatment customer.”

8 mnbprecision.com JULY 2021

Engineering Capacity | OIL & GAS Hardide Coatings are helping an oil well construction specialist deliver significant reductions in CO2 emissions.

The Hardide-T coating was selected to provide a hardwearing surface within DeltaTek’s SeaCure ball drop subsea cementing system which delivers stabbed-in, inner string cementing for subsea wells.

When compared to traditional methods, the system significantly reduces cement wastage, delivering substantial CO2 emission reductions.

The ball drop system requires a bespoke seat to be positioned at the bottom of the inner string within the latch in adaptor.

This internal diameter restriction

Coatings reduce well emissions

requires a hard-wearing surface to ensure no erosion or corrosion damage occurs while pumping cement.

The internal profiles of the low alloy steel seats were coated

with Hardide-T, nanostructured tungsten/ tungsten carbide chemical vapour deposition (CVD) coating.

The tested seats showed no signs of erosion or corrosion and the Hardide-T coating is now specified on the SeaCure seat.

David Shand, chief operating officer at DeltaTek said: “The coating has already been deployed in harsh operating conditions where the system has successfully been pumping up to 3,000 barrels of cement at eight barrels per minute for up to ten hours with no erosion or corrosion noted during post-job inspection.”

8 Hardide.com

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OIL & GAS | Engineering Capacity Protolabs has achieved DNV certification for 3D printed Inconel parts for the oil and gas industry.

The digital manufacturer worked closely with DNV to achieve ‘Qualification of Manufacturer’ certification.

Protolabs is among the first manufacturers in the EMEA region to achieve the certification, and the first certified manufacturer using powder bed fusion technology in its additive process, which gives high resolution and geometrical accuracy.

Daniel Cohn, General Manager and 3DP Lead for Protolabs EMEA said: “Trust is, rightly, an important necessity for the Oil & Gas industry and also the wider energy sector. But now assurance can be given with the work we’ve conducted under the keen eye of DNV - the independent expert in risk management and assurance for the sector. Audits of our manufacturing facilities and processes prove that we comply with the general demands of the Oil & Gas industry so we can now move forward with even greater support for the sector as a whole.”

The certification applies to Protolabs’ direct metal laser sintering (DMLS) technology, specifically for the superalloy Inconel 718 – a high-strength, corrosion-resistant nickel chromium. Combining the exceptional properties of the material with Protolabs’ expertise in DMLS means the company can rapidly produce complex geometries for parts which are exposed to the harsh environments typical of the sector.

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3D print DNV certified

Achieving the certification is a process of technical evaluation of a number of probes within the machinery in combination with the material, individually and the system as a whole. The independent certification provides reliable proof that the probes meet the high qualification standard set out by DNV. Dr. Sastry Kandukuri, Senior Principal Materials Specialist in DNV’s Energy Systems Business Unit, said: “I am very happy our Global Additive Manufacturing (AM) Technology Centre of Excellence was able to support Protolabs to reach this milestone, as the first certified manufacturer using powder bed fusion technology in their additive process. We look forward to continuing our relationship with Protolabs that gives the assurance and confidence of AM products as their use grows in the Oil and Gas and Energy industries.”

Certification of Protolabs’ DMLS process and its Inconel 718 superalloy provides a new level of assurance, but the company offers a variety of materials and technologies that are relevant to the Oil & Gas, Maritime and Offshore industries, as well as the broader energy sector.

Cohn continues: “We offer a number of metals and plastics for additive manufacturing, each suited to the specific needs of a project. We naturally see possibilities in the sector for Inconel 718 but also, in a less extreme temperature range, for Stainless Steel 316L. We also see possibilities with functional polymers in applications where conditions are not so extreme. The DNV certification applies to our Inconel 718 but we see it as testament to our quality process and expect to see that trust extend to our whole offering.”

8 protolabs.co.uk JULY 2021

Engineering Capacity | OIL & GAS DNV has been awarded a contract to investigate whether offshore pipelines can be re-used to transport CO2 in carbon capture and storage projects in the Dutch North Sea. The independent assurance and risk management provider has been awarded the contract for the carbon capture and storage (CCS) pipeline materials study by Neptune Energy Netherlands to assess the fracture and suitability of offshore pipelines for re-use in CO2 transport.

The pipeline materials analysis is part of a wider feasibility study being conducted by Neptune Energy, in cooperation with its licence partners and carbon dioxide (CO2) emitters, to review plans for a large-scale offshore CCS project at the Neptune-operated 10-area in the Dutch North Sea. If the project is developed, it will be one of the largest CCS facilities in the Dutch North Sea and could meet more than 50% of the CO2 reduction being targeted by the Dutch industrial sector.

Prajeev Rasiah, Executive Vice President, Regional Director Energy Systems Northern Europe at DNV said: “We see CCS as one of the ways to accelerate the decarbonization of the energy sector. DNV is a pioneer in the field of CCS, with a track record dating back to the 1990s, and we are excited to be involved in a project of this size with Neptune Energy. With the potential to be one of the largest CCS facilities in the Dutch North Sea, at scale projects such as these will be significant for CCS technology JULY 2021

Green use for offshore pipelines

advancement and cost reduction.”

René van der Meer, Head of New Energy at Neptune Energy said: “Given the existing infrastructure that connects offshore with onshore, there is real potential for the Dutch North Sea to develop new energy faster, more efficient and in a safe way.

With support from partners, such as the experienced team of DNV, we are well placed to enable offshore CCS and offshore green hydrogen production using existing infrastructure. Using what is already there, will not only speed up new energy projects, but will cost significantly less and it doesn’t unnecessarily disturb the surroundings like the seabed.”

The first phase of the DNV study will identify the most advanced

approaches to ductile fracture assessments in dense phase CO2 pipeline systems and the applicability of such assessments to both welded and seamless subsea line pipe.

The most suitable approach, identified in phase one, will be used in phase two of the study to assess the likely suitability of the existing pipelines for dense phase CO2 transport at up to 120 bar.

The output of the study will inform the ongoing Neptune feasibility study to provide an increased level of confidence in the suitability, or otherwise, of the existing pipelines which would be set to inject between five and eight million tonnes of CO2 annually into the depleted gas fields.

8 dnv.com www.engineeringcapacity.com

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OIL & GAS | Engineering Capacity Northumberland-based Arcot Engineering has upgraded its capabilities by installing new 5-axis machining technology.

The company has invested in a Yamazaki Mazak CV5-500 5-axis machining centre, a machine the supplier says is ideally suited for engineering companies looking to make their first move into 5-axis work.

Arcot manufactures parts for a variety of industries and is particularly strong in oil and gas, torque tension tools and hydraulics.

Kevin Graham, Machine Shop Manager at Arcot Engineering, says that the investment will help the company break into new sectors requiring more complex machining work and also help to make Arcot much more productive.

“The company has a long history of working with vertical machining centres, but we’ve had ambitions to move into more complex and lucrative 5-axis work for some time,” says Kevin.

He continues: “The CV5-500 is priced at a very competitive level for subcontract manufacturers like ourselves but still has the usual Mazak build quality. The machine will help take on more complex work and get more jobs through the machine shop.”

Arcot Engineering was established in 1986 by the Graham and Mason families, who continue to be involved in the business that now employs 13 people at its Cramlington site in Northumberland.

“Our new 5-axis capabilities mean we can perform multiple tasks on one machine, which in 18

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Upgraded to 5-axis machining

turn reduces setup times,” says Steve Mason, Machine Shop Floor Manager at Arcot Engineering.

“We’re now doing three, four or five phases of a job in one setup and also reducing cycle-times by a minimum of 30 per cent thanks to the 12,000 rpm main spindle. This machine is going to make us much more competitive.”

The move into more complex 5axis work was aided by Mazak, one of the world’s leading manufacturers of machine tools, who provided a full week of off-site training. “The CV5-500 is programmed using Mazak’s own SmoothX control. I’ve never run a Mazak before but I’ve found the programming to be really easy and very user-friendly,” says Steve.

Alan Mucklow, UK Managing Director Sales and Service at Mazak commented: “One of the main reasons for developing the CV5-500 in the UK was the need to help subcontract manufacturers make the move into 5-axis work at an affordable price, whilst retaining the quality of machine that people expect from Mazak. It is a more complex type of machining but Arcot Engineering are showing what is possible when a company has the ambition to try and the will to make it work. I am sure that this investment will help Arcot break into new markets and improve the company’s machine shop productivity.”

8 Arcot Engineering 01670 735737 JULY 2021

Engineering Capacity | AEROSPACE & DEFENCE An ExoMars Rover will feature at Advanced Engineering UK as part of the show’s new Space & Satellite Engineering zone.

Over the two days of the UK’s leading engineering and manufacturing event, at the NEC, Birmingham on November 3 and 4, 2021, an original prototype of the ExoMars rover will be on display.

The Airbus Defence and Space UK prototype, commonly known as Bruno, is semi-autonomous and equipped with all the same technology as the final rover, including the sensors, actuators and cameras that allow the rover to see in 3D while navigating the red planet. The final flight rover will be equipped with a drill that can bore two metres deep, and metal wheels that have the same flexibility as rubber, without risking contamination to any life that it finds.

The ExoMars rover will be the first rover used to directly search for life on Mars as part of a joint mission between the European Space Agency (ESA) and Russia.

The rover is just one example of how the UK’s engineering industry is leading the way in space and satellite innovation.

“Having Bruno at Advanced Engineering UK will be an extremely important moment for our engineering and manufacturing industry,” explained Aleiya Londsale, Head of Marketing at Easyfairs, organiser of Advanced Engineering. “This year’s Advanced Engineering UK gives our close-knit industry the chance to reunite and do business again JULY 2021

Mars Rover lands at Advanced Engineering UK

and I can’t think of a better place to showcase Bruno’s technology and features. With exhibitor space almost full, and so many exciting speakers and features confirmed, people really can’t afford to miss this year’s show.”

This year, Advanced Engineering UK introduces a new show zone dedicated entirely to space and satellite innovation. The zone, which will be Bruno’s landing site for the show, will be part of Advanced Engineering UK’s

existing Aero Engineering floor and will be supported by two of the show’s longstanding partners, the UK Space Agency and ADS Group.

It will bring together the UK’s space and satellite manufacturers, research and development partners and supply chain businesses spanning R&D, design, test, production, manufacturing and advanced materials, showcasing the UK’s incredible achievements in this sector.

“ADS has always supported Advanced Engineering UK as it is one of the leading manufacturing and engineering shows covering multiple sectors,” explained Bhavin Vyas, Head of Space at ADS. “The UK’s involvement in space and satellite technology is constantly growing, so the dedicated area on the show floor this year provides a brilliant opportunity for this sector to showcase its innovative space capabilities.

8 advancedengineeringuk.com

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AEROSPACE & DEFENCE | Engineering Capacity

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Advanced ceramics for space

Copyright Airbus

CeramTec Group has produced ceramic sample containers for an Electro Magnetic Levitator used for experiments on the International Space Station.

In the course of this and previous joint product developments, CeramTec, together with Airbus Defence & Space and other partners in a project consortium, developed sample containers for experiments as complex components and manufactured them at the Plochingen site in Germany.

The latest pot sample holders and cage sample holders, which are made of silicon nitride, follow a previous lot of containers that were first installed in the International Space Station (ISS) back in 2017.

They are used in the so-called Electro Magnetic Levitator (EML), a multi-purpose research facility for natural science experiments on board the ISS. In the EML, the sample containers are inserted into a coil in which metal alloy samples are fixed all around in a contact-free manner by electromagnetic fields while suspended in zero gravity.

For analysis, the samples are melted, cooled in the liquid state and then solidified again.

These precision measurements of certain thermophysical properties of metals, alloys and semiconductors, which are not possible on Earth, make it possible to analyse the early phases of the formation of material structures and to expand our understanding of transition processes, atomic structures and material properties.

The objective here is to improve

production and casting processes on Earth thanks to the material properties measured in space, in order to achieve an increase in quality while reducing the cost of high-tech castings (e.g., engine blocks).

This will allow manufacturing methods to be refined and materials and products to be improved and redeveloped. This basic research is being carried out by a collaboration between Airbus Defence & Space and the European Space Agency among others.

The ceramic material silicon nitride (Si3N4) is particularly suitable for this purpose due to its zero electrical conductivity, which prevents external influences on the measurements, as well as the

required high heat resistance as the measurement cycles take place in temperature ranges between 500 and 2100°C. The company says that these properties, in combination with the absolute reliability and consistently high product quality it can provide, have once again convinced the project consortium to use CeramTec advanced ceramics for what is perhaps one of the most demanding applications in the universe.

The sample containers of this latest generation started their journey into space with the SpaceX-22 in June 2021 and will significantly support further research activities there.

8 ceramtec-group.com JULY 2021

Engineering Capacity | AEROSPACE & DEFENCE Advanced surface coating technology specialist Hardide Coatings Ltd has received full approval from Airbus to coat and process its components at the company’s new and larger Longlands Road facility in Bicester, UK. This approval follows the relocation of the Company and its equipment from Wedgwood Road, Bicester to newly built premises at Longlands Road, Bicester last year. The final coating reactor

Airbus site approval that remained in the Wedgwood Road site specifically to coat Airbus parts has now been relocated to the Longlands Road facility. The old Wedgwood Road site is now in the process of being decommissioned before the lease terminates in October 2021.

Commenting on the approval, Philip Kirkham, CEO of Hardide plc, said: “This approval is very positive news and is the result of

extensive testing and verification

by Airbus of all the processes at the newly built Longlands Road facility. The Airbus approval is testament to our coatings’ capabilities and means that we can now close the door on our old premises and concentrate all our aerospace processing at our modern and much larger, custom-fitted new site.”

8 hardide.com

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JULY 2021

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TURNED PARTS | Engineering Capacity Rawtenstall-based RPS Precision Engineering has invested in a new Doosan multi-tasking twin-turret, twin-spindle turning centre to enhance productivity and performance.

The machine, a Puma TT1800SY, was supplied by Mills CNC along with a servo-driven Hydrafeed MSV 110 bar feeder as well as a number of differentsized collet chucks and adaptors.

The package allowed the new machine to be ready for full production as soon as its installation, commissioning and training had been completed.

It is now being used to machine a range of complex, highprecision parts, in medium batch sizes, for a number of customers.

RPS Precision Engineering (previously Rochdale Production Services) was established in 1988 by Michael Sirrell and his father Bryan.

The independent, family-owned business specialises in machining complex, high-precision parts from prototypes and one offs through to small, medium and large batch production.

To add value and strengthen its position within customers’ supply chains, RPS has augmented its precision machining services with TIG welding, fabrication and assembly.

RPS also provides a range of ‘Design for Manufacturing’ services that includes consultancy, 3D modelling and rapid prototyping.

Michael Sirrell said: “The TT1800SY is a productivity powerhouse of a machine. It 22

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Multi-tasking for productivity

might appear small from the outside - but its twin-spindle, twin-turret configuration is helping us machine highprecision components quickly and accurately…in one hit.

“Furthermore, by integrating the machine with a servo-driven bar feeder, we have created a ‘de facto’ automated manufacturing cell that is both efficient and reliable, and that we are able to run, unattended, during the day.

“In the near future, when we fully embrace lights-out operations and run the machine unattended overnight and over the weekends, the productivity benefits will be even more impressive.”

Mr Sirrell said: “A significant percentage of the parts we turn are small and have short cycle times. They are made from materials that include hardened and mild steel, aluminium, stainless, copper, bronze, brass and plastics. And they are machined to tight geometric tolerances – generally 0.002mm – and high surface

finishes, in relatively high volumes.

“The profile and characteristics of parts being machined led us, at the beginning of the year, to consider investing in our first sliding head machine. And, because Mills CNC supply Doosan Swiss-Turn machines, we naturally approached them for advice.”

An audit into what RPS wanted to achieve from the new investment was undertaken and completed. The results caused a change of direction.

“On the advice of Mills CNC engineers we changed our investment plans and opted, instead, for a multi-tasking (fixed head) turning centre as opposed to going down the sliding head route.

“We believed that the multitasking turning centre integrated with a bar feeder would provide us with more flexibility and, because we were already familiar with fixed head lathes with Y-axes, driven tools, twin spindles etc., we could hit the ground running quickly,” concluded Mr Sirrell.

8 rps-engineering.co.uk JULY 2021

Engineering Capacity | TURNED PARTS Thread-rolling specialist Dobson & Beaumont has invested in a new twin-spindle turning centre that will enhance its capabilities when processing challenging materials.

Thread rolling is a process that cold forms threads to work harden the thread, strengthen the grain flow and improve overall thread strength by more than 25% when compared to typical thread cutting operations.

Before thread rolling, Dobson & Beaumont has to machine some of the most challenging materials known to the industry – this is one of the many reasons the company has just purchased a Nakamura-Tome AS200 twin-spindle turning centre from the Engineering Technology Group.

Managing Director Richard Guest said: “We machine a lot of parts in batches that can vary from 4 or 5-off through to 50, 100 and beyond, and our turning centres were all single spindle machines.

This meant that most of our turned parts required secondary operations. We knew we needed a twin-spindle turning centre to reduce secondary operations.”

The company increasingly processes challenging materials such as titanium, Inconel, stainless steel, super duplex and Duraheat to tolerances in the region of +/-0.0125mm, with the thread rolled parts often being critical components in their respective assemblies.

The Nakamura-Tome from ETG was supplied as a long-bed version for our 400-500mm parts with a JULY 2021

Thread rolling capabilities

bar feed, part catcher and the twin spindle for one-hit machining.

Installed at the Lancashire company in April, the new Nakamura-Tome AS200 has reduced the cycle time for a number of parts, including connecting rods, from 150 seconds to just under a minute on parts that used to require a secondary turning cycle to complete the parts. The company has also reduced the cycle time of doubleended bolts from 1 minute 30 seconds to less than 45 seconds.

The most dramatic saving has arrived on hexagonal head bolts where the cycle time has

fallen from 8 minutes to 1minute 30 seconds.

Richard Guest said: “We produce a lot of bolts where we have to machine the hexagonal heads, and this is a perfect example of the savings that we can achieve with the NakamuraTome machine. The combination of twin-spindle machining, powerful and robust milling capability and automated production through the bar feed and part catcher has made a significant difference on this component – and it will do on future parts too.”

8 dobsonandbeaumont.co.uk

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TURNED PARTS | Engineering Capacity Witon Engineering’s new 25mm bar capacity Citizen sliding head turning centre is taking work off bigger machines and cutting cycle times by 20%.

At Witon’s subcontract machining facility in Barnstaple, turn-milling of relatively complex components from 16 mm diameter bar used to be carried out on 32 mm capacity slidinghead lathes, rather than smaller capacity models, to take advantage of the extra CNC axes and tools available on the larger machines.

This type of work has now been transferred to a nimbler, 25 mm bar capacity Citizen Cincom D25VIIILFV sliding-head turning centre, installed in January 2021.

The first two jobs have shown significant cycle time reductions of 20% or more.

Since the mid-90s, the contract machinist has bought 17 bar-fed lathes from Citizen UK, of which one was a 42 mm bar capacity Miyano fixed-head machine, the others being various Cincom sliding-head models for turning up to 32 mm stock. There are currently 11 Citizen machines on the shop floor, earlier models having been exchanged over the years. Lathes from this supplier therefore account for approaching half of the 25 bar autos in the factory, comprising 13 sliding-head models, eight single-spindle fixedhead turning centres and four CNC multi-spindle automatics.

The first component to be transferred to the D25 was an EN1A steel shaft for a lawnmower.

The part was formerly produced on an L32-VII, of which there are 24

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New slider cuts cycle times

three on site. As 180,000 have to be produced to fulfil the current contract, the 20% cycle time reduction leads to a significant production cost saving.

The second component benefiting from being machined on the D25 is a 304 stainless steel fuel inlet fitting for an automotive customer. It used to be turn-milled on one of a pair of

Cincom M32s in a cycle time of 72 seconds. This has been cut to 53 seconds, representing a 26% saving. With 55,000-off needed, the economy gained is significant.

Ian Clapp, workshop manager at the Barnstaple factory explained, "We operate a couple of 20 mm capacity, dual-platen sliders of another make and knew this configuration offered quick cycle times.

"However, we saw what our longstanding sliding-head lathe supplier Citizen was offering in the D25, a machine with larger bar capacity plus the ability to carry out work up to 32 mm diameter without the guide bush for more economical material usage when producing shorter components.

"The model also has the benefit of a programmable B-axis, so we decided to go for this option."

8 witoneng.co.uk JULY 2021

Engineering Capacity | FORMING & FABRICATION Sheet metal specialist BIZ Engineering, which can trace its origins back to 1816, has invested in the latest laser cutting technology.

In order to meet growing demand it has replaced its previous CO2-based technology with a 3kW TruLaser 1030 fibre laser cutter.

The machine is designed as an entry-level system, while providing high levels of capability, productivity and quality BIZ Engineering is remarkable in that its history is traceable back to 1816, when it began trading initially as a builders’ merchant from the Commercial Road in Shoreditch, East London.

“We are currently growing yearon-year, which is testament to our investment programme, ongoing diversification and commitment to customers – existing and new,” explains Paul Jones, who joined the company in 2017 as managing director following over 30 years of experience in precision sheet metal and other engineering sectors.

Whilst BIZ Engineering offers a range of subcontract manufacturing services, including CNC punching, routing, bending, welding and shot blasting, the company’s latest investment drive has centred on laser cutting. Two new fibre-laser machines have arrived in the past 18 months, the most recent of which the Trumpf TruLaser 1030 fibre.

“When I arrived, we had two small Trumpf CO2 lasers which were 18 and 20 years old respectively and, although still operational, we took the decision to replace them with fibre-based JULY 2021

Laser does the BIZ

machines,” explains Mr Jones.

“In comparison with our CO2 machines we knew fibre would be around five times faster, provide more capability and cut running costs by two-thirds.”

“We installed the TruLaser 1030 fibre in November 2020, and since then it has become a great asset to our business,” states Mr Jones.

On a daily basis the company is using its recent arrival to process aluminium up to 12mm thick and stainless steel up to 15mm, as

well as many different gauges of mild steel.

The 3kW TruDisk laser supplied with BIZ Engineering’s TruLaser 1030 fibre allows users to cut all common type of sheet metal, quickly and to a high standard.

The TruLaser 1030 at BIZ Engineering produces parts in batch sizes from 1-off to 300-off, 12 hours a day, with plans afoot to extend the current single-shift working pattern.

8 bizengineering.com

From design, sampling and technical support to manufacture, Simpson Springs & Pressings Ltd provide the complete service.

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FORMING & FABRICATION | Engineering Capacity Kloeckner Metals UK has been awarded a multi-million pound contract by BYLOR to produce embedment sleeves for the Hinkley Point C power station.

Part of the global Klöckner & Co Group, Kloeckner Metals UK is a leading multi-metals processing supplier in the UK. It has recently been certified with Fit 4 Nuclear status (F4N) which is a testament to its commitment to continuously improve operational standards in line with nuclear requirements.

This newly awarded contract will see Kloeckner Metals UK supply processed and coated embedment sleeves to Tier 1 Contractor BYLOR – a Laing O’Rourke and Bouygues TP joint venture. Two local South West businesses will assist Kloeckner Metals UK with the coating of the embedment sleeves.

Abingdon-based pressurevessel fabrication specialist LTi Metaltech has acquired Bridgend-based Vessco Engineering Ltd. The former owner of Vessco Engineering, Julian VanceDaniel, is remaining in the combined group in a senior business development role.

The deal, worth £2.6m, will bolster the company’s capabilities and facilitate access into a number of key sectors, including nuclear energy, oil and gas, utilities and food processing, having itself completed several prestigious projects including specialist fabrication assignments with Tokamak

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Multi-million Hinkley Point C win

Peter Whiting, CEO of Kloeckner Metals UK said: “BYLOR’s decision to select Kloeckner as their supplier is a huge endorsement for our capabilities and management expertise. We are extremely

excited to be part of such an important national project.”

Kloeckner Metals UK thanked Somerset Chamber of Commerce and SWMAS for their contribution on the project.

8 kloecknermetalsuk.com

£2.6m fabrication acquisition Energy & Reaction Engines.

Founded in 2006, Vessco Engineering Ltd is a Tier 2 supplier to the turbine hall at Hinkley Point C, supplying large pressure vessels for GE Power Systems.

German-owned LTi Metaltech is a major supplier to Siemens in the manufacture of pressure vessel components for its market leading MRI Scanners. Under the leadership and direction of its UK managing director, Edgar Rayner, has broadened the scope and market reach of the £23m business including the hydrogen technology and aerospace sectors.

The acquisition will enable LTi

to accelerate its expansion programme as it diversifies its portfolio whilst underpinning existing capabilities in medical technology.

Commenting on the acquisition, Edgar Rayner, said: “Vessco Engineering has built up a great reputation and we’ve had it on our radar for some time.

We are obviously delighted to be able to bring it into the LTi family where our combined resources and capabilities will help to broaden and strengthen our offering in a range of important industry sectors.”

8 lti-metaltech.com

JULY 2021

Engineering Capacity | FORMING & FABRICATION Stainless Metalcraft (Metalcraft) is to enter into the second phase of a contract to provide high integrity stainless steel storage boxes for Sellafield.

The 3M3 (three metre cubed) box contract is now worth up to £70m and represents an approximately £20m uplift to the original contract awarded in 2015. The agreement to exercise the option marks Metalcraft’s successful transition to the second phase of the 3M3 box work with Sellafield.

The boxes will be used to store intermediate level waste (ILW) retrieved from silos at legacy locations in Cumbria.

As part of this transition, Metalcraft will be producing circa 1,000 boxes over phase two of the programme, which is currently expected to take 6 years Austen Adams, managing director of Avingtrans’ Process Solutions and Rotating Equipment division, which includes Stainless Metalcraft, said: “Moving on to phase two of the contract is just reward for the hard work and expertise the team has put into developing the 3M3 programme over the last five years.

“Having proven the technology and manufacturing processes involved, we are now in a position to ramp up production and begin the transition towards volume production, which will enable us to support Sellafield in this essential decommissioning work over the coming years.

“Metalcraft and Avingtrans are proud to be working alongside a number of suppliers and the Nuclear Decommissioning JULY 2021

Phase two Sellafield box contract Authority on the project of decommissioning the Sellafield nuclear site, in a way which is both safe and environmentally friendly.”

Susan Lussem, Supply Chain Director, Sellafield Ltd, said: “Retrieval of wastes from Sellafield’s legacy ponds and silos is nationally important work, and we’re dedicated to ensuring this is done as safely, quickly and costeffectively as possible.”

“Moving the waste into modern storage will mean a huge reduction in the UK’s nuclear hazard, but before we can remove the waste, we have to be confident we have somewhere safe to put it and that we have a reliable supply of containers for decades to come.”

“The development, innovation and investment that Sellafield Ltd and Metalcraft have delivered on this project to date gives us this confidence.”

Steve McQuillan, CEO of

Avingtrans PLC, said: “Winning the initial contract back in 2015 was a landmark moment for Metalcraft, allowing us to invest significantly in both infrastructure and personnel to create a world-class centre for the manufacture of ILW containers, and boosting our apprenticeship programme. This training programme can now be securely extended for the long term, providing skilled engineering apprentice roles in a relatively deprived area of the UK.” “Securing the next phase of works wholly justifies that investment and vindicates the Board’s decision to refocus what was our Energy and Medical Division on new markets.

Sellafield’s trust in Metalcraft to deliver this next phase of the project endorses the quality of our management processes in this highly sensitive technology.”

8 metalcraft.co.uk www.engineeringcapacity.com

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FORMING & FABRICATION | Engineering Capacity In the past two years, MJH Fabrications has invested in two automated 9kW fibre laser cutting systems and two press brakes.

The equipment was supplied by Amada UK and comprises two ENSIS-3015AJ 9kW fibre laser cutters with MPF load/unload automation systems and two HFE3i series press brakes.

This significant capital investment is helping the company to better serve its UKwide customer base in sectors that include shop-fitting, agriculture, yellow goods and factory automation.

Mike Hemming formed MJH Fabrications in 1990 with little more than a MIG welding set but by the time it was incorporated as a limited company in 2002 it was supplying finished fabrication and components to customers’ requirements.

Driven by its success, MJH Fabrications has grown to become a progressive subcontract fabrication specialist with £2½ million annual turnover, 20,000 ft2 premises and 18 employees. And, as the company’s recent investment programme indicates, Mr Hemming has no plans on stopping there.

“Our investments with Amada reflect my determination to continue increasing capacity and moving forward,” he states. “The most recent ENSIS arrived in spring 2020, just when the COVID19 pandemic forced the UK into its first national lockdown. It was a worrying time but we opted to press ahead. As things turned out, it was the best decision as our 28

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Fabrication system investments

workload just seemed to get busier and busier from there on.”

The company’s entry into laser cutting arrived a number of years ago when it acquired a secondhand machine. A number of other preowned laser cutters followed before MJH Fabrications purchased its first new model: an Amada F1 4kW CO2 laser with automation tower.

“With the industry transitioning from CO2 to fibre laser technology, it made sense to think about new investment,” explains Mr Hemming.

“To be competitive we knew that adopting fibre technology was the only option and, sure enough, we immediately noticed a difference in speed capability with the new ENSIS – it’s unbelievably fast.”

In December 2019, the company decided to boost its bending capacity and help keep pace with

the new laser cutter. As a result, MJH added HFE3i-1003 and HFE3i- 5020 press brakes to its existing HD-1003 and HFE-1704 machines. The company also leverages the benefits of AMADA software for both its press brakes and laser cutters.

“We quickly reached our threshold with the first ENSIS and found ourselves running flat-out day and night,” explains Mr Hemming. “We were constantly under pressure, so it was time to take action and acquire a second ENSIS machine an identical 3015AJ 9kW model.”

“We work closely with customers to make sure their components and our manufacturing operations are optimised in line with demand.

“Essentially, we want to offer the most cost-effective way of achieving customer requirements.

Having the capabilities of the Amada ENSIS laser cutters and HFE3i press brakes makes this process all that bit easier.”

8 mjhfabrications.co.uk JULY 2021

Engineering Capacity | FORMING & FABRICATION There are multiple benefits from using subcontract rotary friction welding (RFW), including the ability to draw on proven expertise and access industry-leading friction welding machinery without the need for capital investment. A multitude of components can be manufactured across numerous sectors in a range of geometries and material combinations. The subcontractor can advise on materials, geometry, metallurgy and pre and post weld processing.

In the case of bi-metallic, copper-aluminium connectors, there is simply no other viable method of joining these two materials directly thanks to their very different thermal expansion coefficients. Low-cost aluminium is joined directly to high cost copper. Other than the obvious benefit of cost reduction by reducing the use of expensive high conductivity copper, direct costs, waste and the increased threat of theft are also reduced. Aluminium does not impede conductivity and is useful for ease of crimping to electrical cabling. The electrical connector market for power distribution and rail is a significant market for this process.

RFW is a standard bonding method in the automotive sector for producing axles, CV joints, turbo-chargers, airbag canisters, while the aerospace industry uses RFW to manufacture landing gear shafts, steering shafts, ejector seat components and other high integrity parts. The construction industry uses friction welding for piston rods and hydraulic cylinders, JULY 2021

Subcontract rotary friction welding

where large diameter high quality steel chromed rods are joined to eyes, yolks and pinions for heavy duty industrial service.

RFW also shows its strength in oil, gas and mining applications where joint integrity in the harshest conditions is paramount, such as drill pipes and rods for deep hole water boring, directional drilling and rock drilling.

The cost of failure in these components can literally cost the operators millions of pounds in lost revenues. The integrity of the friction welded bond is so superior to other joining processes that most OEMs across these industries own and operate their own rotary friction welding equipment to produce their safety critical components in-house.

Cryogenic applications also benefit from the processes’ ability to join dissimilar materials. For instance, stainless steel to copper and interlayered transition joints

consisting of stainless steel welded to titanium with an aluminium alloy interlayer.

Friction welding has also proved highly successful for welding tools, such as drill bits for example.

Stronger than conventional welding, friction welded drill tools have an enhanced join integrity, as the weld is as strong as the parent material.

Whatever the sector, or application in which the component shall be utilised, rotary friction welded products have proven to have an enhanced structural integrity.

The question that engineers and manufacturers ask when considering their production joining and manufacturing processes is can we do this better, cheaper and more efficiently?

The answer is ‘yes’ and the solution lies in subcontract friction welding.

8 kuka.com www.engineeringcapacity.com

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COMPOSITES | Engineering Capacity

Efficiency beats material problems Resource-efficient production has helped lightweight honeycomb core manufacturer ThermHex keep raw material usage to a minimum and overcome supply problems.

Since the beginning of 2021 there has been a shortage in raw plastic materials. This has resulted in an exponential increase in their price. The cost of polymer resins

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used to make plastic rose by a quarter between December 2020 and May 2021, the highest price in the last six years.

More than 90% of plastic converters within Europe were directly affected by the supply crisis.

This has resulted in many companies having no choice but to take on little to no new business and only able to honour agreements with their existing customers.

Recyclates specifically have seen a huge decrease in availability at sufficient quantities and a consistent level of quality. This has led to increasing in price and decreasing in availability for both virgin and recycled polymers.

Fortunately for ThermHex its highly automated and patented production process of polypropylene honeycomb cores and Organosandwich have barely been impacted. Its production process for honeycomb cores is continuous and saves resources by using much less raw material compared to monolithic materials, like plywood.

Dr Jochen Pflug, CEO of ThermHex said “The shortage of raw materials over the past few months has been difficult for the entire industry. Using of the sandwich construction principle makes especially sense in times of material shortage. Our ThermHex honeycomb cores help customers, which require only thin skins to make stiff and thick panels and can thus contribute to solve the recent shortages of raw materials”.

8 thermhex.com econcore.com JULY 2021

Engineering Capacity | COMPOSITES

Diamorph Group Holdings Limited is to acquire defence sector composites specialist Permali Gloucester Limited.

This follows the acquisition in March of Birmingham-based Tufnol Composites Ltd, which manufactures composites for the aerospace industry.

Diamorph Chief Executive, Gordon MacLeman said:

JULY 2021

Underground escape routes

Photo credit: Siemens Mobility

TRB Lightweight Structures, based in Huntingdon, is working with Siemens Mobility on the manufacture and supply of the emergency evacuation systems for new London Underground Trains.

The ‘detrainment’ system, which is deployed if passengers need to leave the train in an emergency, will include the M Door, bridge and stairs for 94 nine-car ‘Inspiro’ train sets for the London Underground Piccadilly Line.

These state-of-the-art trains will replace outdated rolling stock that first entered service in the 1970s, and will be fully assembled in the UK. TRB has been selected to design and manufacture a unique emergency detrainment system to meet the stringent requirements and specifications of the new fleet, including GMRT 2100 fire and impact tests.

The contract – with potential for follow-on orders – was awarded to TRB thanks to its position as a global leader in the manufacture and design of high quality rail interiors, door leaves and detrainment systems. Almost a fifth of TRB’s 130+ strong

workforce will be occupied in delivering 188 complete systems (two per train) for this project, with the first train sets due for completion in February 2022.

Toni Shepherd, Director of Sales at TRB, commented: “We have over 40 years of experience in the design and manufacture of high quality components for the rail industry, and have manufactured the majority of the UK’s detrainment systems

currently employed on UK rolling stock. Our production methods include comprehensive in-house testing, from load to simulated evacuation tests. We are delighted to have been chosen to be involved in this exciting new partnership with Siemens Mobility, which further highlights our expertise in the sector, and are excited for the opportunities that come with it.”

8 https://trbls.com/

Composites acquisition trail “These acquisitions allow Diamorph to broaden its composites competency and enter new markets.

Permali has a long history of developing bespoke composite solutions for critical defence applications since the 1930s, whilst Tufnol has been

manufacturing high performance composites since the 1920s and has a highly regarded brand and reputation for delivering market leading wear performance in the Aerospace sector.”

8 permali.co.uk diamorph.com

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SUBCON PREVIEW | Engineering Capacity Registration for Subcon 2021 is open, marking a return to live business events and reinforcing the importance to UK manufacturers of being able to meet face-to-face with customers, suppliers and colleagues.

The event will take place at the NEC, Birmingham from 14 to 16 September and is currently 80% sold out.

Subcontractor who are confirmed to be exhibiting include turned parts and machining companies such as Axis Precision, Dawson Precision Components and TruTurn and CNC Leicester, one-stop-shops like PRV, laser and fabrication companies including FC Laser, as well as companies offering everything from contract electronics manufacturing, additive manufacturing and castings to plastic components.

Engineering Capacity is an official media partner of Subcon 2021 and will be previewing the show again in its September issue. If you are exhibiting and wish to contribute editorial please email editor@engineeringcapacity.com.

If you are interested in promoting your presence at the show please contact sales@engineeeringcapacity.com Headline sponsors for the show are IAMP and SCS Concept Group.

Visitors also gain free-of-charge access to The Engineer Expo and new for 2021 - Manufacturing Management Show.

The organisers say that Subcon is the UK’s leading subcontract manufacturing supply chain show 32

www.engineeringcapacity.com

Register now for Subcon

and comes at a pivotal time as businesses of all sizes recover from the impacts of COVID-19 and adjust to operating outside the EU. Gordon Kirk, Subcon event director, said: “We are delighted to be bringing Subcon back this September and provide a long overdue opportunity for UK manufacturing to meet face to face once again.

“The past 18-months has been unprecedented and Subcon will shine a light on the untold challenges and opportunities this industry is facing, including the supply chain disruption caused by the pandemic and how that has served to highlight the true value

of a reliable, local supply chain offering short lead time and better quality.

“This year the show presents a timely and unique platform for any UK manufacturers looking to source or develop a robust and localised network of UK supply chain partners. We are also excited to champion innovators and start-ups and celebrate the engineering heroes whose ingenuity makes such a valuable contribution to the UK, particularly throughout the pandemic.”

The event will take place in accordance with Government guidance on COVID-19, ensuring a safe and comfortable environment.

8 Subconshow.co.uk JULY 2021

Engineering Capacity | SUBCON PREVIEW The Launchpad and Launchpad Awards are returning for a second year to Subcon 2021, the UK’s premier subcontract manufacturing supply chain show taking place 14-16 September at Birmingham’s NEC. The Launchpad and Launchpad Awards are dedicated to providing start-ups and entrepreneurs throughout the sector with a valuable platform for sharing innovation and earning muchneeded recognition and brand awareness among thousands of engineering and manufacturing professionals.

To qualify, businesses must be under three years old with a product or service that relates to engineering and/or manufacturing. Up to eight businesses will get a free stand in the Launchpad area at the show, offered expert advice and marketing support and automatically entered into the 2021 Launchpad Awards.

Launchpad Award participants will be allocated a five-minute slot to present their innovation to a panel of expert judges including Subcon event director Gordon Kirk and chair Jon Excell. Taking place during Subcon, the winner will be announced at the show and receive a free stand on the main show floor at Subcon 2022 worth £10,000, plus ongoing PR and marketing support to help increase brand awareness.

Judging panel chair Jon Excell said: “We’re very excited about the return of the Launchpad competition. Its debut in 2019 uncovered some truly JULY 2021

Innovation lift-off at Subcon

inspirational and potentially game-changing UK engineering innovators and disruptors spanning a range of sectors, so we’re really looking forward to welcome it back and seeing this year’s crop of entries.”

For visitors attending September’s Subcon, the Launchpad is an opportunity to view leading-edge innovation which can drive up productivity and boost competitiveness.

Subcon event director Gordon Kirk: “Young businesses have faced extraordinary challenges as they have sought to bring ingenuity to market over the past year. It’s important that Subcon continues to provide a platform that focuses on the next generation of innovators and showcases their contribution to the future of industry and the UK’s global competitiveness.

“Subcon is a strategic opportunity for companies throughout the manufacturing supply chain to meet face-to-face,

reconnect and secure business growth and a timely and unique platform for any UK manufacturers looking to source or develop a robust and localised network of UK supply chain partners.”

Applications are open now at www.subconshow.co.uk/launchpad Three day conference programme Manufacturing Management is curating a three-day conference which will see panel discussions and keynote addresses from Make UK CEO Stephen Phipson, Made in Britain CEO John Pearce. Other speakers include Bruce Wood, MD, Powertrain, Cosworth; Dr James Widmer, CEO, Advanced Electric Machines; Phill Davies, Director, MAGWAY; Theo Saville, CEO, Cloud NC; Dom Tribe, Vendigital; Dr Nick Wright, Head of Manufacturing Industries, Digital Catapult and Richard Hague, Professor of Innovative Manufacturing, University of Nottingham.

8 Subconshow.co.uk www.engineeringcapacity.com

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BROACHING 8

PEOPLE | Engineering Capacity

Gareth Barker a former apprentice at Sheffield Forgemasters, has been appointed to the company’s board of directors as its Chief Operating Officer. He has progressed through the company, working across all of its production divisions in various managerial roles before his appointment to the board.

Claire Rowley has been appointed by Castings Technology International Commercial Manager to strengthen its capabilities as it expands into new markets. She has worked in a broad range of international market sectors, including aerospace, oil and gas, defence and nuclear industries.

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www.engineeringcapacity.com

CNC PRECISION COMPONENTS 8

Aamir Chaudhry has been promoted to the role of General Manager at injection moulding and chrome plating specialist Borough Ltd. The promotion is partly in recognition of his dedication to maintaining high quality manufacturing standards during the lockdowns.

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

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

PRECISION ENGINEERING 8

Mahantesh Hiremath is the 140th president of the American Society of Mechanical Engineers (ASME). He is one of only a few engineers in the world to have designed and engineered systems in four different environments – deep underground, off-shore, on-ground and in space.

JFL Broaches and Broaching

Qualiturn Products Limited Qualiturn are a very modern subcontract machining service. We offer CNC precision Turned and Milled components to your specifications and quantities. We work with all sizes of customers, offering the same service to all. Supplying various market sectors across the world.

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

DAWSON PRECISION COMPONENTS Manufacturing precision machined components since 1965 Services include: CNC milling, CNC turning, turn/mill machining, sub contracted services, finishing and project management.

Greenfield Lane, Shaw, Oldham, Lancashire, OL2 8QP Tel: 01706 842311

dpc.co.uk JULY 2021

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

JULY 2021

Batchflow Engineering Ltd

Kirkham Engineering Co Ltd 13 - CNC Sliding Heads up to 1”; 14 CNC Twin Turret Fixed Heads up to 65mm; 5 - Twin Turret Twin Spindle; 5 - Twin Turret with Sub-Spindle and 4 - Twin Turret; 4 - CNC Single Turret Fixed Heads up to 6” Billet.

Centreless Grinding & T/rolling. All materials - Stainless Steel; Nickel Alloys and other exotics a speciality.

Prestwood Place, East Pimbo, Skelmersdale, Lancashire WN8 9QE Tel: 01695 727401 www.kirkhamengineering.co.uk

SPRING MAKING 8 TURNED PARTS 8

Budbrooke Road, Warwick, Warwickshire CV34 5XH Tel: 01926 492889 www.batchflow.co.uk REPETITION TURNED PARTS 8

Wealdpark Ltd

Precision manufacturers of a wide range of compression tension and torsion springs. Also circlips, wireforms, contacts, antennas and light pressings. Quality approved to BS EN ISO 9001:2000.

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

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

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

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.

Simpson Springs & Pressings Ltd

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

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Stainles s

5 High quality precision machined components 5 Trusted technical support service 5 Complete and bespoke service from conception to completion 5 AS9100D & ISO 9001:2015 approved

Alloys per Su

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PRECISION ENGINEERING 8

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

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PRECISION ENGINEERING 8

PRECISION ENGINEERING 8

SUBCONTRACT CNC TURNING 8

Engineering Capacity | DIRECTORY

Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts Accredited to AS9100 Rev D Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk

www.engineeringcapacity.com

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