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Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Sales Manager: Arfan Qureshi sales@engineeringcapacity.com Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services. For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company number 10567217 ISSN 0306-0179 COMING UP IN OUR JULY 2018 ISSUE Casting & Forging, Oil & Gas, Forming & Fabrication, Turned Parts, Aerospace & Defence, Composites Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website
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Editor’s View As I read the proofs of the magazine, drank my tea and chewed the chocolate off a chunky KitKat, I was struck by the fact that there’s a lot of clever stuff covered in this issue of Engineering Capacity – from collaborative robots speeding up turned parts manufacturing to making a titanium ribcage for a cancer patient using additive manufacturing. Looking at the pages, I started thinking about how innovation and invention can be facilitated by technology, but that the innate drive and ability of humans to exhibit these attributes doesn’t depend on it. A great innovator will work with the tools at hand. The Bletchley codebreakers cracked enigma without transistors or integrated circuits, Concord flew without composites, and the first industrial revolution transformed the world long before electric motors were available to power the dark satanic mills. Perhaps, I thought, there should be some awards scheme to recognise the achievements of historic inventors and engineers. Well, there is. Looking through my inbox I saw a press release from the Institute of Mechanical Engineers announcing that an 1895 Worth-Mackenzie triple expansion steam engine, one of the oldest working machines of its type, had been presented with the IMechE’s Engineering Heritage Award. Hooray, and congratulations to Messer Worth and Mackenzie, who join 115 other recipients ranging from the aforementioned Concord and Bletchley ‘bombe’ computer to the Rolls-Royce RB211 engine and the Post Office Underground Railway. The awards started in 1984 and are a pretty good innovation in their own right. Snapping back to the present, if you want to catch the latest innovations in products and services you have plenty of opportunity in June and July. First up are Automechanika and Subcon at the NEC from 5 to 7 March, followed by the EPHJ-EPMT-SMT Trade Show the week after in Geneva and Manufacturing & Engineering on 4 & 5 July in Newcastle. You can find out more about all of them in this issue. Andy Sandford, Editor
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Contents May 2018
22 ELECTRONICS
News
Features
06 Subcontracting up 72% in Q1 06 Surveys show the market
14 Machined Components 06 5-axis system for £3.5m facility Automotive parts six times faster
is booming
07 Transformation for plastics company 06 Cotsworld becomes Stroud Plastics
17 Automechanika Birmingham Preview
9 INDUSTRY NEWS
22 Electronics 06 Mechatronics: a holistic approach Why would you make your own PCBs?
08 Demand drives EDM growth 06 A&M EDM has invested £400,00 in new wire erosion machines
26 Subcon Preview 09 Precision Micro sold to managers 06 £22.5m MBO from Meggitt plc 12 New name, new brand, new MD 06 LGG Charlesworth takes on a new identity 4
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32 Additive Manufacturing 06 3D printed rib implant
16 MACHINED COMPONENTS
33 Manufacturing & Engineering Preview
MAY 2018
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
INDUSTRY NEWS | Engineering Capacity The latest Contract Manufacturing Index (CMI) shows a 72% increase in the market for subcontracting in the first three months of 2018. The latest figures suggest that the market has returned to its previous upward trend and the index stood at a record figure of 238 (baseline 100 in 2014). The main drivers for this growth were large companies in industrial machinery, construction equipment and automotive coming back into the market after holding off placing orders before Christmas. The electronics industry, which had previously been the main customer for machining and fabrication services, was still strong but did not grow as much in this quarter. Within those figures the strongest demand was for fabrication services, up 119% on the previous quarter and representing 51% of the market. Machining was up by 44% on the previous quarter and presented 38% of the market. The CMI is produced by sourcing specialist Qimtek and reflects the total purchasing
Subcontracting up 72% in Q1
budget for outsourced manufacturing of companies looking to place business in any given month. Commenting on the figures, Qimtek owner Karl Wigart said: “These are very encouraging figures that show the big players regaining confidence in the strength of the UK market and upping their sourcing levels. We are seeing a very high level of activity among both buyers and suppliers. The one troubling sign is that we are seeing some suppliers struggling with cash flow due to extended payment
Swiss show for high precision The EPHJ-EPMT-SMT Trade Show, which runs 12 to 15 June in Geneva, is the international showcase for high precision technologies in the fields of watch-making and jewellery, medical technology and microtechnology. Engineering Capacity is a
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media partner of the show and has negotiated a special deal for readers including a complimentary exhibition ticket, access to conferences & roundtables, complimentary train ticket within Geneva and a welcome kit: fair catalogue, city guide, maps. 8 Register at bit.ly/ECSwissShow
terms – with some even folding as a result.” The positive trend was confirmed by new research from Subcon. This showed that nearly 40% of manufacturing companies in the engineering sector plan to increase the amount of work they subcontract next year. The research revealed that 2/3 of the businesses surveyed used subcontractors in the past year. The main drivers for outsourcing production were lack of in-house capacity and a desire amongst manufacturers and engineering businesses to focus on core competencies. Of those engineering and manufacturing businesses that do use subcontractors 53% outsource up to 20% of their requirements, with more than a third outsourcing work with £10,000-£100,000. The top 25% of outsourcers place business with £100,000 to £1m a year with subcontractors. 8 qimtek.co.uk subconshow.co.uk MAY 2018
Engineering Capacity | INDUSTRY NEWS Cotsworld Plastics, which became part of the Stroud Group in 2016, has now been renamed Stroud Plastics Company. The name brings the corporate image of the company in line with its sister organisation Stroud Metal Company and highlights the Stroud Groups’ ability to produce both plastic injection mouldings and high-volume metal pressings. The Stroud Group has invested heavily in its plastics operation and recently acquired seven new hybrid/electric plastic injection mouldings machines. Marking the next phase of its development, the Group has now been given the planning go-ahead that will allow it to develop a brand-new 79,000sqft facility to
Transformation for plastics company house both Stroud Metals and Stroud Plastics. Matthew Large, Managing Director of both companies said “I am thrilled that we have finally received the thumbs-up from the local authority and we can at long last commence construction of our new factory. It’s been a very long time coming, but will be well worth the wait” The new facility should be ready for occupation in March 2019 and will provide plenty of much needed expansion space as well as a manufacturing environment
which has been designed to allow optimised material flow and provide facilities such as overhead cranes and clean rooms for assembly and packaging of advanced automotive and medical device products. Stroud Plastics Ltd has Plastic Injection Moulding capacity from 25t up to 320t and specialises in fast tool transfer of existing products in sectors as diverse as automotive component manufacture to technical farming and veterinary equipment. 8 stroudplastic.co.uk
Stroud Plastics Company Ltd. A new Name in Plastic Injection Moulding Stroud Plastics Company Ltd. has Plastic Injection Moulding capacity from 25t up to 320t and specialises in fast tool transfer of existing products in sectors as diverse as Automotive component manufacture to technical farming and veterinary equipment. Stroud Metal & Stroud Plastics Stroud Group offers plastic injection mouldings and high-volume metal pressings from a single source
Unit 17, Nailsworth Mills Estate, Stroud, Glos. UK GL6 0BS Tel: +44 (0)1453 833577 Fax: +44 (0)1453 834104 www.stroudplastics.co.uk
MAY 2018
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INDUSTRY NEWS | Engineering Capacity
Medical plastics accreditation Plastics Extrusion has been added to the list of audit opportunities available through MedAccred, the medical device industry’s collective approach to critical process supply chain oversight. Companies seeking MedAccred Accreditation can now gain industry recognition for Cable and Harness, Heat Treating, Plastics Injection Moulding, Printed Circuit Board Assembly, Sterilisation and Welding, as well as Plastics Extrusion. MedAccred is an industry managed supply chain oversight program that reduces risk to patient safety, assures quality products and compliance with requirements as they apply to critical processes used in the production of medical devices. MedAccred is run by the not-for-profit Performance Review Institute 8 p-r-i.org/medaccred d
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Demand drives EDM growth Smethwick-based precision engineer A&M EDM has invested £400,00 in new wire erosion machines to meet increased demand from automotive, aerospace and motorsport customers. The company says the two Sodick ALC 600G wire eroders will help drive sales to £5 million in 2018. The new machines were commissioned by Charlotte Horobin, Regional Director Midlands & East of EEF, the
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manufacturers’ organisation. Charlotte said: “A&M is a shining example of an SME committed to continuous investment to create a competitive edge and the benefit of working in partnership with its LEP and local authority.” A&M uses spark and wire erosion and CNC machining capabilities to manufacture precision components and tooling for aerospace, automotive, Formula 1 and production assembly customers. A&M annually uses 25,000 miles of conductive brass wire in its 17 wire erosion machines, enough to circle the world. The purchase of these machines builds on A&M’s expenditure of over £5m in the past four years on a second factory, metrology inspection facilities, an R&D rotary engine project and high-speed machining centres. 8 amedm.co.uk MAY 2018
Engineering Capacity | INDUSTRY NEWS
Precision Micro sold to managers The management of etching specialist Precision Micro have purchased the company from Meggitt plc in a £22.5m deal backed by private equity investor LDC. As part of the deal, LDC has invested £13m of equity for a significant stake in the company, supporting a management team led by current Managing Director Ian McMurray. Based in Birmingham, Precision Micro manufactures more than 50 million highprecision metal components each year for major global manufacturing customers across multiple markets. Its photochemical etching process provides a cost-effective alternative to
traditional sheet metalworking when machining precision parts from thin gauge metals. Working to micron accuracy, its components enable nextgeneration aircraft engines, zeroemission vehicle technology, surgical instruments, titanium implants, a wide range of consumer electronics, safetycritical vehicle ABS braking systems and premium interior trim for brands including Rolls-Royce, Mercedes, Jaguar and Bentley. With offices in Germany and The Netherlands, over 75% of its £15m sales come from overseas markets. Ian McMurray said the investment would enable the company to take full advantage of several positive, global trends in
its core markets, including the increasing preference for complex, burr and stress-free components manufactured from high-performance metals, rising quality standards, the miniaturisation of electronics and increasing demand for clean and fuel-efficient vehicles. 8 precisionmicro.com
manufacturing plant producing excellent quality raw materials that are used by all of our members. “The state of trade is very buoyant. Everybody is really busy, including our machine tool members who are reporting a record year with demand for strong machines going forward into this year. Business seems to
be at a high and people are investing – not the message you hear from the media.” The next key date in the BTMA diary is the Congress of the Syndicate Internationale du Décolletage (International Association for Turned Parts Manufacturers) in Limerick in June. The BTMA recently re-joined the international association, becoming its eighth member country. Phil Smith says: “It looks as if it is going to be a really good Congress and we want as many of our members as possible to try to attend. It will be really useful to speak to people from around the world who have the same issues and problems that we have.” 8 btma.org
Men of steel For their first general meeting of the year, members of the British Turned Parts Association (BTMA) visited Liberty Steels in Stocksbridge, Sheffield, and saw for themselves how their raw materials are made. Acquired by Liberty in May last year, Liberty Speciality Steels is a fully-integrated steelmaker with electric arc steelmaking and vacuum induction melting primary steelmaking capabilities combined with casting and remelting facilities. BTMA President Phil Smith said: “We had a very good meeting at a really interesting venue. It was fantastic to see a British MAY 2018
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SPONSORED FEATURE | Engineering Capacity
UK Manufacturing gets the VIP treatment Exhibitions provide purchasers with a plethora of high-quality business introductions, but WKH\ FDQ SURYH YHU\ WLULQJ WR YLVLW 7KDWÂśV ZK\ for the third consecutive year, Qimtek has teamed up with Subcon's event organisers to bring you the VIP Buyer's Lounge - a dedicated area where qualifying buyers can enjoy free drinks and canapĂŠs, whilst taking a break from the hustle and bustle of the show. Subcon - for those not familiar with the exhibition scene - is firmly established as the must-attend event for subcontract manufacturing professionals and is held DQQXDOO\ DW WKH 8.ÂśV QXPEHU H[KLELWLRQ VSDFH WKH 1(& LQ %LUPLQJKDP 7KLV \HDUÂśV show will operate from the 5th to the 7th June and will co-locate with The Engineer Expo to deliver a combined event, dedicated to serving the UK's engineering and manufacturing industry as a whole. The Buyers Lounge will not only serve as a retreat across the entire three-day span of the event, but it will also play host to QimWHNÂśV KLJKO\ VXFFHVVIXO DQQXDO QHWZRUNLQJ OXQFK which attracted over 200 engineering professionals last year. For further details, and to register for the VIP package, visit www.qimtek.co.uk/subcon2018. Qimtek, who represent 400 UK-based subcontract engineering companies via their online manufacturing network, will exhibit on stand E50 alongside a selection of members, showcasing the best in British manufacturing. Some of the companies joining Qimtek at Subcon include:
³3&7 (QJLQHHULQJ LV \RXU RQH-stop manufacturing partner. We offer more services under one roof than most of our competitors, enabling us to offer a complete solution to your metalwork UHTXLUHPHQWV ´ - James Rigby, Director.
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MAY 2018
Engineering Capacity | SPONSORED FEATURE
³73 Engineering Ltd manufacture and develop manipulated tube and welded fabrications, from one-off batch runs to low and highvolume production. We have the experience, expertise, tooling and capabilities to handle a diverse range of tube and pipe manipulation from 4mm - PP GLDPHWHU ´ - Duncan Hall, Director. ³6HQWLQHO 3ODVWLFV DUH D ORQJ-standing, trusted plastics company that have been CNC machining and fabricating all types of industrial plastics since its inception in 1989. Whether a one-off requirement or high volume batch work, customers constantly UHWXUQ WR 6HQWLQHO IRU DOO WKHLU SODVWLF UHTXLUHPHQWV ´ - Lee Houghton, Managing Director. ³-. 'HVLJQ DUH D RQH-stop shop for sheet metal fabrication and finishing, offering a wide range of services such as CNC laser cutting, punching, folding, and on-site powder coating and wet spraying. We offer a high-TXDOLW\ VHUYLFH DW FRPSHWLWLYH SULFHV ´ - Jackie Wilson, Director ³%ODFNKLOO (QJLQHHULQJ DUH D VSHFLDOLVW IDEULFDWLRQ DQG PDFKLQLQJ subcontractor, offering an extensive portfolio of services including large fabrication and complex machine assembly services. We work with our clients to develop long-term stable relationships, offering EHVW YDOXH WR DOO SDUWLHV ´ - Dan Baker, Business Development Manager. ³50 0DQXIDFWXULQJ DUH VSHFLDOLVWV LQ the supply of subcontract sheet metal components, offering a full turnkey manufacturing service. We are experts in our field, working across a vast range of industries from oil and gas, transport, and pharmaceutical, to PHGLFDO FDWHULQJ DQG GHIHQFH ´ ± Lee Farms, Business Development Manager. ³:DUUHQ 6HUYLFHV DUH H[KLELWLQJ DW 6XEFRQ WR VKRZFDVH DOO our in-house services. We offer a complete turnkey solution, from machining, welding and fabrication, through to painting and FRPSOHWH HOHFWULFDO DQG PHFKDQLFDO EXLOGV :H FDQ¶W ZDLW WR VHH RXU H[LVWLQJ FXVWRPHUV DQG PHHW VRPH QHZ RQHV DW WKH VKRZ ´ ± Sophie Hall, Sales and Marketing Manager. ³+HSZRUWK )DEULFDWLRQV LV D µRQH-stop-VKRS¶ IRU DOO \RXU IDEULFDWLRQ requirements. Our in-house capabilities include welding, profiling, folding assembly, finishing and machining, making us us the ideal VXSSOLHU IRU DOO PHWDO IDEULFDWLRQ UHTXLUHPHQWV ´ - Luke Russell, Sales & Marketing Executive.
MAY 2018
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INDUSTRY NEWS | Engineering Capacity
New name, new brand, new MD Precision injection moulding specialist LGG Charlesworth is to become Talisman Plastics with the launch of a new brand, logo and website to be officially unveiled at the Subcon exhibition. Overseeing this transformation is new MD Shaun Champion who took the reins at the Malvernbased company on 1 May. Previously general manager at Linpac, the plastics packaging specialist, Mr Champion has spent the last 10 months as commercial director at the company, guiding a significant investment, recruitment and acquisition programme that will facilitate the company’s growth programme. Graham Ward, managing director at LGG Charlesworth for the past 12 years, will continue in a non-executive role, Turnell and Odell (T&O) managing director Clive Odell is stepping down after 30 years and is succeeded by Kevin Rees, who was previously production director. Mr Odell has played an integral part in the company's development, seeing the company move to new premises and invest heavily into the latest state-ofthe-art CNC machine tools. This strategy will continue under Mr Rees, who joined T&O in 2009 as production manager and has had a huge input on making changes. In 2014 he joined the 12
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Talisman Plastics will incorporate three trading divisions under a brand that conveys a clear focus on the plastics sector
‘‘ looking to bring continuity and balance to the board in his advisory role. Talisman Plastics will incorporate three trading divisions under a brand that conveys a clear focus on the plastics sector. The first of these divisions, operating under the Talisman Plastics
brand, is precision plastics injection moulding serving the 5,000 to 500,000 volume market in the UK. Talisman Security Seals serves the healthcare and general security seals market and Talisman Caps & Closures focuses largely within the packaging sector. Rebranding and restructuring have been supported by investment in new injection mould tooling technology; the appointment of new project development and tooling managers; and the acquisition of caps and enclosures specialist Kennet Plastics. 8 lggcharlesworth.com
Passing the baton at T&O Board and since then has helped steer T&O through the new quality standard AS91000C and Fit for Nuclear. T & O is exhibiting at Subcon on stand H11. Clive Odell said: "Kevin has played a key role in the challenges facing T&O and I feel confident that the business is in very safe hands. We have built an excellent team with high standards and I am very proud of what we have achieved, and I look forward to supporting Kevin from a new role of Business Development Director."
Kevin Rees said: "2018 promises to be an interesting and exciting year - we have invested into every sector of our business including our exceptional workforce and I feel privileged to be only the third Managing Director since the company became limited in 943 - we are in a very strong position to cope with whatever we are faced with next and we see a great future for British engineering and manufacturing which is very highly regarded." 8 toengineering.co.uk MAY 2018
Engineering Capacity | PEOPLE
Trade Leads from the EIA The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk
Amanda Quadling becomes technical director of M&I Materials, which commercialises specialist materials for demanding applications in industry and science. She will be responsible for technical support services and technical developments for new projects and technologies.
Chloe Hyland has been promoted to Marketing Manager for Automechanika Birmingham. She joined two years ago as Marketing Executive after spending almost three years overseeing the UK marketing for Automechanika Frankfurt and a portfolio of other key trade events.
Portable arc welding monitor A Croatian company is offering a license agreement for an innovative portable welding measurement unit which monitors the work of arc welding machine during its performance, as opposed to testing the seam quality of the finished weld. It can be used for monitoring the welding process in nuclear power plants, underwater pipelines etc. Reference: JV1218 Closing Date: 18/08/2018 USA - Structural steel A public works department needs structural steel Reference: 30828 Deadline: 28/11/2018 Ladder stabiliser system Agents, distributors and licensing partners are sought by a UK SME for their retractable ladder stabiliser upgrade system that can be retrofitted to existing ladders and integrated into new ladders to improve safety and meet stringent EN131 regulations. Reference: JV1223 Closing Date: 24/04/2019
Shaun Champion has been appointed managing director at LGG Charlesworth, the Malvern-based plastics specialist. Previously general manager at Linpac, the plastics packaging specialist, he will lead the company through its next phase of expansion as Talisman Plastics. MAY 2018
Gary Cormack has joined the board and taken on the role of MD at engineering and steel fabrication business, ECS Engineering Services. He has significant leadership and board level experience, including working as Trading Director for Boots.
Turkey - Hydraulic cylinders A large contractor is looking for hydraulic cylinders Reference: 30936 Deadline: 01/10/2018 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.
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MACHINED COMPONENTS | Engineering Capacity A new advanced 5-axis machining centre is the latest addition to the Bowmill Group’s £3.5m state-of the-art machining centre in Tewksbury. The Bowmill Group, which provides precision engineering, grinding and surface processing services to the aerospace sector, has installed a Chiron FZ12 FX Magnum Vario single spindle, 5axis simultaneous vertical machining centre to help it supply critical landing gear components and kits to Safran Landing Systems for the Airbus A320/A321. Supplied by the Engineering Technology Group (ETG), the turnkey package comes with 64 off HSK tool stations, the latest measuring cycle probe system from Renishaw and a Fanuc 6-axis robot with automated pallet system to support ‘lights-out’ manufacturing. It has now been installed and is producing 1500 units per month, with a 9% improvement in accuracy across all of the ten prismatic parts that have so far been proven out. Nick Epps, Managing Director of Bowmill Group, explained: “The creation of the Tewkesbury facility is a resounding success and we are now entering phase 2 as part of our commitment to supporting other strategic clients. “More than £2.5m has been spent with ETG on supplying a range of Quaser, Nakamura and Chiron technology and this has not only given us significant additional capacity for existing and future work, but also allowed us to meet the aerospace sector’s exceptional demand for 14
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5-axis system for £3.5m facility
quality, delivery, support and commercial objectives.” He continued: “The latest Chiron FZ12 and Fanuc robot is the latest purchase and is already surpassing our expectations in terms of productivity and quality. The changeover sequence and single point fixturing and workholding from Hyfore, which has significantly enhanced the tooling we have in our main site in Poole, has contributed to reducing the cycle times and we are now exploring the option of machining additional items over to this machine.” As part of the turnkey contract,
ETG had to set up and prove out 10 aerospace components for the Airbus A320 landing gear with the client’s quality department signing the first articles in accordance to its strict drawing tolerance and customer inspection criteria. Pre-acceptance of the machine took place at Chiron’s headquarters in Germany, with specific components for engineering development used to tailor the robot to create authentic loading and unloading of parts. Simon Higgs, Regional Sales Manager at Engineering Technology Group, continued: “The investment in the new machining centre has given Bowmill a second world class facility to join its headquarters in Poole. “The company is consistently achieving and exceeding quality and delivery requirements at a rate no lower than 98% OTD on KANBAN logistical control deliveries and, importantly, now has the capacity to go after and secure components with other customers.” 8 bowmill.co.uk
MAY 2018
Engineering Capacity | MACHINED COMPONENTS Multi-axis machinist Rousant Sherwood is winning business and staying competitive by delegating repetitive tasks to collaborative robots – known as cobots. General Manager Robin Salter said: “Just to be clear, we have not invested in robots to save on headcount, we’ve done it to win contracts.” The Henley-on Thames company is using a seven UR5 and UR10 robots from RARUK automation to feed 11 fixed head and 13 sliding head multi-axis turning and milling centres. Rousant Sherwood Manufacturing has 11 NakamuraTome multi-axis, multi-turret, twin-spindle turn-mill centres, complemented by 13-axis slidinghead turning and four-axis milling capability. As a result the company has already minimised both cycle times and the number of set-ups required. However, faced with an increasingly competitive global marketplace, the 35-employee company wanted to make further efficiency gains, deciding to focus its attention on automation. “In effect, the only advantage that competitors in low-wage economies have is their labour costs, so if we can eliminate that element from the calculation, it levels the playing field,” explains Mr Salter. Key to the decision to choose sixaxis Universal Robots were their ease-of-programming, competitive price and collaborative operating capabilities. Collaborative robots use sensor technology to stop safely in the event of human contact without the need for guarding. MAY 2018
Cobots keep competitive edge keen
RSM’s seven Universal Robots are today busy tending the company’s 14 CNC machine tools, with robots frequently relocated to different machines in line with customer/contract demands. One of the UR10 robots is currently serving a Nakamura-Tome Super
NTJX multi-tasking turn-mill centre. The robot loads square billets of aluminium into the machine, where they are turned into aerospace components in a 40-minute cycle. The machine and robot are running 24 hours a day, seven days a week. Mr Salter says: “We would never have been able to tender for this job without automation. Using a robot makes us profitable on work where we wouldn’t normally be able to compete.” Further applications at RSM include two UR5s at a deburring station making military aerospace components, and a UR10 being used to load billets into a CNC mill. The company plans to invest in more Universal Robots moving forwards. 8 rousantsherwood.com
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MACHINED COMPONENTS | Engineering Capacity
Automotive parts six times faster A six-spindle Tornos MultiSwiss 6X14 turning centre has added capacity and flexibility at Tenable Screw’s Wimbledon headquarters – and is producing automotive parts six times faster. Commercial Director Mr Nigel Schlaefli said: “We initially acquired the MultiSwiss to alleviate capacity issues on our single spindle sliding head machines whilst having the production capacity of multiple single spindle machines in a floor area significantly smaller than 5-6 single spindle machines. Whilst we initially used the MultiSwiss as a flexible centre that was supporting our single spindle machines; like any subcontract manufacturer that has a fluid
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workflow, customer base and component types, the MultiSwiss is now dedicated to producing just one component family. Despite being restricted to a single family of parts, the productivity, precision, cost reduction and floor area benefits are evident.” Just a few months after installing the MultiSwiss 6X14, Tenable Screw won a long term automotive contract. The family of stainless steel pins require numerous external turning processes as well as knurling, drilling and parting-off. The UK contract requires 1,500,000 parts every year, a quantity equal to 30,000 parts every week. Tenable Screw trialled the automotive part on one of its sliding head turning centres and the cycle time was 1.5 parts per minute. In stark contrast, the MultiSwiss 6X14 was capable of producing 9 parts per minute – an output equal to 6 sliding head turning centres.
“We calculated that we would have needed to run 6 single spindle turning centres for 24 hours a day to meet the contract capacity level. We generally run our machines for 8-8.5 hours through the day and re-set the machines at the end of a shift to run for an additional 8-9 hours unmanned. To meet the demands of this specific contract, we would have had to commit staff to running 6 sliding head machines around the clock. In comparison to the 24/7 running of 6 machines, the MultiSwiss 6X14 hits the same output by just running for 17-18 hours a day. This means we can run the machine during a day shift, change tools and re-stock the barfeed at the end of the shift and then run for an extra 8-9 hours unmanned,” says Mr Schlaefli. 8 tenable.co.uk MAY 2018
Engineering Capacity | SPONSORED FEATURE
Re-shoring subcontract machining to the UK? Why with APT Leicester it’s definitely worth it. Competitive pricing, outstanding quality and guaranteed delivery. Over the last few years more and more companies are bringing back their subcontracting operations to the UK. Re-shoring to the UK makes a great deal of sense. Subcontracting in the past has made companies nervous. Overseas manufacturing may have been a cheaper option, but there were always issues with quality, shipping costs, language barriers and lead times. Today, bringing outsourcing back to the UK is a secure, cost-effective solution. The benefits of subcontracting to a respected, expert, UK manufacturer like APT Leicester are clear. British subcontractors have never been more attractive to firms – competitive pricing, quality manufacturing and reduced shipping costs are among the many advantages. In general, choosing to outsource to a respected manufacturer can help you save on site space, operational costs, overheads, taxes, utilities, security and insurance. With a company like APT Leicester, you will also have fewer regulations to manage in-house. For example, they are ISO 9001 and AS 9100 accredited, which both require meeting stringent criteria. By outsourcing to APT, this removes the costs, employee time and general hassle of adhering to these regulations. Providing full traceability of production, from raw material sourcing to the final delivery to customers,
MAY 2018
subcontractors like APT give companies complete peace of mind and confidence in product quality. APT’s relationships with customers are partnerships. They have over 60 years’ experience designing and manufacturing precision parts and supply satisfied customers worldwide, day in, day out. They have consistently invested in state-ofthe-art technologies and staff know-how. Companies can benefit from extensive design knowledge to help refine products, as well as profit from their experience in CAD modelling, CNC milling and turning. This leaves customers to redirect resources and staff into core operations. APT Leicester is an example of the quality of onshore, UK manufacturing. By partnering with APT Leicester, companies can reduce operating and overhead costs. While saving by outsourcing, they can offer lower prices while increasing profit margins. There will be more money to spend on marketing, debt reduction, research and development, salaries and other areas. Based in the heart of the UK, APT can offer a quick turnaround, shorter lead times and fast, efficient delivery. Offering a blanket order service enables companies to keep costs down by ordering over a 12 month period, while optimising their own storage space with deliveries only as and when components are required. British subcontractors like APT Leicester can offer cost-effective, quality solutions for all subcontracting and outsourcing needs and they are right here, in the UK. www.aptleicester.co.uk • 0116 287 0051 www.engineeringcapacity.com
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AUTOMECHANIKA | Engineering Capacity
Automechanika Birmingham 2018 is back 5-7 June at the NEC, with a host of reasons for professionals from the vehicle production sector to attend. The UK’s leading exhibition for the vehicle production industry will bring together over 150 suppliers with automotive engineers and purchasing teams from the UK vehicle manufacturing sector. Companies exhibiting include Bosch UK, Magal/Arlington, TR Fastenings, DJJ Precision, Schmidt Light Metals, Pritex, Keyence, Autocraft Drivetrain Solutions, COBA Plastics and many more. The SMMT (Society of Motoring Manufacturers) and the MIA (Motorsport Industry Association) will hold their own member pavilions during the exhibition too. Hall 6 is the dedicated area for tier 1, 2 and upstream manufacturers to showcase technological advancements and solutions for the vehicle production sector. Managing Director of Automechanika Birmingham, Simon Albert commented “Every year, we create a great networking platform for the UK automotive industry. This June, we have introduced new features showcasing future technologies, advancements in high performance engineering, as well as connected and autonomous vehicles, electrification, ultra-low emissions and battery technology. It really is an invaluable day out of 18
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Vehicle production destination
the office to reconnect with new or existing suppliers and learn what lies ahead for the future of the automotive industry.” The exhibition will offer visitors a series of high level forums and seminars delivered by industry heavyweights and innovators covering topics including Innovation, Tomorrow’s Mobility, UK Automotive, Skills, Advanced Manufacturing & Logistics. Speakers will include: SMMT, Industry Forum, Automotive Council, IMI (Institute of the Motor Industry), MIA (Motorsport Industry Association) and more. Also new this year is Motorsport Valley Innovation, presented by the MIA (Motorsport Industry Association) and sponsored by Staubli, which will deliver an exciting showcase of the newest technologies of high performance engineering. It will bring together
automotive OEMs and Tier 1 suppliers with members of the motorsport and high performance automotive industry. The organisers are working closely with Innovate UK, Knowledge Transfer Network who will present the new feature ‘Tomorrow’s Mobility’, a dedicated area showcasing the UK's capabilities with the latest technologies in connected and autonomous vehicles, electrification, ultra-low emissions and battery technology. In addition to the suppliers and new features on the show floor available all 3 days, Thursday 7 June will deliver a Future Skills Day, a series of initiatives to cater for anyone with an interest in skills, training and development. The day will be specifically focussed on the future training priorities of the emergent MAY 2018
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AUTOMECHANIKA | Engineering Capacity technologies and to address the industry skills gap. Automechanika Birmingham is held in association with SMMT who will once again be hosting their flagship events, Open Forum on the 5th June, and Meet the Buyer on the 6th. From supply chain presentations to connecting buyers with suppliers, their presence at the show offers huge opportunities to network and improve your business. Connecting with suppliers is another focus of the organisers at Automechanika Birmingham, who have introduced a facilitated meetings programme. The software matches visitors’ interests with the capabilities of suppliers to increase relevant
business conversations on stands. Visitors should register free at www.automechanikabirmingham.com to be able to schedule meetings with pertinent suppliers specific to the needs of their business. As last year, the show will be held at the same time with
Automechanika in brief From laser to parts Lasershape can now offer a complete manufacturing solution to the metalwork industry, from laser cut components through to fully finished, fabricated and powder coated goods. Using the very latest pretreatment technology, Oxsilan, it can supply parts with up to 1,000 hours salt spray protection. Stand E10
Rubber and metal bonded Ecem Otomotiv is a manufacturer of rubber to metal bonded parts for FORD, Mercedes & VW passenger and light Commercial cars. The company is looking for importers and wholesalers. Ecem is ISO 9001 accredited and can produce any rubber metal part on request. Stand G41
Free scan RASCO offers 3D scanning, reverse engineering & quality inspection services from India. It is offering one job free of cost to all visitors to its stand at Automechanika Birmingham. Stand K46
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Subcon, the UK’s premier subcontract manufacturing supply chain show. Visitors need only register once to enter both events. Engineering Capacity is a media partner of Automechanika and we will be publishing a full preview in our May issue. 8 automechanika-birmingham.com
Special chemistry For over 25 years Frost Electroplating has been helping to identify and solve automotive connectivity issues. This is usually derived from the end users’ lack of understanding of coating morphology, ultimately leading problems resulting from selecting the wrong specification. Frost’s nickel plating chemistry has been designed to overcome welding/solderability problems encountered when plated directly on to a whole variety of substrates. This recently enhanced coating is proving to be quite innovative in the electric/autonomous vehicle market. Stand C05.Pod 7
Automotive plastic welding Telsonic will be running a live demonstration of ultrasonic plastic welding of parking sensor holders to automotive bumpers. The holders for car park assist systems are welded to fully paint-coated thin-walled bumpers. The weld therefore must be completely invisible from the “A” surface. However, the weld must be firm, reliable and durable. A number of automotive first-tier suppliers use a Telsonic system to achieve high quality welds on these types of parts. Using this system it is even possible to reduce the bumper thickness by 20%. Stand 6A110
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Engineering Capacity | AUTOMECHANIKA On Stand E21, Tier 1 automotive supplier and machined parts specialist DJJ Precision Engineering is showcasing its expanding manufacturing services, with recent new investments in additional sliding head machinery, in-house honing, and laser ID marking facilities complementing its growing CNC capacity. Over the past few months, DJJ has added three more highly skilled personnel to the team, taken on new engineering apprentices, and a new graduate programme is currently in the pipeline. DJJ will also be launching its new multilingual, interactive website, just prior to the show, to enable better communications with its global customers. Since a successful appearance at last year’s event, DJJ has won ‘Tier 1’ supplier status for Ford Motors Global and has also become suppliers for a number of other automotive companies. DJJ was also one of the first companies in Wales to gain the new ISO 9001:2015 quality standard accreditation through TUV Rheinland. The company is currently working for a range of Tier 1 and Tier 2 companies, not just in the automotive sector, but also in industries ranging from aerospace, medical, marine and optical, to oil & gas, energy, rail and CCTV. Shirley Jones of DJJ says the company is ideally placed to take on new automotive customers, particularly with the decades of experience gained supporting the supply chain requirements for MAY 2018
Ready for new automotive business
global companies such as Volvo. “We do everything with total quality focus, and support all of our work with the required certification, from PPAP & IMDS, to CMM computerised reports. We also welcome the opportunity to get on board at the early stages of new design, and prototype production is a way of showcasing our ability to supply industries that require only the best supply chain with the right production standards. “We can be in production in a matter of weeks, and having been long term Tier 2 component suppliers to such likes as TRW, Parker Hannifin, Schaeffler & many others, our quality processes have been vetted to already incredibly high standards. We offer JIT, Kanban and general production management, and up to 4 months credit, and we
are not frightened to invest in crucial high-end machinery if it can help us secure a contract. “Most importantly, we boast a true one-stop-shop service. Everything from beginning to end is taken care of, and our clients always have direct access to our key engineers, and welcome free access to our premises. “We’ve been around for over 40 years, and our customers continue to have the confidence that DJJ will get the job done. We can help with an extensive range of production turning requirements, from 2mm diameter upwards, and milling production up to 1.7m long, through to design tweaks, prototypes, reverse engineering, production, assemblies, finishing and marking - right through to final certification and global delivery.” 8 djjengineering.com www.engineeringcapacity.com
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ELECTRONICS | Engineering Capacity Phil Simmonds of EC Electronics says that when designing new mechanical products, a holistic approach is the best option. When electronics and mechanics meet we get mechatronics. A great example of this is your car – electronics drive the mechanics within most modern vehicles. Similarly, robots are clearly mechatronic systems; microcontrollers and PCBs control their mechanical functionality. Look around at your office or home and you’ll find many more examples of mechanics and electronics working together to create new and inventive technology. From your digital thermostat), to sensor augmented insulin pumps, which measure glucose levels at regular intervals and deliver insulin as needed; there are numerous examples of mechatronic systems. Mechatronics and The Internet of Things (IoT) A major area where mechanics and electronics are working together is in IoT. The Internet of Things requires that each engineering group – mechanical and electrical – work together rather than in silos. Traditionally, mechanics would work on enabling the physical motion of a product, bearings, drive mechanisms, rails etc. Whereas electrical would focus on power, sensors, controllers and more. With mechatronics and IoT these two disciplines have become more integrated, technology is shared and there are cost savings to be had too. An example of this is in smart motor 22
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Mechatronics: a holistic approach
technology. Smart motors are changing motion system design, taking over functions – including data acquisition and control, network communications, diagnostics, and protection – that once involved different systems and components. The result of this collaboration between electronics and mechanics can be measured in various ways. The following points demonstrate some of the key benefits of giving equal weight to electronics and mechanics when approaching product realisation: Enhanced functionality Typically products that are based on a mechanical design only have one function. For example, a mechanical thermostat can only be programmed to heat a room to one temperature between certain times of the day. Whereas a digital
thermostat allows the user to select different temperatures at different times of the day. Incorporating a microcontroller into a product opens up more features and functionality. More user-friendly These additional functions also make the product more userfriendly. Users have more options to tailor the product to their needs. Whether that is programmability, or convenience factors such as LED displays and safety features. Smaller size Solutions using electronics can help reduce the size of a product and deliver benefits for users and manufacturers. In fact, with advances in micro-electronics, many mechanical functions can be replaced with much smaller components and systems. MAY 2018
Engineering Capacity | ELECTRONICS More intelligent Intelligent electronic solutions can also have a positive impact on costs and efficiency. For example, a microcontroller can ensure that energy is delivered to only the parts of the system that need it. This can help improve efficiency as well as deliver energy savings, such as better battery life. Improved safety Mechanical products can also be
made safer when electronics are incorporated. Numerous safety checks can be easily added to a system to ensure that it is operating correctly. Smart sensors can improve machine performance, reduce downtime and implement maintenance when necessary. They can also shutdown machinery if certain parameters are met; sensing temperature, humidity and other factors that might have safety implications.
When designing new mechanical products, or looking at ways to modify or improve existing solutions, EC Electronics recommend that you take a holistic approach to mechanics and electronics. Partner with suppliers with product realisation services and expertise, as they can often help deliver cost savings and drive efficiencies right from the start of a project. 8 ecelectronics.co.uk
Wealdpark Limited Stand number 5126
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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
MAY 2018
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ELECTRONICS | Engineering Capacity As every manufacturer, regardless of size or sector, faces increasing demands on both time and budget they need to find smarter ways of developing and delivering their end products. So why would you make your own PCBs, asks Newbury Electronics Smart engineering processes and solutions that are connected and allow us to harness the power of the Internet are not always the panacea they may at first seem. Sometimes simply taking a shrewder approach to your procurement may deliver equally, but hitherto, unseen valuable benefits. One obvious crucial area where outsourcing can save not only time and money but also arguably supply a higher quality end product is contract assembly PCBs. As boards and the electronics which they house becoming increasingly complex it is no longer viable for each and every manufacturer to have its own in house electrical design and production department. Few, if any, organisations would ever see a decent return on their investment if they were to purchase the necessary plant and equipment to deliver the boards to the standard required in today's manufacturing environment. They need to turn to specialist suppliers for whom board PCB assembly is the mainstay of their business and who understand the benefit of capital investment to keep them at the forefront of their chosen area of specialisation. Companies like this invest not only in the latest equipment, but also have the 24
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Why would you make your own PCBs?
knowledge and understanding of the latest processes, materials and methods and will provide their customers with design guidance, technical support and then deliver the boards to meet both the time and budget restraints. Real benefits from a specialist So where will a specialist PCB assembler be making their investment in the 21st century? There are seven key areas where a specialist provider can deliver real benefit to their customer: 1. Automated first article inspection – checking that you have it right at the earliest stages and making any corrections that may be required there and then incurs far lower costs than discovering
a boarding error at a later stage of the process where project delays can have serious economic implications. 2. In house solder paste stencil manufacture – it is well understood in the industry that the quality of the initial stencil impacts on the final board, and many regard this as the pivotal stage in the entire process. Mistakes can and do occur but it is far quicker and easier to rectify a faulty stencil on-site where you are familiar with all elements of the project than having to involve a third party where neither the end client or the assembler can be entirely confident about what has been included. 3. Vapour phase reflow – This is a high-quality method of reflow MAY 2018
Engineering Capacity | ELECTRONICS soldering. Every PCB assembly will have its own unique reflow profile requirement. When convection reflow is troublesome to successfully qualify, vapour phase reflow is preferred being far more tolerant of thermal mass variation with a far wider operating window. It is the reflow process of choice. 4. 3D AOI (Automated Optical Inspection) – as with Point 1, first article inspection, maintaining the highest quality throughout the process and identifying any potential problems as the earliest opportunity delivers a smoother production process. The high-resolution capabilities of these machine inspection tools supersede the capabilities of the human eye and in effect the equipment is able to 'learn' as it inspects. 5. X-ray inspection – as boards become increasingly complex, many of the connections will be hidden from view underneath the board's components,
MAY 2018
making X-ray examination the only viable option. 6. Robotic selective soldering of lead-in parts – whilst manual soldering has long been a mainstay of board assembly this has inevitably had an element of variability. With robotic solutions quality is maintained and smaller and more complex joints can be handled with ease. 7. In-house bare-board manufacture – with so much of
CEM being automated, bare PCBs must be presented in step & repeated carrier pallets which can be automatically handled through pick & place, AOI, and selective soldering. A CEM with access to in-house bare PCB manufacture will ensure that DFM (design for manufacturing) is designed in from the start The capital investment required to acquire the latest equipment to cope with the processes described above is out of reach of any but those for whom PCBs are the bread and butter of their business. By contracting out the engineering design and the manufacture many large organisations have already achieved internal efficiencies. Using an agile and dynamic supplier that understands both the mechanical and electrical elements of the work and who is able to apply this technology and knowledge is definitely the way forward, and makes both business and engineering sense. 8 newburyelectronics.co.uk www.engineeringcapacity.com
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SUBCON PREVIEW | Engineering Capacity Now in its 42nd year, Subcon returns to the NEC in Birmingham on 5 to 7 June. More than 4,500 manufacturing and engineering professionals across all industry sectors are expected to attend three days packed with keynote presentations and practical workshops. According to the organisers, the exhibition will see over 400 companies on the floor, covering every aspect of contract manufacturing and additional services. From machining and die casting to MRP software, lasers and plastics. The organiser, Centaur Media say that Subcon is a unique platform for engineers to source the latest advanced engineering technology, products and services and optimise production across the manufacturing cycle. Visitors will come from sectors including aerospace, automotive, defence, electronics, energy, materials, oil and gas and rail sectors. In 2017, Subcon saw a record attendance of more than 4,300 visitors. Research by the organisers showed that 92% of those visitors came to source products and services and included buyers from some of the biggest names in global manufacturing. Subcon 2018 is set to be the biggest show to date. Subcon has also partnered with Automechanika Birmingham to enable visitors to benefit from attending both events by registering just once for their visitor badge. Engineering Capacity is a media partner to both shows. 26
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400 exhibitors on show at Subcon
Alongside the show, a sixstream, 36-session conference programme will be held across two theatres. Rolls Royce CTO Paul Stein will present the keynote within a programme that also features sessions on digitalisation, robotics, prosthetics, Blockchain, smart materials and technology transfer delivered by some of the UK’s leading engineers and its most innovative disruptors. 8 subconshow.co.uk More 3D print capacity Bowman Additive Production (Bowman AP) has significantly increased capacity by adding the latest HP Jet Fusion 4200 3D printer. Coming 18 months after the launch of the venture, this will allow it to dramatically increase the size of its production 3D
printing business and complements the company’s existing SLS 3D printer. With this recent investment, Bowman AP will be able to offer its customers an abundance of benefits, including; significantly lower lead times, increased efficiency, better materials, online ordering, volume discounts and batch production. As a part of this investment Bowman will be amongst the very first businesses in Europe able to offer customers the latest material from printing giant HP - HP 3D High Reusability PA11 material. Compared to the current industry standard PA12 material the new material has significantly superior strength, stiffness and flexibility. This is especially noticeable in the Z axis – while most 3D print methods result in vastly inferior MAY 2018
Engineering Capacity | SUBCON PREVIEW
properties in the vertical axis (between the layers of material from which the part is made) the HP Jet Fusion process results in near equal properties in all axis. Bowman AP has also added 3D scanning capacity and invested in the latest DyeMansion Powersot S automated part finishing system to cement its place as an industry leading production 3D printing. Bowman AP was established in 2016 with the aim of using 3D printing as a production process, rather than just a rapid prototyping service. 8 Stand A43 Networking UK manufacturing For the third year running, Qimtek has teamed up with Subcon to bring visitors the VIP Buyer's Lounge, where qualified buyers can enjoy free drinks and canapes away from the hustle and bustle of the show. The lounge will serve as a retreat across the entire three-day span of the event, and will also house its annual networking lunch on Wednesday 6th June at 11am. Qimtek is also hosting a UK Manufacturer's Pavilion, showcasing a selection of its 400 UK-based subcontracting members. 8 Stand E50 MAY 2018
CAD/CAM debut ZW3D, one of the world's leading suppliers of advanced CAD/CAM solutions for the manufacturing industry will make its debut at Subcon with UK resellers Smart Design Service. At Subcon ZWSOFT will present ZW3D 2018 and highlight the enhancements in the forthcoming ZW3D 2018 SP. ZW3D 2018 has struck a partnership with MISUMI, a library for standard components for press dies and plastic moulds to give engineers configurable components to speed up design. Next year ZW3D will integrate VoluMill which is expected to dramatically improve roughmilling productivity. ZW3D is an all-in-one CAD/CAM solution, designed for the whole process of product development, features the fastest kernel for Solid-Surface Hybrid Modeling, non-solid mould parting and
smart CNC Machining tactics from 2-axis to 5-axis. 8 Stand K11 New machining technology Dawson Precision Components Ltd (DPC) has always grown its business through continual improvement, constant investment and expansion, especially on the machine tool procurement side of the business. It has now added new technology for difficult materials. At Subcon DPC will showcase these recent investments which include another Citizen L20 type VIII with the addition of LFV technology and a new venture into the hybrid sliding/fixed head market with a new Miyano BNA42-GTY also featuring LFV technology built in. This LVF technology gives DPC a competitive advantage when machining difficult materials such as plastics and some stringy aluminium grades.
The Production 3D Print Bureau
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Additive Production
- HP J Jet et Fusion T Technology echnology - High Performance Performance HP PA11 Material - 3D 3 Scanning - CAD C & Design Service
www.bowmanap.com www .bow wmanap.com
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SUBCON PREVIEW | Engineering Capacity The machines have been installed, trialed and proven and are already bringing advantages to customers. 8 Stand C44 Quality parts and service ChinaSavvy says the driving force behind its worldwide success is a passion for quality – quality of parts made and quality of service delivered – and this will be reflected at Subcon. ChinaSavvy has achieved and maintained ISO 9001 for 10 consecutive years and its portfolio of satisfied customers who return time and time again has continued to grow since the company began 15 years ago. With a reputation for delivering world-class engineering services to blue-chip and smaller start-up companies, ChinaSavvy will be welcoming to its stand any size of business looking to have metal or plastic products designed and
manufactured to the very highest standards. ChinaSavvy offers 19 different metal forming processes and specialists on the stand will be available to talk to visitors about their casting requirements. Advice and insight will also be available on metal fabrication, precision machining and production using plastics and carbon fibre. Finally, visitors will learn about ChinaSavvy’s ability to source a variety of precision machining processes and why the company is recognised as an outstanding, world-class CNC machining specialist. 8 Stand C27
02031 767 811 811 www.bdiprecision.com www.bdiprecision.com
“BDI Precision is a multinational collective of expert designers and engineers that supports SMEs in reducing design, engineering and prototyping related operating costs.”
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3D Scanning & Reverse Engineering Large Format 3D Printing Mechanical Engineering & Concept Design CFD, Fluid Dynamics FEA, Finite Element Analysis
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Customer-focused services The QSS Group is a provider of cost effective, customer-focused Training, Consultancy and Auditing in Safety, Quality, Environmental and Engineering services. Its stand at the exhibition will focus on the many services it can offer potential customers. Training is a large part of what QSS does and it offers a variety of training courses to meet customers’ requirements and each of the courses will be available to look at in more detail at the stand. Training courses, range from IOSH Accredited courses to Manual Handling training. David Harris of QSS says: “A key project we have been working on is Bishopsgate Goodsyard, a historic site that dates to the 1840’s! The QSS Group helped in transforming this site regarding health and safety. Our work at Bishopsgate allowed us to be involved in several different events linked to the site, several key events were London Fashion Week 2017 and a major franchise film. “Aside from the exciting projects we have been involved in, The QSS Group offers Risk Assessments, Common Area Risk Assessments and Fire Risk Assessments to meet your organisations’ needs. Our inspection services range from third party inspections to site safety inspections through our highly competent inspectors, with a vast range of knowledge to assist you in all your needs. HSQE support and consultancy services are another of the services that we can assist you with.” 8 Stand E4 MAY 2018
Engineering Capacity | SUBCON PREVIEW Multi-axis parts Sub-CNC Precision specialises in the manufacture of multi-axis turned parts & finished components, supplying to a diverse range of industry sectors. Celebrating its tenth year in business, the ISO 9001:2015 company has invested heavily in the very latest sliding head equipment and is able to machine components with multi-axis features from 1mm diameter up to 42mm diameter. The company operates 24/7 utilising the night for an unmanned shift, allowing quick lead times and competitive prices. Stockholding, consignment stock and Kanban are offered to all customers who require volume
components with next day delivery. In 2017 the company was the first in the UK to purchase the revolutionary Low Frequency Vibration (LFV) technology. This enables the machining of difficult materials by creating an air cut and breaking material into small chips rather than stringy swarf, minimising surface scratches. 8 Stand C42 A Serious change Subcontract sheet metalwork supplier Serious Engineering has rebranded as RM Manufacturing. This new name underlines the company’s position as part of the Royal Mail Group of businesses. Lee Farms, Business Development Manager, says: “With the company
focused on developing and growing the business, within both new and existing markets, we felt now was the right time to change and move forward. “Prior to our takeover by the Royal Mail Group, Serious Engineering was owned by several companies and so we inherited and were referred to by more than one brand name. This became confusing to both our customers and employees. “We have developed a new identity that recognises our history, while promoting the fact that we are part of the Royal Mail Group and showcasing the advantages this brings us as a complete subcontract metalwork supplier.� 8 Stand No. F51
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PR Mark Marketing eting Social Media Copywriting Copywriting Events Events Awards Awar w ds Design Desig gn Media Relations Relations Web Web & SEO
www www.aroprandmarketing.co.uk .aroprandmarketing.co.uk
MAY 2018
01752 894786
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SUBCON PREVIEW | Engineering Capacity specialises in non-ferrous, non-metallic materials and thin shims where grinding can be costly and difficult. 8 Stand E2
Casting in aluminium With 50 years’ experience, Finalcast is the biggest commercial foundry in Slovakia, producing aluminium castings from 0.5 to 50 kg using low pressure die casting, gravity die casting and tilt pouring. This versatility allows it to choose the most suitable technology for each component. As well as casting it offers in-house CNC machining and heat treatment. The company is currently awaiting delivery of new low pressure die casting machine as its current plant – four machines with a capacity of 21 tonnes – is close to its maximum output. Recent big contracts have been from Knorr Bremse for railway braking systems and from Edwards for pump components – both new customers. 8 Stand H2 Specialists in lapping Lapping Services Ltd is a dedicated lapping company, specialising in double sided lapping, and allowing for high volume production at precise tolerances. It has the largest double-sided equipment in the UK, enabling high load capacity of a multitude of components, from 4.5mm to 450mm diameter. It 30
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Intelligent control Valuechain has added new capability to its DNA production control software by integrating it with the cloud-based business intelligence tool AnalytiQs to allow it to generate real-time intelligence on business processes. AnalytiQs consolidates production, sales and customer data into one intuitive platform. to provide a complete overview of a business operations. Valuechain’s range of production control solutions are designed for subcontract manufacturing and finishing commodities. It provide software to over 500 manufacturing companies, mostly SMEs as well as companies like Bentley Motors and Airbus UK. 8 Stand F10 Eyeing on new markets PRV Engineering has just completed another £1.5 million investment. Following the award of a substantial, seven-year contract, PRV has invested in further extensions to its premises in Pontypool and the acquisition of two large format machining centres, one high speed machining centre for large aluminium plate and framework and one large heavy duty 5 face machining centre for steel components. The investments will allow PRV to provide a broader range of
services to a wider range of industries and advance further into new and more diverse markets. 8 Stand E19 Castings up to 4 kg Carlton Die Castings Ltd has purchased a new 500Ton Colosio high pressure die casting machine that together with the acquisition of a Mazak machining centre and supporting technology takes its investment over the past year to £400,000. A family business established in 1947, Carlton Die Castings Ltd produces gravity and high pressure die castings in the UK and specialises in providing fully machined castings ready for assembly. This is Carlton’s second 500T Colosio machine in the space of 3 years and the purchase will help increase capacity for existing customers as well as offering capacity for potential new contracts. The current range of die casting machines can make parts up to 8kg, however the new machine will increase capacity for castings ranging from 1-4Kg where it currently sees the greatest demand. The machine has been installed and successfully commissioned and is already producing production parts. 8 Stand B35
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ADDITIVE MANUFACTURING | Engineering Capacity Renishaw has produced a unique titanium rib prosthesis for a Welsh cancer patient using 3D printing. 71-year-old Peter Maggs received life-saving chest surgery at Morriston Hospital, Wales, during an operation to remove a large sarcoma from his chest. As part of the procedure, Mr Maggs received a rib prosthesis which was designed by Morriston Hospital. This is the first chest prosthesis to be manufactured and implanted into a patient in Britain. Chris Pockett, Head of Communications at Renishaw plc stated, “We are delighted to have been the subcontractor for this complex 3D printed titanium implant designed in-house by Abertawe Bro Morgannwg University Health Board. The implant was produced on a Renishaw metal additive manufacturing (AM) machine at our Miskin facility near Cardiff, where all our AM systems are manufactured.” To remove the sarcoma, Mr Maggs’ surgeons had to remove part of his sternum and three of his ribs. Without a prosthesis, this would have left his chest in an extremely unstable condition. Heather Goodrum, Biomedical 3D Technician and Peter Llewelyn Evans, Manager of Maxillofacial Laboratory Services at Morriston Hospital, designed the implant using data from CT scans of Mr Maggs’ chest. Renishaw then produced the implant from titanium using its additive manufacturing technology, to the specification of the hospital. “Additive manufacturing allowed 32
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3D printed rib implant for cancer patient
us to produce an implant that was an excellent fit for the patient,” explained Ed Littlewood, Marketing Manager at Renishaw’s Medical and Dental Products Division. “Conventional prostheses are produced during surgery, once the affected area has been examined and the correct fit determined. Producing the implant in advance meant the surgery time was reduced, which benefitted the patient and the surgeon.” The remaining bone in Mr Maggs’ ribcage was narrow and soft. Conventional prostheses, which are made of biocompatible cement, would not have been strong enough to support this bone. “Traditionally, the patient would have been fitted with a Polymethyl Methacrylate (PMMA) implant, which can only be hand-fashioned during surgery,” explained Peter Llewelyn Evans, Maxillofacial Laboratory Services Manager at Morriston Hospital. “Additive manufacturing allowed us to save around two hours of surgery time,
because the implant could be designed and manufactured prior to the procedure. The shorter the procedure time, the better it is for the health of the patient. “Being able to manufacture the implant from titanium also increased its biocompatibility and closeness to the original bone structure, both leading to a better outcome for the patient.” Due to Mr Maggs’ successful recovery, Morriston Hospital is planning to use additively manufactured implants to treat future patients of this kind.
Conventional prostheses are produced during surgery, once the affected area has been examined and the correct fit determined. Producing the implant in advance meant the surgery time was reduced, which benefitted the patient and the surgeon
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Renishaw’s Medical and Dental Products Division offers metal AM systems to additively manufacture a range of products for healthcare applications, including patientspecific implants (PSIs) for craniomaxillofacial surgery and dental frameworks. To find out more about Renishaw’s healthcare products 8 renishaw.com MAY 2018
Engineering Capacity | MANUFACTURING & ENGINEERING PREVIEW The Manufacturing & Engineering exhibition and conference returns to Newcastle on 4 – 5 July and gives industry professionals in the North of England the chance to see new products and services, obtain high quality business advice, and try out the latest machines, production equipment or design tools. This year Manufacturing & Engineering will be participating in the Great Exhibition of the North’s ‘Inspired By’ programme of events, celebrating manufacturing technology and design engineering and their importance to the economy of the Northern Powerhouse. Manufacturing & Engineering comprises three key elements: keynote conference sessions, practical workshops and an exhibition of suppliers – and is delivered in association with Eureka, Machinery and Manufacturing Management magazines. Education and knowledge sharing plays a pivotal role at Manufacturing & Engineering. Visitors can choose between a programme of keynote conference sessions and practical workshop seminars covering every element of the design and manufacturing process from CAD to customer. Nissan will open day-one of the conference with Ian Green discussing how employers can champion careers in manufacturing for the benefit of the whole UK economy. Day-two opens with Stuart Reilly of Toyota Material Handling, looking at materials handling technology MAY 2018
Go north for Manufacturing and Engineering
and innovation, where we are now and what the future holds. Further highlights include the HypED team from the University of Edinburgh, who will demonstrate the design challenges behind Hyperloop technology developed for the SpaceX project. Rowan Crozier, Chairman of Manufacturing Assembly Network (MAN) discusses how collaboration has been the key to success for members of the MAN group. The Advanced Propulsion Centre’s Philippa Oldham will discuss maintaining the UK’s leading position as an automotive manufacturer alongside the challenge of zero emission vehicle development. The practical workshops at this year’s show offer a wide variety of learning opportunities to support industrial innovation. Spaces are limited so be sure to book your preferred sessions early. Sessions to note include those from Clarity
Visual Management, 3D Systems and Toyota Material Handling. Exhibiting companies cover a wide range of technologies and services such as visual management tools from Clarity Visual Management, metrology technologies from Zeiss and GOM UK, design & manufacturing software from Autodesk and virtual & augmented reality technologies from Theorem Solutions. Visitors will be able to source suppliers, benchmark capabilities and secure contracts that will help their businesses remain competitive on a global scale. Alongside the exhibition and conference, there will be several new feature exhibits to inspire and enthuse visitors. Features include the UK’s first Hyperloop prototype pod, Nissan’s dissected all-electric Leaf car and Sunderland University’s Formula Student 2018 car. 8 mfgengineeringshow.co.uk www.engineeringcapacity.com
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JFL are broach and broaching specialists with amost 40 years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms.
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
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MACHINING (5 AXIS) 8
Qualiturn Products Limited
Bespoke surface heat treatment processors. Gears up to 4.5m dia. Shafts or rollers up to 1.5m dia. and 7.5m in length. Machine beds up to 6m lengths. Wheels up to 2.3m dia. We have over 75 years of experience. Shorter Works, Bailey Lane Sheffield S1 3BL Tel: 0114 276 8167 www.flamehardeners.co.uk/
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
PRECISION ENGINEERING 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 Broaches and Broaching
HEAT TREATMENT 8
BROACHING 8
DIRECTORY | Engineering Capacity
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
ity eering Capac TS | Engin COMPONEN MACHINED
ts g suppor Mill-turnin oach lean appr
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 technology ion can 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 offer. are nce skills we A way part that single 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. specia in, have the assista the compa CNC sliding head listed potenti impos revs/m nce understand They 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
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www.engineerin gcapacity.com
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Get your company noticed with an Engineering Capacity classified profile advert FOR MANUFACTURERS ABOUT SUBCONTRACTORS
September 2017
INDUSTRY NEWS | MACHINING | AUTOMOTIVE | SHOW PREVIEWS
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
MACHINED COMPONENTS: Prismatic parts from bar
www.engineeringcapacity.com
Call 01737 270648
MAY 2018
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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
Saws (UK) Ltd South Easts leading specialist metal cutting machinery and blade supplier. Agents for Fabris, Pilous, Alligator, Comet, Forestor, Carif and many more. Unit 8, Wealden Business Park, Farningham Road, Crowborough, East Sussex TN6 2JR Tel: 0844 8804511 www.sawsuk.com
MAY 2018
TURNED PARTS 8
Accredited to AS9100 Rev D
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Precision T Turned urned P Parts arts Subcontract Machining Surface T Treatment reatment CNC Machined Components Parts P arts Assembly Design & Engineering Support Service A AS S 9100 & ISO 9001
Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk TURNING (CNC) 8
Kirkham Engineering Co Ltd
Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts
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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
SPRING MAKING 8
SAWING MACHINERY 8
REPETITION TURNED PARTS 8
Sutton Road, St. Helens Merseyside WA9 3DJ Tel: 01744 22567 www.wealdpark.co.uk
You Y ou o dream it it,, make it.. we mak e it
Simpson Springs & Pressings Ltd Precision manufacturers of a wide range of compression tension and torsion springs. Also circlips, wireforms, contacts, antennas and light pressings. Quality approved to BS EN ISO 9001:2000. Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk
WATERJET CUTTING 8
Wealdpark Ltd CNC mill-turn facility using Star sliding head lathes with bar capacity up to 32mm diameter. Miyano and Doosan fixed head lathes with bar capacity up to 65mm. Hurco vertical machining centre.
SUBCONTRACT CNC TURNING 8
PRECISION ENGINEERING 8
Engineering Capacity | DIRECTORY
ICEE Comprehensive fabrication facilities offering complete turnkey solution. Design, Precision Engineering, Sheet Metal Fabrication and Welding. Prototypes, one off or batch work. Waterjet Capacity: 4m x 2.25m & dash; materials up to 230mm depth. Aluminium Alloy Specialists. 20 Arnside Road, Waterlooville, Hampshire PO7 7UP Tel: 023 9223 0604 www.icee.co.uk
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Aerospace
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Security
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Automotive
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Medical
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Pneumatics
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Oil & Gas
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Motorsport
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Hydraulics
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Valves
You dream it, we make it.
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Subcontract Precision Turned Parts CNC Machined Components UK and Worldwide Delivery Design & Engineering Support Service Surface Treatment & Parts Assembly Aerospace Accredited