Engineering Capacity November 2018

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

November 2018

INDUSTRY NEWS | FORMING & FABRICATION | 5-AXIS | AEROSPACE

TESTING: Nadcap for composites

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Southern Manufacturing Show Exclusive Offer FOR MANUFACTURERS ABOUT SUBCONTRACTORS

July 2018

INDUSTRY NEWS | FORMING & FABRICATION | COMPOSITES | CASTINGS

COMPOSITES: Metal composites for landing gear

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DIGITAL | SOCIAL | PRINT Let us help you maximise your presence at Southern Manufacturing by putting you in front of your target customers ahead of the Show and during the show.

Engineering Capacity is the UK’s only magazine targeted solely at buyers of subcontract manufacturing services.

Before the show we will be publishing an extensive preview in our January issue – both in print and digital editions – and new for 2019 – we are sending an exclusive digital preview to our 10,000 newsletter subscribers. Being a part of this will help you ensure that visitors of the show pre plan to come and see you at your stand. We will also use our extensive social media reach to promote you before the show.

As an Official Media Partner of Southern Manufacturing 2019 we will also be distributing copies of the magazine to visitors as the come in to the Show. This will allow you to increase your profile at the show and drive more relevant visitors to your stand helping you to sell more at the show.

To help you be a part of this exceptional promotional opportunity we have put together some special packages combining print, digital and social media to make sure your message reaches the biggest possible audience of potential customers.

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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 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 JANUARY 2019 ISSUE Machined Components, Laser & Waterjet Cutting, Casting & Forging, Heavy Engineering, Additive Manufacturing, Southern Manufacturing & Electronics Preview, Electronics Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website

Member of the Engineering Industries Association

Editor’s View You might have missed it, there has been a lot of news around recently, but I think this a great story. One of the world’s leading rolled aluminium manufacturers has signed a deal with a small UK technology company. Novelis is a $11bn company with a 50% market share in the supply of aluminium sheet to the global automotive industry.

Impression Technologies is a small UK company based in Coventry that was set up to industrialise a new process, Hot Form Quenching (HFC), which allows ultra-high-strength aluminium to be formed into complex parts. This in turn means cars can be made from fewer parts, while saving weight, cost and tooling investment.

Under the deal, Novelis will explore innovative new ways to encourage the take-up of the process by the world’s car makers.

Don’t make the mistake of thinking that this is a one-off. There has been a stream of stories this year demonstrating the international appetite for UK research and innovation in metals technology.

Another aluminium giant, with a €5.2 billion turnover, Constellium, is a major partner, along with JLR and others, in the Advanced Metal Processing Centre at Brunel University. This will, according to the University, “accelerate automotive light-weighting through the deployment of world-leading, high-performance aluminium alloys and innovative technologies”.

And there’s more. A £6bn Chinese steel company, NISCO, has put millions of pounds into a UK research centre at the University of Leicester.

It will develop new metallic materials and next-generation manufacturing methods.

According to the head of the centre, Prof Hong Dong, it will deliver funded, high-quality, high-impact collaborative research.

He said: “We aim to achieve world-leading status in the area of metallic materials and advanced manufacturing.”

So don’t worry if things don’t look too bright at the moment – we’ve got the future covered.

Andy Sandford, Editor

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

Tel: +44 (0)23 9267 7747

NOVEMBER 2018

Email: info@dkwengineering.co.uk

1969 - 2014

45 years

www.dkwengineering.co.uk

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Contents November 2018

20 AEROSPACE

News

Features

06 BG investors look to the future 06 New machines will help

13 Turned Parts 06 Solving puzzle productivity Tighter control enhances service Automotive seal of approval

train apprentices

17 Aerospace & Defence 06 Information investment

08 Bigger Southern show will sell out 06 Permanent venue prompts surge in bookings

for aerospace Robot wing assembly jig

17 AEROSPACE

09 Business secretary gets inside story 06 Greg Clark calls on A & M EDM

24 Forming & Fabrication 06 Bumper Bentley contract Third factory for spring-maker Lean fabrication cell Metrology uncoils customer benefits

09 UV laser is up to the mark 06 New marking possibilities on plastics

29 Composites 06 Recycling for composites

10 Gold apprentice award 06 G & W recognised in international automotive awards

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21 Five-axis machining 06 Five-axis UK first

26 FORMING & FABRICATION

30 Measurement and Testing 06 Nadcap for composites testing Multi-sensor measurement NOVEMBER 2018

Engineering Capacity | INDUSTRY NEWS APT Leicester has invested £300k in new machine tools and inspection equipment in order to increase productivity.

At the beginning of October, APT Leicester took delivery of two new high precision lathes, a stateof-the-art image dimension measurement system and a highspeed chamfer machine.

This is all part of APT’s continuous investment programme throughout its manufacturing process – machining, finishing and ongoing inspection. By replacing older models APT is increasing its capacity and efficiency for the benefit of their customers.

The two new multi-axis lathes are made by Doosan and supplied and commissioned by Mills CNC. Both the Puma TT1800SY and the Lynx 220LSTC offer high productivity and rapid accuracy, increasing APT’s turning capabilities. The new Keyence IM-7030T Instant Measurement

£300k technology investment

System has an expanded stage and is able measure up to 99 dimensions and more awkward shapes in seconds. The J&S Engineering STC250S chamfer machine will cut the cycle time to 20 seconds per operation.

Backed by on-site extensive operator training, the company says these new additions will keep APT Leicester at the

Web shop for auto standards Industry Forum has launched an online shop giving easy access to English language versions of all automotive standards in one place.

Industry Forum was set up by the UK government, the SMMT Society of Motor Manufacturers and Traders (SMMT) and vehicle manufacturers to improve the competitiveness of the UK’s automotive supply chain.

The shop stocks all the published standards from the

NOVEMBER 2018

International Automotive Task Force (IATF), the German Association of the Automotive Industry (VDA) and the US-based Automotive Industry Action Group (AIAG), as well as a selection of their publications that have been hand-picked to support training and professional development – all at highly competitive prices. Industry Forum is one of only two organisations in the UK to sell AIAG publications and the only one to offer all three industry bodies' publications.

forefront of UK manufacturing.

Nick Baller, Managing Director said: "We have seen a trend through enquiries for larger diameter work. Customers sending a package of work like to keep it with the same supplier.

We can now offer up to 65mm from bar and for the first time 300mm billet work".

8 aptleicester.co.uk Dr Chris Owen, chief executive of SMMT Industry Forum, said, "Our aim is to improve the performance of automotive manufacturers, and extended learning is crucial to that.

That's why we've decided to grow our offering by making these valuable publications available and affordable via an easy to use web shop. We also support our delegates to apply the learning and theory within their organisations on an ongoing basis."

8 shop.industryforum.co.uk

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INDUSTRY NEWS | Engineering Capacity

BG investors look to the future With an investor taking a strategic stake in its business, BG Engineering is looking to the future with the purchase of XYZ machine tools to train its apprentices.

Investing in the future of its business in terms of skills and capacity, as well as expanding organically and through acquisition, are at the forefront of BG Engineering’s plans. This process has been accelerated following an investment in a strategic stake in the business by Cooper Brown Enterprises Limited in 2017.

Acquisitions include the recent purchase of Sheffield-based Pentag Gears and Oilfield Equipment, which has relocated to BG Engineering’s Chesterfield facility, while organic growth will focus on diversifying from existing markets of energy, process control, rail, automotive, defence, and specifically into the aerospace sector. Here, BG Engineering is well on the journey to AS9100 accreditation, with a planned audit date of September 2018 to add to its existing Lloyds ISO 9001:2015 certification. To deliver on these plans the company is actively recruiting apprentices and has just invested £75,000 with XYZ Machine Tools to create a machining cell for use by apprentices to hone their machining skills.

“Training for the future of BG Engineering is very important to us, we firmly believe in growing and nurturing our own talent 6

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Training for the future of BG Engineering is very important to us, we firmly believe in growing and nurturing our own talent through apprenticeships.

We currently have four apprentices at different stages of training

‘‘

through apprenticeships. We currently have four apprentices at different stages of training, Sam H who is in his final year and is working in a production management role, James who is moving on to start his HNC in September, Sam S who has just completing his HNC and is working towards a production engineering role and Dylan who is focused on machining, and the XYZ cell was

purchased with him and those that follow in mind. We have also recruited three more apprentices to start in September by which time apprentices will make up 20% of our team. These are exciting times around Chesterfield and Sheffield with developments such as AMRC, Boeing and McLaren all happening, this brings with it lots of investment in the greater manufacturing community, and we want to play our part. In addition to our own apprentices, we are also involved with Work-Wise.co.uk and Getuptospeed.org.uk, two charities that are actively involved in inspiring young people to choose a career in engineering and manufacturing,” says Chris Brown, Director, Cooper Brown Enterprises.

The apprentice machine cell at NOVEMBER 2018

Engineering Capacity | INDUSTRY NEWS BG Engineering comprises an XYZ SMX 5000 ProtoTRAK Bed Mill, and an XYZ SLX 355 ProTURN lathe. Both machines are controlled by XYZ’s ProtoTRAK control system whose simple to program capability makes apprentice training and the machining of one-off and small batch parts straightforward.

Apprentices at BG Engineering are trained under the guidance of the company’s senior engineers and technical engineers, as well

In addition to our own apprentices, we are also involved with Work-Wise.co.uk and Getuptospeed.org.uk, two charities that are actively involved in inspiring young people to choose a career in engineering and manufacturing

‘‘

as machining they will experience all aspects of the business, they are encouraged to take their

academic training as far as they can whether this be Level 3 BTEC National Diploma in Mechanical Engineering, HNC or beyond. Their time on the XYZ machines will give them experience of the production environment, as they are entrusted with producing one-offs, small batch quantities and, with the production of jigs and fixtures for the bigger machining centres BG has, for all of which the XYZ machines are ideally suited.

8 bgeng.com

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

CONTACT CONT TAC CT US TODAY TODAY FOR A QUOTE QUOTE

NOVEMBER 2018

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INDUSTRY NEWS | Engineering Capacity

Bigger Southern show will sell out Next year’s Southern Manufacturing show will be bigger than ever after its move to a new venue proved to be a success with both visitors and exhibitors and is expected to be a sell-out.

The event, the UK’s largest annual engineering show, returns to Farnborough from February 5th to 7th 2019. The move to a new permanent venue has prompted a surge in stand bookings for the 2019 show. The organisers are forecasting a 20% increase in exhibitors for 2019, which will bring the show to its maximum capacity.

Along with a record number of exhibitors expected, the show has formalised links with several influential industry organisations, including Composites UK, the Confederation of British Metalforming, Farnborough Aerospace Consortium, The British Gear Association, Society of Motor Manufacturers and Traders and the Gauge and Toolmakers Association.

The partnerships will enable the roll-out of new show features d

ite

d re cc

ow

and access to authoritative technical expertise via the show’s comprehensive free technical seminar programme, open to all visitors. Some of the new areas to be addressed as part of the 2019 programme include a look at incremental sheet forming processes, automated mould design and large-scale 3D printing.

Engineering Capacity is pleased to be a media partner of Southern Manufacturing. It will be exhibiting on stand C275 and distributing copies of its show edition at the entrance.

8 industrysouth.co.uk

Brazing Body of Knowledge A new Brazing Body of Knowledge focussing on Furnace Brazing, both Vacuum and non-Vacuum, has been published by the eQualified Brazing sub-team, with approval from the eQualified Management Council.

This new Body of Knowledge contains the aerospace industry’s expectations for a Process

to

D

A

N

FM10101

Manufacturers of High Quality Mill-Turned Parts

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Planner’s knowledge and experience of Furnace Brazing.

The document includes topics such as brazing procedure qualification and specification, vacuum equipment and process requirements, and atmosphere (non-vacuum) equipment and process requirements.

Based on a template issued by the International Aerospace Quality Group, eQualified Bodies of Knowledge are unique documents that capture the knowledge and skills required by personnel operating in specific special process areas. They are available to download free of charge on the Performance Review Institute website and provide all relevant information needed to prepare for any corresponding assessments.

8 p-r-i.org NOVEMBER 2018

Engineering Capacity | INDUSTRY NEWS Greg Clark, Secretary of State for Business, Energy and Industrial Strategy visited precision engineers A&M EDM in Smethwick, West Midlands to understand what drives growth and the issues facing a manufacturing SME. The Business Secretary met A&M’s current and recent apprentices, speaking to each individual about their motivation to become an apprentice, the work they undertake and the skills they are developing by working with experienced engineers. All of A&M’s apprentices study for academic engineering qualifications at Dudley College.

Mark Wingfield Managing Director of A&M EDM said, “We had an informed discussion with the Business Secretary, Greg Clark on how the Industrial Strategy can accelerate West Midland manufacturing and A&M’s investment to develop our apprentices, skills and machinery as a thriving precision engineering SME.” Greg Clark said, “We’re committed to supporting this innovative region. The Industrial Strategy for the West Midlands

UV laser is up to the mark A successful first year of trading has spurred ES Precision to invest in new ultraviolet (UV) laser technology.

ES now has eight laser systems using Vanadate, Nd:YAG,

NOVEMBER 2018

Business secretary gets inside story

will harness its distinctive strengths to unlock greater growth and earning power across the region’s cities and places.”

A&M showcased engines and components manufactured for aerospace and automotive customers. In addition, Greg Clark saw a new CNC high speed machining centre and handheld alloy analyser in action.

The Business Secretary discussed the implementation of the Industrial Strategy in practice with senior representatives of the

Black Country Chamber of Commerce, Black Country LEP, Dudley College and EEF, the body for UK manufacturers.

A&M has grown from a two-man start-up in 2002 to 67 staff and record sales over £6m in 2018. This has been achieved using electronic discharge machines (EDM) and CNC machining to design and manufacture precision components and tooling for prototypes and production runs for a range of UK and international customers.

8 amedm.co.uk

fibre and CO2 sources as well as the new frequency-tripled Vanadate UV source from Coherent-Rofin UK. The company aims to be at the forefront of laser marking and fine drilling/cutting and says that no other subcontract marking specialist offers such a broad range of laser technologies.

The UV laser in particular

opens up opportunities that conventional lasers miss as the shorter wavelength is absorbed extremely well by plastics, organics and many ceramics.

ES is happy to produce samples to find the best solution for customers that need permanently marked parts.’

8 esprecision.co.uk

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INDUSTRY NEWS | Engineering Capacity Machined castings specialist Grainger & Worrall has been recognised for its commitment to the engineers of the future with a prestigious, international automotive sector award.

The company held off strong competition to take the Apprenticeship Programme category at the Automotive Global Awards at a gala ceremony at London’s Savoy Hotel.

The Apprenticeship Programme award recognises the company which has implemented the most comprehensive, exciting and beneficial apprenticeship programme. It encompasses both the apprentices and those who train them and support their development.

Having taken on apprentices throughout its 72-year history, Grainger & Worrall is at the forefront of apprentice

Gold apprentice award

development both locally and in the automotive sector. The company led a consortium of likeminded business in raising £4.5m of funding, culminating in the launch of the world-class Marches Centre of Manufacturing & Technology last year, where the initial group of technical apprentices are completing their first year of training. Grainger & Worrall has also taken on Adult Apprentices since 2014, and

overall continues to employ up to 10 new apprentices each year.

Many former apprentices now hold senior roles within the company, including one of its directors.

First taking place in 2012, the Automotive Global Awards celebrate excellence across all parts of the automotive logistics, purchasing and supply chain sector.

Grainger & Worrall join a highly prestigious list of winners who over the last seven years have included Jaguar Land Rover, TNT and Kia. Grainger & Worrall’s innovative approach and commitment to excellence have established the company as a key strategic partner to leading players in the global automotive, motorsport, and wider engineering sectors.

8 gwcast.com

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Trade Leads from the EIA

PEOPLE | Engineering Capacity

The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk Romania – Engineering Services A Romanian engineering company, offering numerous engineering services and finite element analyses, seeks partners for a commercial agency agreement.

Reference: JV1235 Closing Date: 30/04/2019 Turkey – Plastic Parts A Turkish manufacturer of plastic parts for the automotive industry is looking for commercial agencies.

Reference: JV1236 Closing Date: 30/04/2019 Israel – Oil valves A leading corporation has issued a tender for valves to be used in the oil industry.

Reference: 32115 Closing Date: 10/12/2018

Judson Smythe has joined the board of directors at Lancashire-based moulding specialist MGS Technical Plastics as Technical Director.

He is a time served Tool and Die maker, and read Industrial Engineering at Durban University of Technology.

Dame Jane Jiang has been selected a strategic advisor to Engineering and Physical Sciences Research Council for the development and implementation of its plans. She is Professor of Precision Metrology at the University of Huddersfield’s Centre for Precision Technologies.

David Sutcliffe has been appointed as the new Sector Head for Automotive for Siemens Digital Factory in the UK. He will be responsible for the development and implementation of the business strategy for growth in the automotive market.

Colin Smith CBE former Rolls-Royce plc group President, joins directors at Sheffield Forgemasters International Ltd as non-executive chairman, completing a new executive team. He joins new CEO David Bond who took over from Dr Graham Honeyman.

Cuba - Wires and fibres An opportunity to export wires, fibres and filaments for hygiene tools manufacturing.

Reference: 32116 Closing Date: 05/01/2019 India - Steel braided hoses An auto components manufacturer is looking for a UK supplier of steel braided hoses for its shocker and brakes systems.

Reference: 32235 Closing Date: 31/12/2018 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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NOVEMBER 2018

Engineering Capacity | TURNED PARTS Dawson Precision Components (DPC) is supplying British engineered parts for thousands of 3-D revolving Revomaze metal puzzles.

The Greater Manchester engineering firm is manufacturing components for Revomaze developer Ashton Pitt Ltd, based in Cumbria, which sells the cylindrical mazes globally.

Players need dexterity, memory, endurance and self-control to unlock the metal puzzles. They have to avoid traps and stick closely to tiny walls and bridges to find their way out.

Oldham-based DPC has so far supplied 5,000 mazes plus other precision-engineered parts including aluminium sleeves and stainless-steel drawbars and pins.

The first Revomaze puzzles went on sale in 2009. Since then, the range has expanded to 18 designs, each offering increasinglycomplicated challenges.

Simon Dawson, managing director of DPC, said: “The Revomaze concept is a top-of-therange maze or executive toy comprising brass nickel-plated bodies, stainless steel pins and draw bars, and aluminium outer sleeves. Our client, Ashton Pitt, wanted a highly-reliable precision engineer to manufacture the parts while they focus on promotional work and designing new puzzles.

“DPC first made parts for the beginner level blue-coloured maze. There are currently eight different versions in production with more planned.

“The mazes have very complex designs, with square and circular NOVEMBER 2018

Solving puzzle productivity moves, different paths and depths.

For example, the indigo-coloured game has seven depths. Precisionengineered parts include ramps leading from one level to another, sliders, pins and bridges. Some mazes include magnets.

“Machining the parts requires very complicated G-code programming for our equipment, which can take two days to complete. The client provides the designs for each maze then DPC works hand-in-hand with them to develop their designs into machinable parts.

“DPC uses a top-of-the-range Citizen M32 machine for the main maze bodies and a Mazak turn/mill centre for aluminium sleeves.

Other Citizen machines are used to manufacture other parts.

“In addition, DPC’s product inspection and process control services are also critical. There are 21 aspects that we check thoroughly.

“The finish of the mazes is also crucial. The brass raised body is

nickel-plated to a bright, durable finish. The outer sleeves are diamond-turned to get a beautiful finish, then colour anodised to match the particular maze design it is to be mated with.”

Chris Pitt of Ashton Pitt said: “We looked carefully for a production manufacturer who has the same passion about quality that we, and all our worldwide clients require for a premium product. We have enjoyed a very successful relationship with DPC due to the meticulous attention to detail by Simon and all the staff.

Our success to compete worldwide relies on the very high quality of the machining and the sub-contractors to provide the best finish to allow us to grow year-on-year.”

8 dpc.co.uk

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TURNED PARTS | Engineering Capacity

Tighter control enhances service Rodmatic’s new PSL Datatrack production control system gives it tighter control over production, improved quotation times for customers and the ability to meet their order requirements more quickly and effectively.

In 2017 Rodmatic Limited, the Reading based precision machining subcontract company, decided to invest in a new production control system that would give them much more effective management of their business. An existing system was being replaced and the new one needed to be up and running as quickly as possible with a smooth transition phase so that day-today business would not be compromised in any way. Already familiar with PSL Datatrack through both companies' membership of the British Turned Parts Manufacturers Association (BTMA), Rodmatic selected the company to supply their modular software package as the replacement. One year later, that decision has helped the business make all round improvements to its production processes and customer service.

Due to the expiry of the licence for the existing system and the fact that it was beginning to slow down and corrupt, Rodmatic needed a 14

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quick response from PSL Datatrack. In addition, the company also had to use a number of external databases alongside their old system in order to achieve the desired levels of control resulting in much more manual inputting of data. A more versatile and all-embracing system was therefore another requirement.

As a company, Rodmatic has always looked at new ways to improve the way it works and after reviewing its processes and listening to customer feedback, came to the conclusion that a new system would also benefit its business at every stage of the production process.

“We wanted a solution from a supplier that had a better understanding of the needs of our subcontract engineering business.

As a BTMA Technical Member, we knew that PSL Datatrack had expertise, a good track record in our sector and there were also the advantages of the flexibility and customisation opportunities

possible with their software,” says Martin Wilson, General Manager at Rodmatic.

From the date of the order confirmation, PSL Datatrack started to acquire a firm understanding of Rodmatic's production control requirements.

“Once these were understood, PSL Datatrack were able us to give us the benefits of their considerable experience in the subcontract engineering sector and indeed recommend improvements to our existing processes that would benefit not only us but also our customers,” says Martin.

From investing in the system to going live took just three months.

During this period, PSL Datatrack provided assistance for a parallel run of both systems to ensure a smooth transition. Concise targeted training for the Rodmatic team also took place during this phase so that each member understood how the changeover would work. Ongoing technical NOVEMBER 2018

Engineering Capacity | TURNED PARTS support was provided as new challenges arose as a result of the change in software. “The PSL Datatrack team were incredibly helpful during this whole period,� says Martin.

Some twelve months down the line, Rodmatic can now assess how the change to PSL Datatrack has assisted their successful specialist CNC and volume production machining business.

The company provides components to a range of

customers from many different market sectors using materials as diverse as steel, alloy steel, stainless steel, brass, aluminium, titanium, nylon and plastics.

Achieving consistent quality in both production and service within Kanban and Just-In-Time customer requirements as well as vendor-managed contracts is essential for Rodmatic. “PSL Datatrack's approach to running the business along a logical ‘Quote to Delivery’ way of

thinking has been the most beneficial,� says Martin. It means that by using the software, Rodmatic can fully trace the progress of any order for any customer and has much tighter control over the whole production process.

The company also has much better visibility and traceability of its production performance thanks to PSL Datatrack's Works Order reporting functions.

8 psldatatrack.com rodmatic.com

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NOVEMBER 2018

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TURNED PARTS | Engineering Capacity

Automotive seal of approval Neida Products (Engineering) Ltd has achieved the new IATF16949:2016 automotive accreditation.

Neida is a contract manufacturer of precision turned and milled components employing 106 people at its two manufacturing facilities and dedicated warehouse.

The International Automotive Task Force 16949:2016 (IATF16949:2016) accreditation at its Isle of Wight manufacturing base is a newly revised accreditation that will cancel and replace the current TS16949 certification, which the IOW plant has held since 2004.

Simon Fisher, general manager of the site, said “We are pleased to announce that we have been approved for registration to the new IATF standard. The goal for IATF16949:2016 is to emphasize defect prevention, provide

Visit our website or contact us for a quote or advice

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continuous improvement and reduce waste and disparity in the supply chain.

“Our transition gap analysis and the amendments to the procedures manual was highly praised by the auditor and has made our processes much more efficient. I would like to thank everyone for their support and hard work in achieving his registration, in particularly our quality department whose work to bring the procedures and systems into line with the new standard have not gone unnoticed.”

The transition to IATF has coincided with a recent

£2,000,000 of investment in new technology, which Neida believes will help to further boost its increasing business with the automotive sector.

Neida has also recently renewed the quality management system at its head office in Stoke-on-Trent which, as of April this year, now conforms to ISO9001:2015.

David Brown, Commercial Director of Neida, said "The new IATF standard provides guidance for companies who want to ensure that their business and products meet their customers' demands. This combined with our recent re-accreditation to ISO9001:2015 at our Head Office will give our customers confidence that Neida can satisfy their quality requirements, regardless of complexity".

With over 100 machines, Neida produce over 250,000,000 components per year from 0.3mm-250mm diameter in ferrous, non-ferrous and exotic materials, in batches from 10-offs to millions.

8 neida.co.uk NOVEMBER 2018

Engineering Capacity | AEROSPACE & DEFENCE

Information investment for aerospace Thomas Brown Engineering has invested in CNC communication and program management software to support competitiveness and growth in the aerospace market.

The software, developed and installed by industry leading Cambridge Numerical Control, incorporates a real-time, machine tool data collection system. This system provides real-time information direct to production control about shop floor productivity and allows for informed decisions to be made regarding production schedules and delivery information to customers. The analysis capabilities of the software mean that production bottlenecks can be easily identified, downtime can be analysed and machine maintenance can be effectively scheduled.

The CNC Program Management side of the software also aids the CNC programmers and operators on the shop floor. The integrated management, search and editing environment allows the production team to work Causeway Aero Group, a full design, build and supply chain management company, has acquired Belfast Aircraft Stress Engineers Ltd (BASE).

This is its first acquisition and the company will also move to new premises in Lisburn.

Altogether this represents a seven-figure investment.

The company aims to be a ‘one-stop-shop’ of manufacturing

NOVEMBER 2018

effectively, reducing hold ups and inefficiencies on the shop floor.

The Crosland Moor based company secured part funding for the project from Digital Enterprise, an innovative business support programme, which is providing funding and digital knowledge support for Leeds City region businesses who are looking to invest in digital technology in order to grow and secure high-quality jobs for the future.

Managing Director Tom Brown said of the project: “This investment in software will help us to compete in the complex and

competitive global aerospace market. It complements the large investment we have made in recent years in state-of-the-art CNC machine tools. We recognise that data collection followed by analysis and action, coupled with effective CNC program management procedures will enable us to maximise on our investment in manufacturing equipment. This in turn contributes to us delivering on our mission to consistently deliver an exceptional precision machining service to our customers.”

8 thomas-brownengineering.co.uk

Another link in the supply chain and technical solutions combining quality management, procurement, subcontract and assembly capabilities. It primarily operates in the aerospace and mass transit sectors.

BASE’s 16-man design, stress and technical team has over 18 years of experience working on programmes for customers such

as Bombardier, GKN, BAE Systems, Thales, Marshalls and Thompsons.

Operating from Lisburn, Causeway Aero is an AS9100 accredited provider of design, build, procurement, sub-contract manufacture and assembly solutions.

8 www.causeway.aero

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AEROSPACE & DEFENCE | Engineering Capacity AIM Engineering has partnered with robot suppliers to design and develop a new generation wing assembly jig for NEO (new engine option) converted Airbus aircraft.

The jig, which can be used in a simple standard assembly jig or a fully robotic solution, meets the new rate increase for NEO converted aircraft and comes with a host of benefits.

The jig structures have been designed to take all the robotic drilling and fastening loads, the staging element of the jig is a fully automated/interlocked system with a high level of safety interfaces/equipment applied.

They also ensure that expansion and contraction compared to the component is no longer an issue, and come with an inbuilt jig crane to remove the constant need for the overhead systems.

The robot is independent to

Robot wing assembly jig

the jig structure and manipulated on a simple trolley, guided via cam rollers which run around on a track.

AIM Engineering, a division of Arlington Industries Group, carried out all civils works, electrical/PLC systems installation and full manufacture of the jig structures including welding, turning and milling assembly.

Demand taking off for NEMA North West aerospace supplier NEMA is targeting further growth after securing £2.3m sales and investing in a new CNC turning centre.

NEMA Ltd, which manufacturers motors, actuators and electromechanical assemblies for UTC Aerospace, BAE Systems and Airbus, has installed a Hardinge GS200 from ETG at its factory in Chichester Street in Rochdale.

“The last twelve months have seen us deliver a number of complex and demanding projects for the aerospace sector and that has placed a lot of pressure on our 20

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machining capabilities,” explained Andrew Wilding, Managing Director of NEMA. “This resulted in a spindle bearing failure on an existing machine. It wasn’t practical for us to try to repair it, so we instead

Mark Franckel, Arlington Industries Group CEO, said: "The design, development and manufacture of our new generation wing assembly jig is something in which we take great pride. We’re pleased to meet the new rate increase for NEO converted aircraft, and helping our customers achieve greater success.”

8 arlingtonindustriesgroup.com took the longer-term approach of replacing it with a new machine.

“ETG was quickly briefed and its response time was excellent, coming back to me with an option that we were happy to invest in.

This was quickly specified, delivery agreed and a training plan put place so that we didn’t lose any production time on our motor housings and end plates.

“Our ability to get involved in early stage design is helping us secure a lot of new orders, boosting our turnover to £2.3m and necessitating the need for five more people – taking our workforce to 40.”

8 nema.ltd.uk NOVEMBER 2018

Engineering Capacity | FIVE-AXIS MACHINING Norjon Precision Engineering has installed a 5-axis Makino machining centre designed with automation in mind as part of a turnkey package.

The high-speed DA300 vertical machining centre is the first of its kind in the UK and was supplied by sole agent NCMT complete with an Erowa storage and handling system for 24 pallets.

It is the subcontractor's ninth trunnion-type, 5-axis machine. It is intended primarily for highly productive milling and drilling of aluminium components but is equally capable of machining stainless steel for long periods.

We only buy high quality machines, which we have always needed as most of our customers demand a high-quality finish

‘‘

Kevin Fox, Norjon's managing director said, "We only buy high quality machines, which we have always needed as most of our customers demand a high-quality finish. Makino has a reputation for being at the top end of machine tool suppliers in terms of accuracy and reliability and this particular model is very fast, with 60 m/min rapids and 20,000 rpm spindle.

He went on to explain that the DA300 is built with automation in mind as it is prepared with pneumatic ports in the table, so interfacing the Erowa Robot Compact 80 was seamless. It provides quick, efficient component exchange, maximising machine utilisation.

NOVEMBER 2018

Five-axis UK first

If production work is involved, Norjon would in future not consider installing a machine tool that does not have automation, as in Mr Fox's opinion it is essential to achieve the required output.

Without it, and the extra 60 hours unmanned production every weekend, the subcontractor would not be able to keep pace with customer requirements.

The alternative would be to install additional machine tools, which would be added expense and in any case there is little spare room on the shop floor.

Moreover, as operators are free to attend to other jobs, automated pallet handling is important for minimising the labour cost content of component production.

A typical example is on a family of aluminium prismatic components.

Mr Fox explained; "We set the job up initially on a Friday evening and inspected the first-off component. The cell ran continuously over the weekend and the following Monday we measured the first component produced that morning. The dimensions were exactly the same, so the accuracy we are achieving in the cell is excellent."

8 norjon.co.uk

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FIVE-AXIS MACHINING | Engineering Capacity Boyce Precision Engineering, which primarily serves the commercial aerospace sector, has moved into 5-axis machining in response to the increasing complexity of the parts it is producing.

A majority of throughput at the Northern Ireland subcontractor involves producing aluminium parts for first-class and businessclass seating, plus various aluminium structural components.

Aerospace recognitions include AS9100 accreditation (the global quality management system for the aerospace industry), as well as supply chain recognition SC21 (Bronze Award) and ADS Group membership.

The contract machinists started operations in 2006 and in little more than a decade have made significant strides, the company now employing 34 staff. Earlier this year, Democratic Unionist Party MLA (Member of the Legislative Assembly) for the local Upper Bann constituency, Carla Lockhart, hosted a visit to the firm by party leader Arlene Foster and the Chief Executive of Invest Northern Ireland, Alistair Hamilton.

In recent years, there has been an increase in the complexity of the prismatic aerospace parts that Boyce Precision manufactures, making a progression from 3-axis to 5-axis machining necessary.

For the new machining capacity, joint owners and brothers George and Brian Boyce opted for a 600 x 550 x 450 mm capacity, Germanbuilt Hermle C 250, which was supplied in July 2017 by sole UK and Ireland agent, Kingsbury.

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5-axis for more complex parts

Arlene Foster; Carla Lockhart, MLA for Upper Bann; and George Boyce, during a visit earlier this year to Boyce Precision Engineering

The 5-axis machine's suitability was immediately apparent and a second, identical model was installed three months later. The configuration of Hermle vertical machining centres places the three linear axes within a modified gantry above the working area, whilst the integrated trunnion provides a rigid, stable platform for the two rotary axes, which includes a ± 115 degree swivel for considerable production flexibility. The machines in Craigavon have integral Blum tool breakage detection to allow long periods of unattended running across the two shifts that Boyce Precision operates.

A further trend within the aircraft seating sector is towards larger components, which are even more complex, to avoid the labour costs and delays associated with assembly. Once orders for such parts were promised,

Mr Boyce had no hesitation in placing an order for a larger Hermle C 400 with a working volume of 850 x 700 x 500 mm.

It will be delivered in November 2018 directly to a new, 18,000 sq ft factory unit currently being built for the subcontractor in Portadown. Treble the size of the current premises, the building represents a £3 million investment, taking into account the capital cost of the third Hermle 5-axis machine and the imminent purchase of two further 3-axis machining centres.

The benefits of 5-axis machining to Boyce Precision are farreaching. One-third of the time, the two Hermle C 250s are executing programs requiring interpolation of all five CNC axes simultaneously – work which formerly could not have been carried out.

8 boyceprecisionengineering.com NOVEMBER 2018

Engineering Capacity | FIVE-AXIS MACHINING East Sussex based UHV Design has invested in workholding technology that will allow it to give customers the maximum benefit from its 5-axis CNC machining capacity.

One of the company’s key capabilities is the manufacture of components for university and government research laboratories.

“A lot of what we do is bespoke to the application and has to work in an Ultra High Vacuum environment whilst still providing motion and manipulation…typically these components will end up in scientific experiments like CERN’s Large Hadron Collider,” explained David Heward, Machine Shop Manager at UHV Design, part of AIM-listed Judges Scientific.

“We have grown 15% over the last twelve months and the future pipeline was rich with opportunities that necessitated investment in new technology and the purchase of our first 5-axis machine, which we sourced from the Engineering Technology Group (ETG).”

He continued: “The Quaser MF500UH was equipped with a 15k ‘face and taper’ spindle and a 48strong carousel that allows us to store 80% of all our tools in the one machine – ideal for reducing changeover times and reducing secondary operations.

“However, to make the most of it we needed to find the right tooling system.”

The company turned to workholding specialist Hyfore to source a dedicated tooling system.

Working closely together, the two companies identified a £30,000 Acrow package that provides the NOVEMBER 2018

Tooling boosts 5-axis service control, flexibility and speed required to cope with increasing volumes in the machining shop.

The solution focused on interchangeable NR collets that would be used exclusively on this machine and tend to be smaller in diameter, offering greater contact with the components, improved tool life and the ability to move freely around tight clearance spaces.

“Its engineers spent a lot of time at our East Sussex base looking at the components we were planning to machine, before identifying the package that best suited what we were trying to achieve.”

Hyfore, which offers a large selection of bespoke jigs, fixtures, gauges and workholding systems, used its exclusive UK distribution agreement with Acrow to devise a 30-strong tooling system.

This solution was trialled on an existing machine and the results – combined with competitive pricing and excellent lead times – were enough to secure the business from UHV Design.

The core Acrow range comprises specialist NR, HC and CH (milling) tool holders, which have all been designed for high-speed precision manufacturing.

8 hyfore.com

A lot of what we do is bespoke to the application and has to work in an Ultra High Vacuum environment whilst still providing motion and manipulation… typically these components will end up in scientific experiments like CERN’s Large Hadron Collider

‘‘

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23

FORMING & FABRICATION | Engineering Capacity Metal pressings and deep drawn component specialist Frank Dudley Ltd has won a prestigious contract from Bentley.

Frank Dudley Limited (FDL), which is celebrating its 70th anniversary, beat off significant competition to win the contract to supply bumper finishes for the Continental model and has already invested heavily in setting up a dedicated clean room and cell for the job.

This deal, along with significant body and white work for Sertec Group, is the latest in a long line of contract wins that have helped sales rise 20% to £6m over the last twelve months.

“We’ve come a long way since my grandfather Frank started the business in his small shed in Birmingham,” explained current Managing Director Grant Dudley-Toole.

“His approach of ‘getting products, right first time’ is one that we have built our business around and has been crucial in helping us introduce lean manufacturing and world class quality and delivery performance – two important factors in us winning the recent contracts for Bentley and a major earth moving equipment manufacturer.”

He continued: “2018 has been a rollercoaster year with significant growth and lots of investment.

However, it has been slightly tempered by the passing of my mother and company matriarch Jill Dudley-Toole in April, shortly after receiving an MBE for services to manufacturing and the local community.

24

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Bumper Bentley contract

“It was an especially poignant day when we visited Buckingham Palace as a family, with Warren Dudley-Toole collecting her MBE from HRH Prince Charles.”

Established just a few years after the second World War, Frank Dudley initially started life supplying quality washers for automotive businesses.

The qualified toolmaker was armed with only a small supply of hand presses and sons and daughters that would help him after school to transport the products to local platers.

As word spread of its expertise, the company was able to buy more equipment and diversified its product offer into manufacturing parts in kit format and selling them through Quinton Hazell Autoparts.

Unfortunately, Frank died in 1966 at just 53 years of age, but his family were keen to make sure his legacy continued, a decision that has withstood three

recessions, the MG Rover closure and increased volatility in the automotive market.

Elliot Dudley-Toole, Manager at FDL and 4th generation family member, continued: “Today, we operate from a 57,000 sq ft facility in Birmingham and have an array of presses from 30 tonnes to 630 tonnes on both progression and tandem lines.

“We have also invested over £200,000 into a nut insert machine, a new grinder and additional spot-welding capabilities to ensure we can manufacture volumes ranging from 50 components per batch to 15,000 parts per week.

“The recent purchases – combined with recruitment of a Buyer, Project Manager, Tool Maker and four apprentices – will give us the capacity to target £7m of sales by 2019, with a specific focus on growing our export work.”

8 frankdudley.com NOVEMBER 2018

Engineering Capacity | FORMING & FABRICATION European Springs & Pressings has doubled the size of its Cornwall operation with the purchase of a new 2000 square metre site.

The spring manufacturer, with factories in Redruth, Cornwall and Beckenham near London, has multiplied the size of its South West operation to over 4000 square metres with the purchase of new premises in Penryn, Cornwall.

Michael Gibbs, Managing Director of European Springs & Pressings in Cornwall says: “Purchasing the new Penryn based factory is a really exciting new chapter for everyone in European Springs & Pressings and a fantastic achievement in our 70th year. This significant investment allows for continual growth across our industrial

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Third factory for spring-maker and automotive product divisions and affords new opportunities for expansion across the sites in Redruth and Penryn.”

The new site will specialise in the industrial element of the business, supplying springs across multiple sectors ranging from aerospace to rail to the food and drink sector.

Mr Gibbs concludes: “In the last year turnover in Cornwall has increased by 40% and we’ve grown from a team of 43 to over 60. Five

years ago we relocated to a larger site in Redruth from Indian Queens - we then extended that factory to meet demand, and have been rapidly outgrowing our current premises ever since. This year we’ve invested over £3m in new infrastructure, machinery and technologies, which is a strong indicator of the strength of manufacturing in the region and we’re delighted to be further investing in, and supporting, the South West’s £14bn manufacturing industry.”

Over 20 staff will be based at the new site which is planned to be fully operational from Q4 2018.

8 europeansprings.com

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25

FORMING & FABRICATION | Engineering Capacity In the specification of springs and other wire components, secondary processes and finishes can be an important consideration, says wire and strip forming specialist William Hughes Ltd. They can help the design engineer to address environmental considerations or meet the needs of aesthetics in high value applications. These secondary processes can tailor the properties of the component to its application.

Plastic coating gives an aesthetically pleasing finish, with a coating up to 0.5mm thick. As well as looking good, the coating can be useful in applications where it is advantageous to have some cushioning between metal components. A good example might be a component inside a car, where you would like to avoid direct metal-on-metal contact.

It is important to note, however, that typical plastic coatings such as Nylon PA11 or PA12 are hydroscopic, so they suck in water.

Further, the thickness of the plastic coating could interfere with the functioning of the spring.

An alternative to plastic coating is to paint the component, with electrophoretic painting and delta-tone finishing being two popular options. Electrophoretic painting is a very thin coating that can provide an aesthetically pleasing product finish.

William Hughes employs a KTL-black electrophoretic process to deposit a shiny black, coating just a few microns thick on the spring – thin enough not to interfere with the functionality of 26

www.engineeringcapacity.com

Adding the finishing touch

the part. The coating can provide outside protection for up to 800 salt spray hours – enough to meet even some quite challenging environmental requirements.

William Hughes can offer Delta-Tone finishing in a number of different colours, including red, green, blue, silver and black. Not only does this meet aesthetic requirements, it also enables components to be colour coded for easy identification in different applications.

‘‘

High levels of corrosion resistance can also be provided by Delta-Tone® finishing. This organic paint process is particularly suitable for wire components because of its flexible finish. It also has a low curing temperature, so there is no risk of changing the properties of the spring.

William Hughes can offer

Delta-Tone finishing in a number of different colours, including red, green, blue, silver and black. Not only does this meet aesthetic requirements, it also enables components to be colour coded for easy identification in different applications.

Another useful process is passivation. Primarily a cleaning process, it is typically applied to stainless steel components to remove any particles that might remain on the component after machining or grinding, thus preserving the corrosion resistance of the part. Such is the quality of William Hughes’ passivation process that the company has been awarded Nadcap accreditation for the supply of parts to the aerospace industry.

With the availability of a full range of secondary finishing and painting processes, William Hughes is well placed to advise on the most suitable finish for a specific spring application.

8 wmhughes.co.uk NOVEMBER 2018

Engineering Capacity | FORMING & FABRICATION A lean laser cutting and bending cell at Stevens & Carlotti is helping the Sandwich-based metal fabrication company cope with a major increase in business.

The company produces metal fabrications for customers in the UK and continental Europe. A jump in turnover of 25% in 2017 compared with the previous year looks set to be followed by a further 50% increase in 2018, which has unsurprisingly caused some production and logistical issues. The situation has resulted in an increase in headcount from 70 to 100 staff in the last 18 months as well as a ÂŁ1.5 million investment in new machinery since September 2017.

Part of this sum was allocated for the purchase in October 2017 of a Bystronic fibre laser cutting machine of 3 metre by 1.5 metre sheet capacity, together with two press brakes from the same Swiss manufacturer. The three machines are installed in one unit, forming a lean production cell on the Sandwich site for processing mild steel and aluminium from 1 mm to 25 mm thick and stainless steel up to 15 mm.

Managing director Marco Carlotti commented, "Orders have flooded in recently across the board for batch sizes ranging from one-off to several thousand.

"They are being placed by existing and new customers, from powergen and pumps to street furniture and road sweepers to electronics, filtration and building.

Our success is partly because we offer a complete subcontract solution including cutting, NOVEMBER 2018

Lean fabrication cell bending, machining, welding, assembly and painting.

"Several cutting methods are in use here, each of which has specific advantages that give our customers best value for money.

Laser cutting is the lead technology, however, and we have been using CO2-powered equipment for nearly 20 years.

"Due to the current higher level of business, we decided to replace one of our two second-generation 4kW CO2 machines with a Bystronic ByStar Fiber 3015 fitted with a 6kW power source and a ByTrans Extended automated sheet loading and unloading system.

"The benefits have been astounding. On thinner sheets, say around 5 mm, the machine is four to five times faster, accuracy of cut is better and it is possible to produce finer detail than on a CO2 machine. Fibre laser cutting is also not so expensive to run, as it consumes less electricity, does not need any laser assist gases and maintenance costs are lower."

The ByTrans handling system stores up to six tonnes of material, enough for typically a couple of hours' lights-out production at the

end of a day shift, yet it allows convenient manual intervention at a moment's notice to fulfil a rush job if necessary.

An extra piece of Bystronic software that is about to be harnessed at the Sandwich facility is Plant Manager, which will provide visual support to the machine operator when planning which materials to stock near the machine for the next jobs and when unloading cut parts. All components belonging to a particular customer order can be colour-coded on the cutting plan so that they are distinguishable from parts associated with other orders. Moreover, the first and last cut part can be labelled so that the operator knows when an order begins and when it is completed.

Mr Carlotti concluded: "Overall, the efficiency and accuracy of fibre laser cutting are allowing us to deliver competitively priced goods in a highly competitive industry, without having to compromise on quality or service. It is also helping to mitigate today's higher material costs, so we do not have to eat into our margins too much."

8 stevens-and-carlotti.co.uk www.engineeringcapacity.com

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FORMING & FABRICATION | Engineering Capacity An investment in advanced multisensor metrology is giving Adwin Spring’s customers more accurate parts more quickly.

Adwin Spring Co produces prototypes in both wire and flat materials, catering for a diverse client base - including some of the world’s largest companies - in both short-batch and largevolume productions.

However, when it found that traditional part-measurement methods were no longer fully satisfying the speed or accuracy needs of its growing customer base, it turned Derbyshire-based OGP UK to help address the challenge.

Part of the Carfulan Group, OGP UK’s range of advanced optical and multi-sensor SmartScope systems can gauge the characteristics of even the most complex parts quickly and without human error, leading to better quality, reduced scrap and increased throughput.

Will Hayes, Quality Manager at West Bromwich-based Adwin, said: “Before we purchased the OGP we used traditional measuring methods of Vernier calipers, micrometers and shadowgraphs.

“With a lot of those methods you can get different people getting different readings that can be quite inaccurate.

“We were looking for an alternative method because our customers were demanding more accurate results as well as different types of reports and feature sets to what we were traditionally using, as well as 3D measurements.

28

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Metrology uncoils customer benefits

“So we looked into different methods such as laser scanning and other non-contact companies, but found OGP UK to offer the best product.

“We needed a non-contact form of measurement as a traditional CMM would move the springs instead of making a definite assessment.”

Backed by intuitive and simpleto-operate software, the OGP CNC 300 machine purchased by Adwin utilises a high-quality autocalibrating camera and supports a combination of touch probes, micro probes and laser scanners.

It is designed for use on the shop floor and, across a multitude of industry applications, collects detailed data quickly, precisely, reliably and automatically.

Working with more accurate and real-time statistics, from a single reference point, means tighter control of production processes, as any issues can be identified and remedied immediately.

Mr Hayes said: “During the demo stage we realised that the OGP interface was more suited to our business as we produce a large range of parts, so set-up and programme initialisation needed to be much quicker than most other machines because of the vast array of products we’re making.

“We started to see the benefits within the first month. A lot of our parts, as we’re doing process inspection, were programmed up very quickly and then the machine runs the programme in 30 seconds rather than the five minutes it took checking things on a shadowgraph.

“Other than a major improvement on process inspection and the time saved on writing reports and producing firstoff inspections, it’s also drastically improved the quality of the product we send to our customers.

“It’s completely eliminated any sort of inaccuracies.”

8 adwin.co.uk NOVEMBER 2018

Engineering Capacity | COMPOSITES A new process developed by Prodrive enables composites to be re-used several times and negates the need for an autoclave, significantly reducing cost and increasing production capacity The process for manufacturing recyclable composite components can satisfy future end-of-life requirements without any compromise in the performance of the original parts. Called P2T (Primary to Tertiary), the process not only simplifies recycling, but endows a composite material with the potential to fulfil three or more useful lifetimes.

P2T composites do not require heat or pressure during manufacture, which means there is no need for an autoclave, reducing costs and enabling the scaling up of production without major investment. The basis of the process is the use of a reactive thermoplastic resin instead of the more usual thermosetting type; a plastic monomer is reacted with a catalyst in the presence of the fibres to produce a cured laminate. Prodrive believes it is the first to develop this technique, which emerged through a development programme with an automotive OEM customer who required a high-performance structural material with lower environmental impact than conventional composites.

“End-of-life recycling is one of the biggest debates in the composites world today,” explains John McQuilliam, Chief Engineer, Prodrive Composites. “The issue affects automotive manufacturers and wider industries too, such as NOVEMBER 2018

Recycling for composites

marine, where old fibreglass boats are often broken up and sent to landfill. The main barrier to recycling has been the type of resin used; thermosetting resins predominate but these cannot be readily recycled.”

Historically, the composites industry has been based on the supply of rolls of ‘pre-preg’ (woven fibre sheets pre-impregnated with resin) which customers then lay up in moulds to produce 3-D parts, curing through heating to fix the final shape. Thermosetting resins were highly convenient materials to support this supply chain but, as tighter end-of-life regulations are introduced, better alternatives are required.

Composites produced by the P2T process can be recycled multiple times. The highest mechanical properties are obtained during first use of the virgin fibres, enabling highly loaded structural items such as suspension wishbones to be

manufactured. At the part’s end-of-life, the fibres and much of the resin can be recycled by chemical or thermal depolymerisation, supplying the raw material for a secondary part, such as a body panel.

When the secondary part reaches the end of its life, it can be chopped and remoulded into block material with properties suitable for 3-D solid components. This tertiary part can itself be recycled several times until, finally, just the re-melted resin is recovered while the fibres are milled to supply other, lower grade parts.

“This is a really exciting development which finally addresses the recycling challenges faced by composites,” says McQuilliam. “We have developed and refined the process and could bring new customer applications into series production within as little as twelve months.”

8 prodrive.com www.engineeringcapacity.com

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MEASUREMENT & TESTING | Engineering Capacity R-Tech Materials has achieved Nadcap accreditation for the testing of non-metallic materials for the aerospace industry.

The scope of accreditation covers a range of mechanical tests on composite materials and opens the way for R-Tech to offer its testing services to the aerospace sector.

Nadcap accreditation is a requirement for entry into the safety-critical aerospace materials testing market. Nadcap assessors are industry specialists, applying the highest level of professional scrutiny to the test procedures and methods of approved laboratories. At the time of the assessment of R-Tech Materials they commented on the quality of the test procedures saying they were some of the best they had seen.

R-Tech has been accredited by UKAS for testing of polymer and composite materials for many years and has one of the widest scopes of accreditation for these materials of any test laboratory in the UK. The laboratory is already recognised as a leading testing partner in the marine industry.

This accreditation now enables RTech to offer its highly regarded testing services into the aerospace sector.

Supporting its testing services, R-Tech is also able to offer laboratory-based materials investigation services, including reverse engineering, failure analysis, product characterisation and problem solving. R-Tech also has extensive experience of partnering in publicly and 30

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Nadcap for composites testing

privately funded research and development contracts.

R-Tech Materials Managing Director, Dr Tony Franks acknowledges the achievement which the new Nadcap accreditation rewards: “As a business we have invested in the latest testing equipment and software, and our wellqualified and experienced staff have worked hard to develop our testing capabilities to achieve this accreditation. We are delighted that this confirms our position as a significant player in the market for testing composite materials”.

R-Tech Materials Composites Manager, Dr Geraint Havard is enthusiastic about the opportunities that the Nadcap accreditation brings: “The aerospace sector represents some 70% of the

composites testing market. We already have a great reputation with our clients, for customer service and short turnaround times, and we know that we have the technical and commercial base to be a very competitive player. We are already speaking to aerospace clients about their requirements, and expect to see significant growth in the next couple of years”.

R-Tech Materials is a group of materials testing, analysis and consultancy businesses based in Port Talbot, South Wales, consisting of R-TECH Services Ltd, a UKAS and Nadcap accredited materials testing and analysis business, and R-Tech Consultants Ltd, specialists in laboratory-based and plant-based materials investigations.

8 r-techmaterials.com NOVEMBER 2018

Engineering Capacity | MEASUREMENT & TESTING Manchester Metrology recently celebrated its 10th anniversary with an Open Day at its new premises in Ashton-under-Lyne.

The new premises are five times larger than its former site, and to celebrate the event the company hosted a live metrology event attended by leading equipment suppliers Verisurf, Faro, Optimax, Hexagon Metrology, Measurement Solutions, PolyWorks and Aberlink.

Director Paul Bulman said: “It is such a huge honour to be joined by so many leading metrology suppliers at what is for us a great celebration of 10 very exciting years. It is a great testament to the dedication and commitment of our team to be able to host such an event.”

Now employing a total of 13 staff, the company’s client base includes global machine manufacturer JCB, engineering giant Babcock and world water speed record project Quicksilver.

A bigger bang DNV GL has commission the world’s largest industrial explosion testing chamber at Spadeadam Research and Testing.

Located at Spadeadam in Cumbria, the chamber supports not only a joint industry project (JIP) initiative but also an identified need in the market place. DNV GL has just completed five commissioning runs of varying explosion severity.

NOVEMBER 2018

10 years of metrology Manchester Metrology aims to maintain future sustainable growth and expansion and invested £700k in the latest metrology equipment in 2017, including an Aberlink Xtreme CNC CMM, Leica and Cybergage 360.

The company’s long-term partnership with equipment

supplier FARO and the significant investment in new technology has enabled Manchester Metrology to become a UK leader in the inspection of engineered components, offering an extensive range of equipment hire packages and on-site services.

8 manchester-metrology.co.uk

In 2017 Spadeadam was engaged to run near full-scale explosion experiments for a new DNV GL-led joint industry project called CostFX which is investigating cost-efficient explosion load descriptions for process areas.

Dan Allason, Head of Research and Innovation at Spadeadam, DNV GL – Oil & Gas, said: “‘The successful commissioning of this chamber for the CostFX project has shown it to be capable of delivering explosion loadings in excess of 2 bar with durations

greater than 200 ms. This is well suited to providing the types of loads required for the project and will also provide a world leading capability for other explosion research.”

8 dnvgl.com

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MEASUREMENT & TESTING | Engineering Capacity

Boosting measurement capability Investment in a new milling hall with 3, 4 and 5-axis machining capability boosted capacity at VES Precision and led to a further investment in an Aberlink CMM. Based in Crewkerne, Somerset, VES Precision was established in 1991 to provide a range of precision engineering and subcontract machining services to local companies, such as Westland Helicopters (now Leonardo Helicopters) and Normalair Garrett (now Honeywell Aerospace), both of which are located in nearby Yeovil.

Prompted by customer demand, over the past three decades the company has considerably expanded its footprint and now operates from a modern 14,500 square feet production facility.

Having considerably expanded its range of competences, VES Precision now offers an allembracing machining service with a wide range of capabilities including CNC milling, turning, EDM Wire Erosion, grinding, lapping and surface blasting. VES is able to produce components from a broad range of materials, including plastics, stainless steel, high-speed steel, brass, copper, bronze, tungsten and aluminium. The company also has considerable experience in machining exotic materials such as Nimonic 90, Inconel, Stellite and MAR-M-247.

Recent substantial investments in advanced, high-yield machine tools have enabled VES Precision to significantly increase its output.

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www.engineeringcapacity.com

Prompted by an ever increasing work-load, several months ago we opened a new, purpose-built milling hall that includes an advanced 5-axis machine with a pallet loader, 3 and 4 axis CNC mills and an overhead gantry crane

‘‘

As this rise in production had started to place a strain on the company’s inspection provision, VES Quality Assurance Manager, Steve Trigg recently investigated the available, precise and fast acting CNC Coordinate Measuring Machines (CMMs).

After evaluating the merits of CMMs from several leading manufacturers, an advanced, high-speed Axiom Too HS machine was purchased from Aberlink.

Steve Trigg explained. “Most engineering subcontractors are either geared-up for high-volume work or for one-offs and small batch work. Our success is based largely on our flexibility and our ability to offer complete, one-stopshop machining solutions, embracing, from one-off bespoke

jobs, through to large, repeat order production. We use a wide range of techniques including 5-axis milling, 3 and 4 axis mill-turning, dedicated CNC milling and CNC turning, EDM wire erosion, surface and cylindrical grinding, lapping and grit/glass bead blasting.

“Prompted by an ever increasing work-load, several months ago we opened a new, purpose-built milling hall that includes an advanced 5-axis machine with a pallet loader, 3 and 4 axis CNC mills and an overhead gantry crane. The additional capacity provided by our new milling hall has enabled us to considerably increase our output.

“Although our inspection system has been able to keep-pace with our increased output, as it was working at full capacity we were aware of the need to boost our measuring capabilities. Having weighed-up the available fast acting CMMs against our list of requirements, we decided that Axiom Too HS CNC CMM was the ideal machine for our needs; therefore we placed an order with Aberlink.

“Not only has the Axiom Too HS satisfied our current inspection requirements, our new CMM’s speed will enable it to handle any foreseeable increases in production. Also, its impressive accuracy specification will enable the inspection of all the most demanding of our high-precision components now in the future.”

8 ves-precision.com NOVEMBER 2018

Engineering Capacity | MEASUREMENT & TESTING Bespoke metrology specialist, Torus Group has invested in multisensor inspection technology to offer customers a faster and more comprehensive service.

The Torus Group has customers across the aerospace, medical and packaging industries, all of which demand accurate and quick results when it comes to measuring their manufactured parts.

When a client came forward with a metrology challenge that Torus could not resolve using its previous equipment, it decided to buy a SmartScope CNC 500 from OGP UK. SmartScope systems employ optimum-performance sensors and probes to complete the work of traditional co-ordinate measuring machines, as well as laser scanners and profile projectors, with no compromise on quality.

From a single reference point the technology is able to collect detailed data and gauge the characteristics of even the most demanding components and features.

By doing so quickly and reliably, users are assured of high levels of speed and accuracy, increasing

Multi-sensor measurement

their throughput and therefore profitability.

Dean Richardson, an Inspection Services Engineer at Telfordbased Torus, said: “The major factor for us was that one of our long-standing customers had a very specific issue where with our previous equipment we could not access a part feature. The lighting just wasn’t good enough.

“The OGP in terms of the balance between speed and the lighting capabilities was perfect for that solution - it’s been a good purchase and has proven that it was the right one.

“The hardware is absolutely fantastic. We struggled with our

Sarginsons boosts process control Coventry-based lightweight castings business Sarginsons Industries has invested £125,000 in technology to enhance its process control and measurement processes.

The company has purchased a Faro Quantum 3D scanner that will improve its metrology capabilities as it uses the latest

NOVEMBER 2018

laser technology to analyse tooling and components made by Sarginsons to exactly match its customers’ CAD data.

Four engineers are now being trained to use the PolyWorks Software, which is also developed in Coventry, that supports the operation of the scanner.

The firm has also bought a

previous equipment in the sense that we would occasionally have to go back and re-set a part of the programme, but that’s not something we’ve ever had to do with the OGP. “In a shop-floor scenario it does the same programme day in, day out without fail.

“We’re now able to offer a more complete measurement solution.

It allows customers to have more confidence in us, meaning they’re more likely to come back to us, and it also means that for our reputation it’s very positive because our customers will spread the word of Torus around.”

8 torus-group.com GNR Lab 300 machine that will be used to measure the chemical composition of the aluminium in its products and, on top of that, the company has invested in barcode technology in order to fulfil a major order with Jaguar Land Rover that required the additional traceability on the products.

8 sarginsons.com

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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

LATHES.CO.UK Lathes.co.uk store.lathes.co.uk - where Manuals, Catalogues Drive Belts Books Accessories & Spares are listed The world’s largest machine tool reference archive. Manuals, Catalogues, Books, Pictures Specifications, Technical Guides Wardlow, Tideswell, Buxton, Derbyshire, SK17 8RP Tel. 01298-871633 (from overseas: +44-1298-871633) from 09:00 to 23:00 UK time www.lathes.co.uk

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PRECISION ENGINEERING 8

Qualiturn Products Limited

PRECISION ENGINEERING 8

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

Bridwey Precision Manufacturing Ltd A one stop shop for….

Competitive CNC machining service.

Responsive to customers’ needs & deadlines. Prototype & development parts and assemblies.

Low- to medium-volume production parts and assemblies.

DKW Precision Engineering Celebrating our 49th 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

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

8 Albany Road, Weymouth DT4 9TH Tel: 01305 774 552 www.bridwey.co.uk PRECISION ENGINEERING 8

MACHINE TOOL MANUALS 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

Mini Gears (Stockport) Ltd

PRECISION ENGINEERING 8

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

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

PRECISION ENGINEERING 8

JFL Broaches and Broaching

MACHINING (5 AXIS) 8

BROACHING 8

DIRECTORY | Engineering Capacity

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

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

Hurco vertical machining centre.

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

NOVEMBER 2018

Parts Assembly Parts Subcontract Machining ity eering Capac TS | Engin COMPONEN MACHINED

ts g suppor Mill-turnin oach lean appr

AS AS 9100 & ISO 9001

year half of this In the first has committed to ing Roscomatic investment, includ More than Engineering of 1000 latest Capacity | £750,000 medium-size small to INDUSTRY ation of the axis NEWS the install (SMEs) have d manufacturers 1MSY multibeen given Miyano BNE-5 . business a centre boost turn-mill ing-based months thanks over the last ten company The Worth to a new £9.7m nist business machi suppor million parts subcontract The Manufa t initiative. some 1.5 cturing Growth completed dispatches from Progra g mme (MGP), ssemblies a year – rangin funded European and sub-a Regional Develo by the assemblies ned castings and Fund (ERDF) pment machi is to large Economic and delivered by parts – and Growth Solutio small turned ing a record has helped achiev companies ns (EGS), 98%. currently the UK to across 13 mins to just ry rate of grow, Martello from on-time delive products and develop been cut new r complex director Joe is driven overcomemins. A furthe nent which ny Managing Keet says: the compa r Seanproduc tion ity 2.5 issues steel compo taking flexibil explains that of constant Cell Leade that ional sly previou weress stainle g ions phy of operat d us them holding by a philoso of lean manufacturin three operat reduced to a “The levels o BNE has hadback.

Thisenable has ning now developmentsupported by machialready led tominutes is in the Miyan reduce jobs, with new inute cycle. ent an additio 11 400, four-m ing £1 techniques, significantly positio 359 important, -on-investm to often exceed liaison’ to ns expected nalsingle most ent and investm tivity.” to be Further return setters an ‘opentimes once l produc ongoinne year and the has s createdfrom freeing-up from the g project million a improve overalcomple are and comes y which keeps new machi ted.machi By thenes other tasks for each m people strategto date on the He says the£1.6m end of perfor July, time up of grant ium existing 3-axis arising. ion of lost reducing the workforce replaced beenofmade, utions 10 alumincontrib reduct have and any issuesin tion, four family withedmoney errors We’ve company requir so that a to suppor first-off inspec reloca gottion “We invest ass. te in place andstill previouslyt anothe lot of grants He says: deliver a separa r 2200 firms parts that betwee to and we want risk of setting and the latest n and leadership nownow work in progre g operations 1MSY andbeMarch which manuf automation and manag acturer and cutting Lorrain 2019. of turnin operat ion can technology of the BNE-5 ge ement, R&D, lean ity le e cycle. ction come Holme and see howassitto capabforwar illing produ s, Chief manufacturin The flexibil me the shorta er, milling Execut d s theyiscan e productivity in oneiveturn-m g, Officer its succes take helps to overco require. Howev ofaverag EGS, produced and capacit is that with three age explain is key toadvant of the would cutting ed: “We systems and ve bonus at y, quality assista cycle has pped we still need massi are offer. nce skills we A way part single that It’s never on targets of above the tant sly overla we per times beenateasier, development.supply chain have set for the as the procesaneou it is so imporown engineers total cycle s isworkp proving that ourselves,tools simult quickiece by and the Martin Coats, there is a suppor up toscope to grow our ends oftacan support and our bar real from nt both Operations appetit using SMEs for Director at and be tailored to the of e exact time, through consta to maximise EGS, continu needs ofter. support that targeted business same in order firms come ed: “When diame the busine can barManufa and so training, The to us they “The differen help them grow. 51 mm 15 kW mainss.” vestment and what cturing ead receive strateg -on-in rt ic review from Progra a return kW The fixed-h mme programme ce with our is 7.5Growth we suppo was set one MGMs that two-ax is upwith the void e and improve how customers.” to fill determines of our spindl by manufacturinthat it is delivered left e, both by the o r to barriers are what spindl Manufacturing Advice dary g we delive n to the new Miyan d experts in the way secon Service (MAS) understand s of 5,000 of support is and what the challen who y ordere In additio by tage um speed advan providi needed to maximng companies ges access to ny has alread help them reach their are facing. special in, have the assista the compa CNC sliding head isted potenti impos revs/m nce They understand to d / super “Since Octobe al. manufacturer the langua nes. The to synch ronisehelp two Citizen grow and ge improv12-station, s centre machi L20-VIII MDs are talking highest barrier r 2016, the l for both e. Ideal for turn-mill and can guide This contro is being with 15% . nes, a Citizenfrequency them on making was ‘Contin achieve ven turrets an 18-stro d through two machi low uous Improv of clients all-dring adecisions, before the right featuring followed by ement’, logy) and experienced network of LFV (LFV bringing in ‘Environment specialists BER 2017 manufacturin cutting techno will bring ‘Marke on al’ on SEPTEM and specifi ting growth vibrati g and Market c issues are facing managers ange M16-V 14.

Knowledge’ (MGM) ations to they’re or opportunities they to industr top-of-the-r (12% each). y specialists , access Citizen install looking initial stage Once the and the opportunity the total has She continu to explore.” to we then bring been completed, ed: “1000 m average grant apply for an acity.co benefic ringcap of £1400, rising iaries is just works with in an expert who maximum the manag the start. www.enginee to a to £3,500 14 ement team address these Support can . be used for 8 manufacturin issues.”

SEPTEM BER 2017 programme.c ggrowth o.uk

Growth su helps 1000pport SMEs

INDUSTRY NEWS | MACHINING | AUTOMOTIVE | SHOW PREVIEWS

MACHINED COMPONENTS: Prismatic parts from bar

www.engineeringcapacity.com

Call 01737 270648

NOVEMBER 2018

Precision Products (Brighton) Ltd

Accredited to AS9100 Rev D Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk

Grenville Engineering (Stoke-on-Trent) Ltd With more than three decades of experience and dedication in producing the highest quality products, Grenville maintains its position as the leading precision sheet metal fabrication company.

Unit 3 Newfield Industrial Estate, High Street,Tunstall, Stoke-on-Trent ST6 5PD Tel: 01782 577 929 www.grenville-engineering.co.uk

WATERJET CUTTING 8

September 2017

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.

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

5

Get your company noticed with an Engineering Capacity classified profile advert FOR MANUFACTURERS ABOUT SUBCONTRACTORS

Design & Engineering Support Service

Simpson Springs & Pressings Ltd

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

Precision Turned Turned P Parts arts CNC Milled Components

www.engineerin gcapacity.com

SPRING MAKING 8

APT Leicester, Leicester, the ar artt of precision precision..

TURNED PARTS 8

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

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

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

SUBCONTRACT CNC TURNING 8

Kirkham Engineering Co Ltd

SHEET METAL WORKING 8

REPETITION TURNED PARTS 8

Engineering Capacity | DIRECTORY

ICEE Comprehensive fabrication facilities offering complete turnkey solution.

Design, Precision Engineering, Sheet Metal Fabrication and Welding.

Prototypes, one off or batch work.

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

Aluminium Alloy Specialists.

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

www.engineeringcapacity.com

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FARNBOROUGH | Hants | GU14 6XL

5th – 7th February 2019 9.30am – 4.30pm (3.30pm close Thurs)

The UK’s must-attend event for every industrial engineering and manufacturing professional

FREE SEMINARS & PARKING

Meet over 800 national and international suppliers under one roof in the brand new Farnborough venue next February at Southern Manufacturing & Electronics (inc AutoAero) 2019.

See live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labeling & marking, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment.

Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 5th February.

Pre-register online now for your free entry badge and show preview at www.industrysouth.co.uk

SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd Tel 01784 880890 email philv@etes.co.uk

Register here with your smartphone