Engineering Capacity Digital Edition September 2017 by andy sandford

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

September 2017

INDUSTRY NEWS | MACHINING | AUTOMOTIVE | SHOW PREVIEWS

MACHINED COMPONENTS: Prismatic parts from bar

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FREE SEMINARS FREE PARKING

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

The Leading Manufacturing Technology Exhibition in the North Over 300+ national and international suppliers will gather in Manchester this September for Northern Manufacturing & Electronics 2017 together with the RoadRailAir event. The exhibition will feature live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D printing, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment. Free industry seminar programme online @ www.industrynorth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Wednesday 27th September. Pre-register online now for your free entry badge and show preview at www.industrynorth.co.uk

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

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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 NOVEMBER ISSUE Forming & Fabrication, Aerospace & Defence, Five-axis Machining, Composites, Turned Parts Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website

Editor’s View Maybe we should’ve thought of it before. The continued volatility and uncertainty around Brexit seem to be working like a tonic on UK manufacturing. The latest Manufacturing PMI was at a four-month high, its second highest level in over three years. An interesting and important trend seems to be the rate of improvement in foreign demand, with the latest figures some of the strongest in 21 years. It seems the weakness of the pound, which has cut effective prices by around 20%, has proved a powerful stimulus, and the challenge now is to capitalise on this and carve out more export business in markets where there is the potential to take on the local incumbents. Another major survey published by EEF showed that exports were going from strength to strength, 60% of companies saw Europe as offering most growth opportunities and industry was ‘making hay while the sun shines’. Well, of course, the other thing to do when the sun is shining is to fix the roof – and here the Government’s maintenance men are slacking somewhat. Speaking to Engineering Capacity, Sir Ronald Halstead, President of the Engineering Industries Association, said that rather than helping SMEs to capitalise on this, the Department of International Trade (DIT) has its eye off the ball. He said: “At the present time, too much attention is being given by the DIT to negotiating potential trade deals with other countries in 2-5 years’ time. Too little attention is being paid to exploiting export opportunities now. In particular, we are lobbying the DIT to give greater support to SMEs exhibiting at trade shows, which are the best ways of introducing companies and their products to markets.” Because of distractions such as Brexit and the general election, the TAP (Trade Access Programme) funding that facilitates this was late and reduced in 2017 and hasn’t even been agreed yet for 2018. So DIT, let’s make sure our SMEs have the support they need. Andy Sandford, Editor

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Contents September 2017

22 AUTOMOTIVE

News

Features

06 Ton-up for welding qualifications 06 Training coded welders

14 Machined Components 06 COVER STORY: Lathe takes over prismatic machining

in-house at WEC

07 Fourth Nadcap for Fine Tubes 06 Chemical processing is the latest area to be accredited

20 Automotive 06 New service stops leaky castings

16 MACHINED COMPONENTS

08 More secure fasteners 06 TR Fastenings invests in

26 Advanced Engineering Show preview

10 New site for growing composites specialist 06 Pentaxia takes over

28 Northern Manufacturing preview

Rolls Royce site

staff and digital manufacturing 4

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23 Waterjet & Laser Cutting 06 Tube and sheet laser expansion Robot boosts welding capacity by 30%

data security

11 Constant growth for fabricators 06 Sheet metal worker invests in

More additive for ARRK Getting bike carrier on the road

32 Moulding 06 500t press for larger mouldings

33 MOULDING

â&#x201A;Ź4m European investment at Proto Labs

SEPTEMBER 2017

Engineering Capacity | INDUSTRY NEWS More than 1000 small to medium-sized manufacturers (SMEs) have been given a business boost over the last ten months thanks to a new £9.7m business support initiative. The Manufacturing Growth Programme (MGP), funded by the European Regional Development Fund (ERDF) and delivered by Economic Growth Solutions (EGS), has helped companies across the UK to grow, develop new products and overcome production issues that were previously holding them back. This has already led to 400 new jobs, with an additional 359 positions expected to be created once ongoing projects are completed. By the end of July, £1.6m of grant contributions have been made, with money in place to support another 2200 firms between now and March 2019. Lorraine Holmes, Chief Executive Officer of EGS, explained: “We are way above the targets we have set for ourselves, proving that there is a real appetite from SMEs for targeted business support that can help them grow. “The difference with our programme is that it is delivered by manufacturing experts who understand the challenges companies are facing. They understand the language MDs are talking and can guide them on making the right decisions, before bringing in specialists on specific issues they are facing or opportunities they’re looking to explore.” She continued: “1000 beneficiaries is just the start. SEPTEMBER 2017

Growth support helps 1000 SMEs

We’ve still got a lot of grants to deliver and we want manufacturers to come forward and see how they can take advantage of the assistance on offer. It’s never been easier, as the process is quick and the scope of support can be tailored to the exact needs of the business.” The Manufacturing Growth Programme was set up to fill the void left by the Manufacturing Advice Service (MAS) by providing access to specialist assistance to help manufacturers to grow and improve. This is being achieved through an 18-strong network of experienced manufacturing growth managers (MGM), access to industry specialists and the opportunity to apply for an average grant of £1400, rising to a maximum £3,500. Support can be used for

leadership and management, R&D, lean manufacturing, productivity and capacity, quality systems and supply chain development. Martin Coats, Operations Director at EGS, continued: “When firms come to us they receive a strategic review from one of our MGMs that determines what barriers are in the way and what support is needed to help them reach their potential. “Since October 2016, the highest barrier with 15% of clients was ‘Continuous Improvement’, followed by ‘Environmental’ and ‘Marketing and Market Knowledge’ (12% each). Once the initial stage has been completed, we then bring in an expert who works with the management team to address these issues.” 8 manufacturinggrowth programme.co.uk www.engineeringcapacity.com

INDUSTRY NEWS | Engineering Capacity

Ton-up for welding qualifications WEC Group Ltd, one of the largest engineering and fabrication companies in the UK, has provided over 100 coded welding qualifications to staff since becoming a TWI (The Welding Institute) certified welder training centre earlier this year. As one of only a few TWI certified welder training centres in the North West, the company currently provides the qualifications internally to apprentices, skilled and semi-skilled welders as a way of enhancing their skillsets and improving quality throughout the company overall. Since becoming accredited, WEC Group has saved £38,000 on external weld tests which used to take 4-5 weeks complete. They now take on average just one week to complete, from training to documentation. All the welders are trained and assessed in-house by WEC Group’s Training & Development Manager, Kris Mercer, who is now one of just 50 CSWIP certified Master Welding Instructors globally as a result of

Pattonair acquisition Aerospace and defence supply chain specialist Pattonair is set to be acquired by the global investment firm Platinum Equity. Headquartered in Derby, Pattonair supports blue chip

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completing a rigorous four month qualification process. Welders are then examined by William Barr, a former welding inspector at WEC Group who also passed four welding theory exams to achieve the new position of CSWIP Welding Examiner. Kris Mercer said: “The ability to train our own staff gives our welding personnel more knowledge on weld defects, causes and most of all preventative action which will make the company much stronger in the future.” The Group will be opening up the welder qualifications to external personnel in the near future, offering qualifications in MIG, TIG and MMA welding

processes. This will enable it to boost the competitiveness of other engineering companies on a global scale. He added: “Our new TWI certified welder training centre status will enable us to fill our skilled vacancies as the company continues to grow, as well as giving local people who don’t necessarily work here the opportunity to learn new welding skills.” The new training service is a welcome addition to the Group’s five-year advanced welding/fabrication, CNC machining (mechanical engineering) and technical production engineering apprenticeship schemes which are also delivered in-house. The Group is currently employing apprentices at its sites in Lancashire, Yorkshire and the West Midlands to start in September 2017 and is also recruiting permanent and temporary Skilled Welders across the UK to join as soon as possible. 8 wec-group.com

engine and airframe manufacturers and MRO customers with tailored supply chain management solutions. It offers a global service though facilities in Singapore, China, Poland, Brazil, Canada and five cities in the United States. Platinum Equity Partner Louis Samson said: “Pattonair is a well-respected business with a proven management team and

strong long-term customer relationships. We share the company’s commitment to exceptional customer service and look forward to partnering with ... Pattonair’s leadership team to pursue additional growth, both organically and through prospective add-on acquisitions.” 8 pattonair.com

SEPTEMBER 2017

Engineering Capacity | INDUSTRY NEWS Fine Tubes, a UK-based manufacturer of high-quality precision tubing for critical applications, has been awarded a Nadcap accreditation for Chemical Processing. This means that Fine Tubes is now one of the very few companies holding four Nadcap accreditations simultaneously. Fine Tubes’ first accreditation was awarded for Heat Treating in 2004, followed by Non-Destructive Testing (Ultrasonic Testing) in 2005 and Fusion Welding in 2013. Chemical Processing is a critical part of the Fine Tubes production process. Tubes must be chemically milled after the cold-working and heat-treating manufacturing processes, by being etched to

Fourth Nadcap for Fine Tubes

ensure they meet the customer specification requirements. Fine Tubes anticipates receiving yet a further accreditation, for Fluid Distribution Systems, in the near future.

David Killoran of Fine Tubes’ Technical team said: “The tubing we manufacture is designed to withstand in-process fatigue loading, and failure is not an option.” 8 finetubes.com

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SEPTEMBER 2017

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INDUSTRY NEWS | Engineering Capacity Fastenings manufacturer and distributor TR Fastenings has achieved certification to the ISO 27001 information security standard for its IT service desk and technical teams in the UK. The quality stamp from BSI relates to the handling and storage of data and information on staff, the company and its customers. The board of TR’s parent company Trifast Plc, led by CEO Mark Belton, was keen to obtain certification to the standard to show customers its commitment to information security, which is a major issue facing businesses around the world. TR’s IT department in the UK has been audited and certified to the 2013 version of the standard, and there are now plans to roll this out to other departments and locations. In order to prepare for the audit, TR undertook a comprehensive review of processes including access to information, data storage, security measures, data transmission and disposal of information. In practical terms, this meant ensuring screens showing sensitive information were not left

More secure fasteners

unattended, shredding confidential documents and keeping detailed logs of activity and any potential incidents. Policies covering use of the internet, social media and IT facilities were also visited and updated. Having passed the audit, the ISO 27001 certificate will now be valid until 2020, but the auditing process will be renewed every year for the first three years to ensure measures are kept in place. The company will conduct internal audits every year to check assets and processes are in line with the terms of the standard.

Mark Belton said: “Information security is an extremely topical issue at the moment, thanks to recent high-profile attacks on the NHS and international governments. As a global business, we are committed to maintaining an excellent standard across all of our processes and departments, and IT is no exception. We take great care in storing, curating and protecting our company data and our customers’ data, and this certification is recognition of that commitment and care.” 8 trfastenings.com

Moulding press added

New premises for PCD specialist

RP Technologies, which specialises in the manufacture of prototype injection mould tooling and components has purchased an additional Borche 120 tonne injection moulding machine. This is part of the company's ongoing investment and expansion plans and will add to its existing suite of Borche injection moulding machines. The new machine will increase capacity and help the West Midlands company keep up with the increasing demand from both new and existing customers. 9 rptechnologies.co.uk

Exactaform, one of the UK’s largest manufacturers and suppliers of Polycrystalline Diamond (PCD) tools to the automotive and aerospace industries, has moved into its brand new, purpose-built premises on Prologis Park. The 43,000 sq ft industrial unit, which includes office space, an on-site gym, and canteen, is the first step in major expansion plans for the company – which hopes to increase its headcount from 55 to 150 over the next five years. The new unit was built after the firm outgrew its former site on Little Heath Industrial Estate. 9 exactaform.com

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SEPTEMBER 2017

ADVANCED ENGINEERING2017

1 & 2 November 2017, NEC, Birmingham The UKâ&#x20AC;&#x2122;s largest annual gathering of advanced engineering professionals Advanced Engineering is the industry event where high-technology manufacturing sectors converge under one roof to meet and do business. Join us where the familiar and the unfamiliar collide to provide new opportunities across the engineering supply chain.

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INDUSTRY NEWS | Engineering Capacity

New site for growing composites specialist

the aerospace, motorsport and luxury automotive markets. “We have grown more than 60% in the past 12 months and to maintain that kind of growth we need a lot more space. It’s

A conference and exhibition on 13 October will look at the latest developments in cost reduction and improved productivity in the international heat treatment industry. The second Surface Engineering and Heat Treatment Industry Conference/Exhibition takes place on 13 October at historic Kenilworth’s Chesford Grange. The event is again co-sponsored by the UK’s Contract Heat

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essential that we maintain the high quality and reliability that we’re known for, which results from completing every element of our work in-house and working very closely with our customers. Predictably meeting quality standards and delivery dates is just what major multinational companies need from suppliers like us. The new site is three times the size of our existing facilities, which gives us space to expand effectively and dependably.” 8 pentaxia.com

Heat treatment developments in focus

Advanced composites manufacturer Pentaxia has purchased a large manufacturing site on Alfreton Road in Derby to accommodate its rapid growth – 60% in the last 12 months. A six-month programme to refurbish and upgrade the site will start immediately and the family-owned firm will move in next year. The £1m investment in the site will include new manufacturing equipment which will double the firm’s existing production capability. Constructed in the 1960s as the composite manufacturing facility for Rolls Royce, the site was at the forefront of advanced manufacturing until 2002. This deal will see the site return to its former glory as a centre of innovation and a composites hub for the Midlands. Managing director Stephen Ollier said: “This marks a big step forward in our company’s nineyear history. We’ve seen a rapid increase in demand for lightweight, high performance components from our blue-chip customers in

Treatment Association (CHTA), the Surface Engineering Association and Wolfson Heat Treatment Centre. Chaired by CHTA’s Alan J Hick, the emphasis of the international heat treatment sessions is on practical developments aimed at reducing costs and increasing productivity whilst enhancing quality, efficiency and environmental aspects. There will also be sessions on metal finishing and an exhibition featuring 25 leading suppliers. 8 sea.org.uk SEPTEMBER 2017

Engineering Capacity | INDUSTRY NEWS

Brexit drives demand for UK suppliers

Constant growth for fabricators Sheet metal fabricator, Constant Group Ltd, has expanded its premises by 60%, gained ISO 9001:2015 certification and is investing in staff and digital manufacturing. The company was recently able to purchase neighbouring units which took its factory space from 32K sq ft to over 50k sq ft. Managing Director Matt Garlick said: "The expansion of the business is a direct result of a growing customer base that have placed increased demand for a wider variety of projects, leaner lead times and project stock holding. We've also benefited from a rising demand in complex assembly such as IoT retail display units that require greater floor space in our assembly division. The extra space will allow us to create the factory floor that we have always wanted, and give greater flexibility to what we can offer." He continues: "Our business development team has trebled to SEPTEMBER 2017

enable us to liaise with new and existing customers alongside working with operations for a prompt service. As a direct result, we charged ahead to embrace a new digital infrastructure, introducing several internal systems such as Radan's e2i package. This digital upgrade has reduced our production lead times, and streamlined our design to delivery processes." This recent growth phase has also coincided with Constant Group gaining ISO 9001:2015 certification. Matt Garlick concluded: “We’re pleased to be able to offer services to new customers who require ISO accreditation for sheet metal subcontract work, as well as maintain our standards to our existing client base. The ISO certification will also ensure our physical site growth is managed to enhance our customer base and operations effectively.” 8 constantgroup.co.uk

A survey of supply chain managers showed that Brexit concerns mean 37% of procurement professionals in the manufacturing sector are looking for UK suppliers. The survey, which was carried out on behalf of the Chartered Institute of Procurement & Supply, also showed that 27% of supply chain managers are making efforts to get closer to EU suppliers and 75% said supply chains becoming more expensive, with 25% considering costs of potential tariffs. The longer-term impact is bad news for suppliers to the industry as 43% of respondents said that input costs for manufacturing production would have to be negotiated lower. Around 18% said they would bring some of their operations to the UK but 25% said more of their supply operations would be located outside of the EU. The report ‘The Brexit Storm – How procurement and supply chain professionals are tackling the issues’ can be downloaded on the CIPS website. Due to the level of interest in the survey after its launch a fuller report was produced at a later date with more detail. The results will be announced at the CIPS conference on 17 October. 8 cips.org

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SPONSORED FEATURE: SUPPLY CHAIN FUNDING

How do you fund the manufacture of goods when your overseas customer takes three months to pay?

When Ecospin found itself losing orders because it needed cash up front to fund the build, the future looked grim. How could Ecospin find a way of satisfying orders while giving customers time to pay? Ecospin manufactures the Raptor – an innovative three-wheeled electric vehicle. Aimed at the lawenforcement community, it’s the only road-legal vehicle of its type and has been adopted by police forces and security firms around the globe. Ecospin exports virtually all its production. A product as technologically advanced as the Raptor is expensive to build. This was a constraint for both Ecospin and its customers. Paul Loomes, Ecospin’s Managing Director explains: “The Raptor’s USP is its Type Approval; this is what makes it road legal. However, to get Type Approval cost £200,000; we managed this without investment but by the time we had an approved product to build we had no money left in the company. “Having no cash in the business meant we couldn’t fund build costs. So on every order we had to ask for 50% up front. This was losing us business.” This is clearly a difficult sell to a customer. It takes around twelve weeks to fulfil an order so asking a dealer in Singapore to stump up £25,000 on a

£50,000 order three months before receiving anything is bound to cause consternation. Paul was concerned that without a capital injection from an investor Ecospin’s future looked bleak. Then he found a way forward. “I was describing the problem to a friend, Stuart Garner at Norton Motorcycles. Stuart uses URICA, he explained to me how it works and it sounded like just what we needed. I set up a meeting with URICA and we’ve never looked back. “A recent order from a new dealer in Mexico is a great example. The opening order was for $191,000. We put it through URICA and once approved I know the money will appear in our account immediately while the customer doesn’t have to pay for three months. This means we have the cash to pay our suppliers and fulfil the order, and by the time the customer has to pay the goods have been shipped. Without URICA we might lose an order like this. “For any business that is exporting URICA really is the solution. You can’t put a value on peace of mind but that’s what the URICA solution gives us. We know we’ve got money in the bank and we know the customer is solid because URICA has checked them out.”

www.urica.com 12

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SEPTEMBER 2017

Engineering Capacity | PEOPLE

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

Adam Bradley has been appointed export manager at Hillfoot, the specialist carbon and alloy steel stockholder. He will build on the Sheffield based company’s existing international sales which currently involve exports to manufacturers in 38 countries.

Malcolm Christie has taken on a senior technical support role at OEM Group, a specialist in engine services and spare part procurement. He will be responsible for the tendering process and provide technical assistance to OEM engineers and customers.

SEPTEMBER 2017

Brian Bowers takes up the role of Welding, Fabrication and Pipefitting Tutor at Merseyside’s Engineering College and will be responsible for training new apprentices. He served his apprenticeship at Cammell Laird Shipbuilders and has also worked for BAE Systems and Airbus-UK.

Ian Humphries has been promoted from project director to managing director at engineering services provider Boulting Group. He has over 25 years’ engineering experience, having previously managed materials handling and chemical engineering projects in China, New Delhi, Hong Kong and Taiwan.

Aerodynamic technology for wind turbines A French company has developed an innovative wing-tip device that can be adapted to all type of wind-powered generator blades to give an average 14% increase in power. It is looking for worldwide licensees Reference: JV1168 Closing Date: 17/10/2017 Spain - Plastic industrial components A Spanish company specialized in the design and manufacture of plastic industrial components seeks a manufacturing agreement with companies working mainly in the building, automotive, cleaning or agro food industry Reference: JV1172 Closing Date: 14/11/2017 Denmark - Metal and wood wall sculptures A Danish design company specialises in wall design based on laser cut metal and wood with a high-quality finish and is looking for an experienced manufacturer, a strong communicator used to working with designers and exclusive products, to produce their existing three designs. Reference: JV1174 Closing Date: 06/12/2017 For more information please email head.office@eia.co.uk quoting reference number. Please remember to use due diligence in responding to Trade Leads. Engineering Capacity provides you with the above information in good faith, but is unable to accept any responsibility or legal liability arising from any use of these leads.

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MACHINED COMPONENTS | Engineering Capacity In the first half of this year Roscomatic has committed to £750,000 of investment, including the installation of the latest Miyano BNE-51MSY multi-axis turn-mill centre. The Worthing-based subcontract machinist company dispatches some 1.5 million parts a year – ranging from completed assemblies and sub-assemblies to large machined castings and small turned parts – and is currently achieving a record on-time delivery rate of 98%. Managing director Joe Martello explains that the company is driven by a philosophy of constant development of lean manufacturing techniques, supported by investment often exceeding £1 million a year and an ‘open-liaison’ people strategy which keeps the workforce up to date on the company and any issues arising. He says: “We invest in automation and the latest production technology which helps to overcome the shortage of skills we would require. However, it is so important that we still need to grow our own engineers through constant support and by training, in order to maximise our return-on-investment and so improve how we support and what we deliver to customers.” In addition to the new Miyano the company has already ordered two Citizen CNC sliding head turn-mill centre machines. The two machines, a Citizen L20-VIII LFV (LFV featuring low frequency vibration cutting technology) and a top-of-the-range M16-V will bring the total Citizen installations to 14. 14

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Mill-turning supports lean approach

Cell Leader Sean Keet says: “The levels of operational flexibility in the Miyano BNE has enabled us to significantly reduce machining times and most important, improve overall productivity.” He says the new machine has replaced existing 3-axis machines so that a family of 10 aluminium parts that previously required four turning operations and a separate milling operation can now be produced in one turn-milling cycle. A massive bonus is that average total cycle times per part has

been cut from 13 mins to just 2.5 mins. A further complex stainless steel component which had three operations taking 11 minutes is now reduced to a single, four-minute cycle. Further return-on-investment comes from freeing-up setters to perform other tasks and from the reduction of lost time for each first-off inspection, reducing the risk of setting and relocation errors and cutting work in progress. The flexibility of the BNE-51MSY is key to its success as it is capable of single cycle cutting with three tools simultaneously overlapped at both ends of a workpiece at the same time, and using bar up to 51 mm bar diameter. The fixed-head 15 kW main spindle and two-axis 7.5 kW secondary spindle, both with maximum speeds of 5,000 revs/min, have the advantage of synchronised / superimposed control for both 12-station, all-driven turrets. Ideal for SEPTEMBER 2017

Engineering Capacity | MACHINED COMPONENTS complex and heavier drilling and milling cycles, each driven tool position has 2.2 kW drive delivering 25 Nm of torque and speeds up to 6,000 revs/min. Altogether Roscomatic has some 50 CNC machine tools including 13 Citizen CNC sliding head turnmill centres and a large 104 pallet flexible manufacturing system. There are also 17 machining centres in the plant involved in supplying medical (20% of Â£6.5

We invest in automation and the latest production technology which helps to overcome the shortage of skills we would require. However, it is so important that we still need to grow our own engineers through constant support and by training, in order to maximise our return-on-investment and so improve how we support and what we deliver to customers

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million turnover) aerospace (12%) vacuum technology, oil and gas, motion and hydraulics and nuclear sectors involving the processing of a wide range of

materials from plastics through to alloy steels such as Inconel. Parts are also exported to France, Germany and Czech Republic. 8 roscomac.com

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SEPTEMBER 2017

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MACHINED COMPONENTS | Engineering Capacity As part of a multi-million-pound machine tool investment programme, Bowmill Engineering is to install an advanced cylindrical grinder at its new Tewkesbury manufacturing plant for Airbus landing gear kits. In addition to the Jones & Shipman Suprema EASY cylindrical grinder, the investment includes eight new machining centres and high levels of automation throughout. The factory in Tewkesbury replicates a similar bespoke facility at Bowmill’s headquarters in Poole, Dorset where it operates a dedicated facility for Airbus landing gear kit production. Bowmill has been manufacturing A320 and A330 landing gear kits since 2002 as well as complex components and assemblies for other OEM’s. Both sites operate as full production manufacturing

Machining investment lands at Bowmill

operations producing Class 1 critical components with a particular emphasis on the A320 and A320neo aircraft which are currently on intense build schedules. Kits from Tewkesbury – which are delivered on a tight KANBAN regime – are despatched to

customers based in nearby Gloucester as well as Canada and Mexico. Phase one of the new investment will see the Tewkesbury plant concentrate on A320 kits but Phase 2 – accommodating components for other Airbus aircraft and aircraft builders – will come on-line later in 2017. Bowmill has identified nine critical Class 1 kit components that require grinding tolerance finishes – retaining pins, uplock pins and spacers. Some are chrome plated – a grinding challenge in itself – but all grinding programmes are stored in the memory of the machine’s EASY graphical software which offers a real advantage with its speed of set-up for dressing and

Uprated inspection solves customers’ problems Birmingham-based precision engineering firm, GB Precision has expanded the benefits it is obtaining from its toolmakers’ microscope by equipping it with a microscope camera which transmits the image from the microscope directly, in real time, to an attached PC screen. As Director, Paul Turner, explains; “This has greatly increased the advantages we gain from the toolmakers’ microscope, transforming it from solely an inspection tool into a flexible communication

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device that helps us solve engineering problems and so improve the engineering solutions we provide to our customers. One of the issues with using a microscope on its own, is that, naturally, only one person at a time can view the image. That’s inconvenient when you want to discuss a specific feature, angle or geometry with members of the team. Using the camera attachment, the image is displayed directly on the PC screen, so several people can simultaneously see the

component under discussion, and if the viewing angle, position, magnification needs to be altered, again, all parties see the change immediately.” Another significant benefit is the ability to automatically store data directly to the PC, so maintaining a detailed record for future use - a growing requirement of customers in many advanced engineering sectors, such as aerospace, medical and pharmaceutical. 8 gbprecision.co.uk

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Engineering Capacity | MACHINED COMPONENTS grinding cycles utilising touch screen technology. Bowmill’s machine has a 650mm grinding capacity between centres although longer 1000mm and 1500mm capacities are available. The model is also the external wheel head version specifically designed to offer ease-of-use coupled to the highest levels of productivity. Managing Director of Bowmill, Nick Epps, said: “We identified that in the Tewkesbury factory there

were specific processes that need grinding so we needed a machine with proven production capability and consistent high tolerance repeatability. It was a tight brief and one the Suprema has met. In addition, the EASY software is well liked by the engineers. “Throughout the new operation we have concentrated on optimising and reducing machining times as we operate in a very ‘cost down’ environment,” he adds. “Also keeping grinding

in-house gives us very much more control and manufacturing flexibility. All components are NDT flaw detected as part of our quality regime so full transparency is all important. “On cost reduction we have reduced machining times by 21%, defects by 17% and reduced raw material usage by 28% and the Suprema has certainly made a major contribution to these efficiencies and savings.” 8 bowmill.co.uk

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urned P arts Precision T Turned Parts CNC Machined Components Subcontract Machining

SEPTEMBER 2017

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MACHINED COMPONENTS | Engineering Capacity

One-hit capacity wins business Bristol subcontractor Mil-Tu-Fit Engineering has increased capacity, reduced delivery times and won new business since investing in a DMG MORI Y-axis driven-tool lathe. Mil-Tu-Fit Engineering has been manufacturing precision components for the electronics, oil and gas, defence, construction and medical industries for over 40 years. As well as machining facilities, the company can also offer laser cutting, surface treatment and welding, enabling it to supply complete high-quality assemblies to its customers. Paul Beattie, Production Manager at Mil-Tu-Fit explains, “Some of our existing machinery was reaching the end of its useful life and we needed to replace it and at the same time upgrade our manufacturing capabilities.” The company’s machined products are generally under 125 mm diameter with low batch quantities from just one or two parts up to around 100 and the most commonly machined materials are 303 grade

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stainless steel and plastics. Mil-Tu-Fit evaluated a range of machines before deciding on the DMG MORI CLX 450. The main criteria were 4th axis and driven tools, the spindle diameter, the number of tool stations in the turret, accuracy and ease of programming. The CLX 450 is fitted with a bar feeder and can feed 80 mm diameter through the spindle, giving Mil-Tu-Fit the opportunity

to bid for larger work at a competitive cost. Paul Beattie says, “Previously, we would often have to carry out turning and milling operation on multiple machines. We can now combine the operations on the CLX 450, with many parts coming off the machine completed in one hit. As well as manufacturing parts around 20% quicker, we save on handling, we only have to set one machine, and fixtures for different operations have been largely eliminated.” As well as these savings, the company also reports that the parts are more accurate with better concentricity and parallelism and that tool life has improved. Paul Beattie says, “What appealed to us was the large 80mm bar feed, which means that parts which were previously billet work can now be bar fed. In addition, the operating system is user friendly, the machine has a small footprint and the reliability of the machine is very good.” Since the company installed the CLX 450 it has seen an increase in its order books from existing customers. It has been winning more of the work it is bidding for and, because of the machine, it has increased capacity enabling it to keep to short delivery schedules. Paul Beattie says, “We now have the capacity to absorb the increasing workload we are experiencing through winning more business. It is a major step forward in our manufacturing capabilities.” 8 miltufit.co.uk SEPTEMBER 2017

Engineering Capacity | MACHINED COMPONENTS Looking at the cuboid aluminium components produced for medical diagnostic equipment by subcontractor AES Precision Engineering, one would think they were milled, drilled and tapped on a machining centre rather than a lathe. Until April this year they were produced from sawn billet in two separate operations on a pair of 3-axis vertical-spindle machines in a total cycle time of 12 minutes. Since then they have been machined complete from round bar in one operation in an Italianbuilt Biglia B565-YS 6-axis turnmill centre supplied by UK agent Whitehouse Machine Tools. Program run time has more than halved to 5.5 minutes, accuracy is improved and there is no handling between machines or work-in-progress on the shop floor, significantly reducing the cost of production. Only two turning tools are in the 12-station turret for facing the bar end and for parting off, the remainder being axial and radial driven tools. Mark Wilson, a director of the family-run subcontracting firm commented, “We have been making these parts for years, during which time the volume has gradually increased to 1,000 per month. So, we needed to find a more efficient way of machining them.” Production engineer Trevor Orman added: “Although tolerances on the medical part are fairly open at 0.1 mm, the Biglia repeats to within microns, which means we no longer have to chase tolerance all day as SEPTEMBER 2017

Lathe takes over prismatic machining

the temperature varies on the shop floor. “The machine’s accuracy will also be invaluable for production of more tightly toleranced components and its rigidity means that tool wear is noticeably lower than on our other lathes.” The existence of the turn-mill machine has already brought in a new contract for the manufacture of 316 stainless steel automotive components that AES Precision Engineering could not have quoted for previously. The subcontractor intends to transfer jobs from other lathes to the Biglia to enable more economical production. It is also looking for further bar auto work to a maximum of 70 mm diameter by up to 560 mm long, preferably involving runs above 1,000-off, to fill the machine’s capacity.

Founded in 1987 initially to manufacture components for the medical industry, AES Precision Engineering has since expanded into the automotive, leisure, marine, cosmetics and defence sectors, including the production of complex parts for drones and reverse-engineering of replacement parts for production lines. In 2004 it moved to the present, larger premises on the New Street Farm estate in Ashford, Kent and has invested heavily over the years in a range of new machining centres, including 5-axis models, and multi-axis CNC lathes. 8 aes-engineering.co.uk www.engineeringcapacity.com

AUTOMOTIVE | Engineering Capacity The owners of Stourbridge based metal finishing specialists Midland Deburr & Finish have invested £300k to open a new company, Midland Impregnations Limited (MIL). It will to provide a specialist casting impregnation service to foundries and casting machine shops predominantly across the Midlands region. MIL will shortly add a further £50k investment in impregnation capacity and other associated processes. MIL director Chris Arrowsmith explains: “When you make a casting, you can get micro or macro porosity. This will cause the casting to leak and potentially fail in operation. A lot of companies will pressure test their castings and if they leak, they can be sent out for impregnation. Essentially what we are doing is sealing the porosity within the castings. Some companies like to send a large quantity out to be impregnated, others prefer to pressure test and send us the ‘leakers’. Within the automotive component industry in particular, we felt that there was a gap in the market for the specialised impregnation of castings.” Along with co-director Paul Young, Chris Arrowsmith identified an opportunity to improve the impregnation process. Around £20k was invested in a specialised oven to dehydrate castings prior to impregnation. Mr Arrowsmith adds: “The dehydration is necessary to remove contamination including machining fluids from within porosity in preparation for 20

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New service stops leaky castings

effective impregnation. We also have a solvent degreasing facility utilising ultrasonics to remove oil or other contaminations from within porosity if required. We have combined experience in this field of over 35 years and wanted to add this engineering expertise to our process.” Vacuum and pressure impregnation is carried out through high capacity equipment that can process both small and large castings in both the as-cast and machined condition. The inclusion of high performance rotational spray/flood washing ensures high standards of cleanliness on complex finish machined castings during the impregnation process. The largest basket can accommodate loads up to a tonne in weight and the process can handle ferrous and non-ferrous components in both the ‘as cast’

and machined conditions. MIL uses internationally approved sealants with high levels of sealing performance and cleanliness and processes are designed to avoid component damage and sealant contamination in blind holes. It offers a fast turnaround service within 24 hours and transport, delivery and collections are available. Mr Arrowsmith concludes: “Our target market is casting companies and companies that machine castings. We have seen high levels of demand since the launch of MIL, ranging from requests for large volume work down to one-offs.” Both companies are approved to ISO 9001 and ISO 14001. Midland Impregnations and Midland Deburr and Finish are both approved to ISO 9001 and ISO 14001. 8 midlandimpregnations.co.uk SEPTEMBER 2017

Engineering Capacity | AUTOMOTIVE ARRK Europe has made further investment in its Gloucester Prototyping Centre, with the installation of a new 3D Systems ProX800 Stereolithography machine. The machine is one of the most advanced supplied by 3D systems and its installation follows earlier investment at the centre this year, with the opening of a new, dedicated Metrology room. ARRK’s head of Prototyping and 3D Printing Operations in Europe, Craig Vickers said: “It has been well documented that the demand for 3D Printed components for prototype or low volume production use is expected to grow significantly in the future. “Our centre in Gloucester has a

More additive for ARRK long and well-established history in this field, providing some of the world’s leading companies with components as part of their product development programmes. “This new machine will allow us to build larger, more complex SLA parts more accurately and in shorter timescales. In the last 12 months or so, we have also invested heavily in our Prototyping operations in Gloucester, but also in our facility in France, near Annecy, where we installed three ProX800 as well”. Demand for 3D Printing and low volume manufacturing across Europe has also resulted in ARRK

opening a new operation in Bydgoszcz, Poland to provide additional production capacity as well as being strategically located to support ARRK’s growth in Germany and Eastern Europe. ARRK Europe’s new German Sales representatives, Stephan Pflueger and Volker Rechlin are having great success, working with many new customers, providing them with a range of services including stereolithography, selective laser sintering, vacuum castings, CNC machining, block models, metal pressings and rapid tooling and moulding service. 8 arrkeurope.com

Development manager, said: " We have a very wide in-house range of capabilities at Proto-Tech. Probably uniquely, this encompasses prototyping and low volume production of metals, including hot and cold stamping as well as

plastics prototyping and together with our engineering excellence, quality and competitiveness we really look forward to building business in the UK with a wide range of customers and partners." 8 proto-system.com/en

Automotive development capabilities Low volume production and prototyping specialist, the Proto-Tech Group, has now built on its European operations by setting up in the UK. The group specialises in a wide range of services for OEM and Tier 1 companies. These include hard and soft show and check models up to full size, traditional and rapid prototyping for plastics and metals, hot stamping prototypes and tooling, including for low volume production, as well as jigs, fixtures cubing and full engineering support for designers. Peter Rawson, the UK Business SEPTEMBER 2017

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AUTOMOTIVE | Engineering Capacity

Getting bike carrier on the road The manufacturer of an innovative vehicle bike carrier drew on the rapid prototyping and 3D printing capabilities of Proto Labs to bring the design to the point where it was ready for manufacture. The growing popularity of cycling has led to an increased demand for vehicle bike carriers so people can transport their bikes wherever they go. However, identifying a carrier suitable for a specific model of car and bicycle is not always as easy as you may think. Recognising this as a business opportunity, Craig Broadbent established Auxtail in May 2016 to develop a more secure and effective bike carrier solution. The result: EasyRide2. In place of tow bar or tailgate/boot mount, EasyRide2 is connected to a fitting attached to the vehicle’s hidden, but immensely strong bumper beam. This means the carrier can support more weight than the traditional tow bar approach, is also lighter and less costly to produce. Having completed the design and specification for the EasyRide2’s structure, the challenge for Auxtail moved on to how to secure bikes to the carrier. In order to protect the cycle frame, the decision was made to use wheels and tyres as the anchor points. A more exacting design process with a tyre grip combining ratchet handle and release facility, EasyRide2 also had to accommodate different sizes of wheels and tyres. Given the 22

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essential safety considerations, Auxtail determined that the design would require the completion of a diligently managed prototype programme. Only then, with a fully tested product, could injection moulding tooling and manufacturing commence. Auxtail designed the tyre grip using CAD and Finite Element Analysis (FEA) tools and reached the stage where prototyping could start for the three constituent components. Proto Labs’ expertise and track record for rapid prototyping and 3D printing in the automotive sector made it the partner of choice. The company was able to define the material, process requirements and delivery timeframe – feeding the CAD models directly to Proto Labs online. Also, at the request of Auxtail, the two companies exchanged ideas to refine the

product prior to final manufacturing decisions. “We knew that in addition to carrying out simulation tests, we would have to test the prototype ‘in the field’. To make this work successfully and to give us the most accurate outcome, it was important for the EasyRide2 prototype to reflect production level qualities as closely as possible. In the event, Proto Labs produced a product with a 90% match in terms of material qualities. For us this was an excellent outcome to take us forward,” said Craig. Craig and his team, Auxtail took the prototype EasyRide2 to the Millbrook Proving Ground for durability testing. With this stage completed satisfactorily, Auxtail could move to the manufacturing and injection moulding preparations with confidence. 8 protolabs.co.uk SEPTEMBER 2017

Engineering Capacity | WATERJET & LASER CUTTING ML Fabcuts has added laser tube processing to its subcontract waterjet and flat sheet cutting services. Founded 14 years ago by Matthew Levett and his wife Maria, the Crayford-based company has built its success on offering a rapid response to customers’ needs. To be able to achieve this it kept a stock of various materials ranging from 0.7 mm up to 50 mm thick, and the result is an diverse customer base ranging from motorsport through the construction industry and signmaking sector to processing one-off commissions for artists. The arrival of a new 5 kW fiber laser BLM LC5 with integrated tube cutting module aims to build on this customer service. Production manager James Waldron-Stevens says: “The combination of flat bed and tube gave us peace of mind as the machine could still be used as a flat-bed machine if the tube business didn’t develop.”

Tube and sheet laser expansion

In fact, since being installed in May this year, the machine is already running at 50/50 tube/sheet capacity with the aim to increase its use on tube processing to 75%. Mr Waldron-Stevens says: “While we bought it for the tube processing capacity the

option of being able to instantly switch to flat sheet means that we have also increased our sheet processing capacity, and it fits our philosophy perfectly adding to our commitment to be a one-stopshop for customers.” 8 mlfabcuts.co.uk

Latest laser-punch speeds throughput The UK’s first TRUMPF TruMatic 1000 fiber laserpunch, is helping Luton-based Islebest achieve cycle-time reductions of 35% against stand-alone laser and punching machines. “At first, we just looked at a new 2D laser machine, but that didn’t bring anything extra to our capacity,” says Managing

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Director Paul Burchmore. “The TruMatic fiber offers so much more, with its marking, folding and tapping capabilities. Furthermore, it is a lot quicker on thinner materials and uses far less electricity. “Thanks to our investment, we are able to run parts quicker and to a better standard of finish and specification,” states

Mr Burchmore. “I estimate we are saving 35% on cycle times, as well as eliminating many secondary operations. Just the fact that the machine will laser-cut intricate shapes and punch lots of holes, as in the case of our perforated shelving, is such an advantage time-wise.” 8 islebest.co.uk

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WATERJET & LASER CUTTING | Engineering Capacity

Robot boosts welding capacity by 30% Full-service sheet metal manufacturer, Malton Laser, has increased its welding capacity by 30% following its investment in an advanced robotic welder. Malton Laser invested in the two station Panasonic Tawers MAG 1600WG Welding Robot System in response to increased demand for precision welding projects. The innovative robotic welder will undertake jobs for a number of high-profile clients, initially completing projects for one of the UK’s leading boiler manufacturers. The machine has the ability to weld four times faster than current methods, speeding up and streamlining production, while

reducing lead times for the client. The automated nature of the new equipment also means that engineers in Malton Laser’s fabrication department will have the capacity to focus their expertise on other areas of the business. Charles Corner, managing

director of Malton Laser, said: “The introduction of the two station Panasonic Tawers MAG 1600WG Welding Robot System is an incredibly exciting opportunity for Malton Laser, and with the ability to increase capacity by up to 30%, the investment is sure to assist us in continuing to grow to become one of the leadin sheet metal manufacturers in the industry. Members of the Malton Laser team have been selected for specialist training to ensure the welder is in capable hands and performing to the best of its ability, producing high-quality weld finishes for our customers’ products. 8 maltonlaser.com

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

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

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SEPTEMBER 2017

Engineering Capacity | WATERJET & LASER CUTTING Diversification into supplying new areas of retail is paying dividends for Loughborough manufacturer JC Metalworks after it announced a 24% increase in sales. The company, which employs almost 100 people, offers inhouse metal part and product manufacturing services including laser cutting, punching, metal forming, fabrication, powder coating and final assembly. It has any secured a string of new contracts to supply precision metal parts for point of sale and products being used by high street brands, restaurants and clients involved in the automotive, retail and Heating Ventilation and Air Conditioning (HVAC) sectors. Backed by expert support from the Manufacturing Growth Programme (MGP), the company has completed a strategic business review that identified the need for a more cohesive approach, a programme of upskilling across the workforce and the implementation of new lean manufacturing processes. This has resulted in the £1m surge in business and is just the start as the firm plans to achieve £10m turnover by 2020, a £3.3m increase on its current £6.7m order book. Nick Oakland, Managing Director, commented: “There’s a lot of opportunities in retail POS and we are now pro-actively targeting those with very good effect. “Our flexibility, manufacturing capabilities and ability to get involved in design makes us a natural fit and the recent new contracts underline this…these SEPTEMBER 2017

Business focus boosts sales

If we can hit the £10m as anticipated we’ll definitely need more staff; there could be as many as 20 new jobs

‘‘

are technically demanding projects that need a strategic approach with the client.” He went on to add: “It’s all about building relationships and ensuring customers know our full range of expertise and how we can support them going forward. We are now up to £6.7m annual sales and want to increase this year-onyear between now and 2020. “If we can hit the £10m as anticipated we’ll definitely need more staff; there could be as many as 20 new jobs.” JC Metalworks has been working with the Manufacturing Growth Programme (MGP) since

the beginning of the programme in October last year. As part of the strategic review, the company was introduced to expert John Collins and his team at PCA, who supported the firm with internal organisational structure, developing training plans and creating a new approach to sales. A ‘5S’ manufacturing strategy was also devised and implemented, which has resulted in better ownership on the shopfloor and initial improvements in capacity and efficiency. JC Metalworks, which also runs its own apprenticeship programme, has invested over £250,000 into improvements over the last 18 months. 8 manufacturingrowth programme.co.uk jcmetalworks.co.uk www.engineeringcapacity.com

ADVANCED ENGINEERING SHOW PREVIEW | Engineering Capacity Advanced Engineering 2017 will feature five co-located zones and keynote speakers from companies including Airbus, Boeing, GKN and Dassault Systemes. The event, which is set to be the UK's largest advanced engineering show this year is conceived as a place where UK supply chain meets face-to-face with engineering management, spanning: process, control and plant industries; R & D; design; test; production & procurement from OEMs, integrators and top tier industry players within multiple industries. The event takes place on 1 and 2 November at the NEC, Birmingham. Now in its ninth year, the show is set for record breaking visitor numbers – all looking to source, specify and invest in the most upto-date products and explore the latest industry innovations – with over 700 exhibitors. The five zones that make up Advanced Engineering 2017 are: Aero Engineering, Composites Engineering, Automotive Engineering, Performance Metals Engineering and, new for this year, a dedicated zone for industry 4.0 – Connected Manufacturing. The show also includes an expanded zone for start-ups – Enabling Innovation - sponsored by Magna International and supported by Innovate UK network partner, the Knowledge Transfer Network. The zone provides a unique opportunity for 50 startups & researchers to showcase the next generation of exciting new technologies in front of a huge audience of potential 26

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Keynote speakers for Advanced Engineering

investors and customers across all engineering sectors. Alison Willis, industrial divisional director at show organiser, Easyfairs, said: “This year, we have expanded the Enabling Innovation showcase so that more start-ups will be able to access this fantastic marketing opportunity. Last year we surprised ourselves with the amount of innovation on show by these companies, and I’m sure that this year will top that. “We will welcome thousands of visitors, many of whom will be potential investors, customers, suppliers and technology professionals – all of whom will beat a path to this area. With a raft of exciting submissions received already, we’re still accepting applications for the showcase until September 30th, so start-ups can apply on the website, or simply register to visit the show – come

and let the innovations dazzle you!” Ian Simmons, Vice President Business Development at Magna International, R&D, said: “Sponsoring the Innovation Hub at Advanced Engineering has given Magna a direct link to the start-up and research communities. At last year’s showcase, we received a strong response that led to direct potential for projects and proof of concept engagement – key to helping us deliver the next wave of technology for the future of mobility.” Dr Amrit Chandan, Co-founder of Aceleron, who exhibited at last year’s showcase, said of their experience: "It played a crucial part in establishing our credibility and had a direct impact on at least five business relationships we have today. It has been instrumental in accelerating the growth of our business . . . We have now started a trial with a SEPTEMBER 2017

Engineering Capacity | ADVANCED ENGINEERING SHOW PREVIEW major automotive OEM to assess the reuse potential of their electric vehicle battery.” In the latest in a string of awards for Aceleron since the show, HRH the Princess Royal presented Dr Chandan the Hawley Award for Engineering Innovation of the Worshipful Company of Engineers on the 20th of July 2017. Photocentric, Winner of Enabling Innovation Award at Advanced Engineering 2016 and recipient of a Queen’s Awards for Enterprise in Innovation 2016, said: “The award for Enabling Innovation for our disruptive new type of 3D printer is a great honour. It proved a great success for us.” The conference programme will include keynote speakers from leading organisation in areas such as aerospace and automotive and cover topics such as how specific engineering problems have been overcome, as well as more strategic issues such as the fourth industrial revolution, Brexit, additive manufacturing and advances in aluminium engineering. The programme will include a session from Airbus on ‘The wing of the future’ an overview from EEF on the current UK manufacturing environment and the effect of Brexit, an insight into digital manufacturing from ADS, a session on power electronics from the Society of Motor Manufacturers & Traders (SMMT), a focus on Industry 4.0 from a connected manufacturing viewpoint by Magna International and sessions by GKN and Meggitt Modular Modifiable Manufacturing (M4) on SEPTEMBER 2017

aspects of manufacturing within aerospace engineering. Alison Willis said: “We’re very excited about the speakers at this year’s exhibition; with presentations from Airbus, GKN, NetComposites and Magna we’re set to have an interesting two days! “The conference will provide insights into topics affecting the

array of industries our show covers. We have something for everyone and expert industry keynotes will allow for interesting discussions and Q&As, especially around the hot-topic of industry 4.0.” For more information on Advanced Engineering, or to secure your free ticket for the show, visit: 8 advancedengineeringuk.com

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NORTHERN MANUFACTURING | Engineering Capacity

Northern view on manufacturing

Northern Manufacturing & Electronics returns to its regular venue, EventCity Manchester, for the fifth consecutive year from September 27 to 28. Once again the show provides a unique opportunity to meet potential subcontract suppliers and see the latest machines from many leading manufacturers being put through their paces. Despite being a smaller event than its long-established southern sibling, by virtue of its location in the heart of the UK’s most industrious manufacturing region, Northern Manufacturing is nonetheless a key event for machinery and tooling firms and suppliers of manufacturing services. Engineering services are one of the key aspects of the show. Once again, the selection of firms exhibiting spans a wide range of engineering disciplines. Among the many subcontract firms exhibiting is Chesterfieldbased Mintdale Engineering, a well-equipped CNC machinist that also offers clean medical assembly, brazing and induction brazing to medical standards. Items produced to ISO 9001-2008 quality standard for the medical, brewery, aircraft and shop fitting industries. Other well-known names from 28

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the subcontract world include Orbital Fabrications and Jenks & Cattell Engineering, specialists in sheet metal presswork, with presses from 10t to 1000t, as well as laser fabrication and welding. Aside from subcontracting, there are also a good number of servicebased firms exhibiting. Industrial equipment refurbishment experts UNIS Group-EDMR specialises in industrial electronics and motors, offering a “no fix, no fee” service backed by a two year warranty. MES(NW) is a Manchester-based engineering services provider with a wide range of in-house expertise in both electrical and mechanical engineering disciplines. The firm has recently been awarded a fiveyear facilities management contract with a prestigious automotive manufacturer located in the North West. The show also features a wide range of machining and production hardware.

Two new machines from Haas Automation make their UK debut at Northern Manufacturing 2017; the new 2017 ST-15 turning centre and DM-2 high-speed drill-mill centre. Both will be put through their paces with live cutting demonstrations. The ST-15 is the latest addition to Haas Automation’s line of big bore turning centres, the DM-2 compact drill-mill centre is pitched at highmix production shops looking to increase throughput, as well as job shops looking for a small, fast 40taper machine. Yamazaki Mazak has expanded its presence to two stands for 2017, giving live demonstrations of its Variaxis range of 5-axis machining centres. Combining a compact footprint with the ability to offer simultaneous five-axis machining across multiple surfaces, the Variaxis j-500/5X can be used in a variety of sectors, including aerospace and oil and SEPTEMBER 2017

Engineering Capacity | NORTHERN MANUFACTURING gas. Its advanced manufacturing capabilities - it comes equipped with a 5-axis version of Yamazaki Mazak’s SmoothX technology - are suited to small batch, volume production or prototype work, says the firm. Amada will show advances in both standalone and automated press brake technology. Built on the solid foundation of its HFE series, the HFE3i 1003 press brake includes additional productionenhancing features and an innovative touch-screen AMNC 3i interface. Also on the stand will be the HG-ATC (automatic tool changer), designed to load even the most complex tool layout within three minutes, allowing operators of varied experience levels to operate the bending system effectively. Regular exhibitors Bystronic returns with its Xpert 40 press brake paired with its innovative

Mobile Bending Cell. The system is designed to help users to produce quickly by automating as many processing steps as possible while at the same time providing the option to work manually when required. The compact Xpert 40 can be set up and put into operation in virtually any environment, claims the company. Users can set up the robotics system on the Xpert 40 in just a few minutes. When not in use, the bending robotics can simply be moved to one side. Automation also features on the Olympus Technologies stand. The firm’s Universal Robot welding system provides a cost-effective robotic MIG welding solution, ideal for companies who have previously not been able to justify the investment in an industrial robot cell, or simply do not have the space for one. Following very successful

outings at Southern Manufacturing, Devon-based YMT will exhibit its comprehensive range of tooling and workholding at Northern for the first time. The firm’s portfolio encompasses spindle tooling, collets and machine vices, through to angle heads, heat shrink technology and rotary tables. Oil and mist extraction systems are also included. These are supplied to a variety of markets including Formula 1, medical, aerospace and electronics. Another familiar face from Southern is CNC machine tool service and sales company, Leader CNC Technologies, the main European dealer for Toshiba Machine, and UK distributor for Kitamura, DMC, Gruppo Parpas and FAT Haco machine tools. The firm specialises in factory relocation, preventative maintenance, machine rebuilds, DNC interfacing and the ➠

CNC investment enhances components High quality parts and components that have been engineered precisely are a vital commodity within many industries. Finding a reliable supplier which can supply these to exact specifications can be crucial to the success of a business advises Northern Manufacturing 2017 exhibitor, Mintdale Engineering. The family-run business has been supplying precision engineered parts to clients throughout the UK and internationally in a variety of

SEPTEMBER 2017

industries for over 40 years. It has moved from producing one-off specials to medium volume, automated production. Investing in the latest CNC technology it now has turning centres with sub-spindles, live tooling and magazine bar feeds to enable one-hit machining. Working to customer drawings and in most metals and plastics, the company can produce items at one-hit without complex jigs and fixtures adding to the cost and lead time. There are also machining centres with rotary axis for

complex machined items, and the company sub-contract manufactures turned and milled components to all industries and provide clean assembly and assembled brazed items for the medical industry. The company produces items for the medical, brewery, aircraft, shop fitting and office furnishing industries. A quality management system is to ISO9001-2015. Visit Mintdale Engineering at Stand A68 8 mintdale.com

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NORTHERN MANUFACTURING | Engineering Capacity management of complete turnkey projects. Customers include Rolls Royce, Cameron, GE, VTL Group, Caterpillar, Gardner Denver, JCB, Weir Group and Goodwin. Along with conventional machining, advanced manufacturing is also well represented this year. Laser Lines, a Stratasys Platinum Partner for UK & Ireland, offers a portfolio of over twenty 3D Printer and Rapid Manufacturing systems, together with industrial lasers for cutting, welding, marking and cladding. On display will be a compact laser marker, together with a mechanical marking system. Also exhibiting is Tri-Tech 3D, offering a complete package of services from initial specification and supply of 3D printing hardware and software, to onsite 3D printer installation, staff

LCL 25 year anniversary 2017 sees Northern Electronics exhibitor, LCL Electronics, celebrate its 25th anniversary. The contract electronics manufacturer offers turnkey manufacturing, including design and prototype, small batch assembly, pre-production and medium-large volumes of PCBs, product build and cable harnessing. The company is growing and diversifying into new markets such as leisure, education, energy, food processing and entertainment. It still operates in more traditional markets, including fire

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training and full product support. Rob Pitts of Tri-Tech 3D is also one of the presenters of the showâ&#x20AC;&#x2122;s free technical seminar programme. In his Introduction to 3D Print Rob will be sharing case study examples of the limitless applications that are being discovered for this new technology across all manufacturing sectors and the new opportunities it could open up. Some of the other topics under review in the 2017 seminar

programme include implementing Lean, CE Marking, the advance of Industry 4.0 and an insight into the forthcoming General Data Protection Regulations that will have profound implications for all businesses, but for which an estimated 30% of UK companies are currently woefully unprepared. The showâ&#x20AC;&#x2122;s free entry and free onsite parking for 3000 cars make it possible to easily fit in a visit as part of a working day. EventCity is also easily reached by public transport from Manchester city centre for those wishing to spend a more relaxed day exploring what the show has to offer. To see a full list of exhibitors, the seminar programme and to register online for free tickets simply visit the show website. 8 industrynorth.co.uk

safety, gaming, automotive, audio and medical, where its quality and reliability is proven. LEDs are still proving strong in electronics production. As they become smaller and more sophisticated, so the production and technology used needs to adapt, something that the experienced manufacturer has the skills, equipment and technology to do. It claims to have the ability to achieve higher yields than other contract manufacturers, coupled with a technical team with an in-depth knowledge and understanding of the LED assembly and production process. Located at the heart of the country, in the Midlands, the company can help customers

from the start of an initial product design through to testing and delivery, on-time and to budget. In addition, its global purchasing expertise can drive down component cost, which coupled with its technical capabilities, can lead to a reduction in time and cost. Working to BSI ISO 9001:2008 accreditations and producing RoHS-compliant products, manufacturing and production benefits include reduced operating costs, freeing up of internal resources, allowing for fewer vendors to manage, reducing inventory and accelerating time-to-market. Visit LCL on Stand D1 8 lclelectronics.co.uk

SEPTEMBER 2017

Engineering Capacity | NORTHERN MANUFACTURING

Smart plastics add intelligence Visitors to the igus stand at Northern Manufacturing 2017 will see a wide range of cost-effective, lightweight and maintenance-free bearings and cable management systems for a variety of applications. Predictive maintenance is the cornerstone of Industry 4.0 and the factory of tomorrow, says the company. Its smart plastics warn of potential failure in good time before unplanned and very costly downtimes occur. New and improved smart plastics will be on show this year, including the isense EC.RC, a new system for monitoring e-chains, the CF.Q module for the intelligent chainflex cables that customers are using today, and the intelligent iglidur PRT slewing ring bearings. Injection-moulded, 3D-printed or machined from bar stock, engineers have a range of possibilities to obtain self-lubricating parts, such as gears or plain bearings quickly and cost-effectively. During the show, a new process for the production of 3D printed injection mould tools will be introduced. It allows engineers to solve difficult technical challenges quickly. The entire range of 50 iglidur high-performance plastics is available using the process, including specialists for high load, food contact, underwater or high temperature applications. Depending on the iglidur material chosen, the mould is SEPTEMBER 2017

either SLA or SLS printed and then used immediately in the injection-moulding machine. Parts are ready for shipment within days. The material structure of the printed injection mould ensures that it can withstand high temperatures during injection moulding, which means that one mould can produce prototypes and small batches up to 500 pieces cost-effectively and quickly. Optimum use of installation space, light weight and high stability are benefits of the E4.1L lean energy chain (pictured). The weight saving, compared to the E4.1, saves drive power. The chain can also accommodate more hoses and cables in a given space envelope. It is available from stock in a choice of interior heights and widths. An ESD version of the open energy chain, and a high-temperature option are also available. Team members will be available to take visitors through the benefits and potential applications of bearing products and cable management systems. Visit igus at Stand D44 8 igus.co.uk

Northern debut for CEM Trojan Following its successful participation in Southern 2017, Trojan Electronics is exhibiting for the first time at Northern Manufacturing & Electronics 2017. The firm says itâ&#x20AC;&#x2122;s looking forward to seeing its many customers in the region as well as being able to introduce its wide range of services to new potential customers in the North. The company offers a comprehensive CEM service from design to final product build, services include surface mount and through-hole assembly, cable assemblies, electro-mechanical assemblies and box build. Continued growth has led to the decision to relocate from three sites in 2015, to occupy a new, purposebuilt 180,000 sq.ft development in Swansea. This consolidates the three business units, return and repair, e-tail sales and fulfilment and contract electronic manufacturing (CEM). The new facility provides additional surface mount lines, extra capacity for through- hole assembly, as well as enabling large increases in box build output. Experience from its e-tail division means it can package and despatch box built products direct to consumers. Visit Trojan Electronics at Stand A55 8 trojanelectronics.co.uk

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MOULDING| Engineering Capacity

500t press for larger mouldings Contract moulder LGG Charlesworth (LGGC) has installed a 500-ton injection moulding machine (IMM) from Wittmann Battenfeld UK that will allow it to build its business in larger parts. This is part of a round of £0.5 million investments to support the company’s continued growth. The current wave of investment and expansion in the past 12 months is aimed at creating further capacity and driving standards and performance even higher. Commercial Director, Shaun Champion, says: “Our Wittmann Battenfeld 500-ton press was selected following a detailed exercise that compared the current market offerings. MGS Technical Plastics Ltd is using a Telsonic twin-head ultrasonic system to weld inlet aperture mouldings into left and right hand blow moulded ducts. The HDPE (high density polyethylene) blow moulded ducts have PP (polypropylene) injection moulded apertures at each end of the part. These apertures are designed to engage with a nominal clip fit to produce an initial, loosely held sub-assembly. A supporting twin spot weld, on one side of the large aperture end of the assembly, is also required to maintain the integrity of this

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“Eight different machine manufacturers and a total of 12 different machine options were considered. A full review of all the various options showed the Wittmann Battenfeld press as being one of the most technically advanced available. In addition, all the ancillary equipment – made and supplied by Wittmann Battenfeld - created a total package which succeeded in ticking all of our boxes and needs.”’

A key feature sought by LGGC was to have all production cells fully integrated and utilising the latest Industry 4.0 technology. Mr Champion adds: “‘Industry 4.0 is clearly near the top of the Wittmann Battenfeld agenda, as it is for LGGC. In short, we found Wittmann Battenfeld to be professional, detailed and responsive to our needs.” 8 lggcharlesworth.com

Welding plastic inlet ducts sub-assembly until the parts are finally assembled into the vehicle. The ultrasonic process offers a fast, consistent and repeatable process, capable of penetrating these thick walled parts. Other, mechanical fix methods such as staples were ruled out as being unsuitable. The process also fits the recyclability requirement of the parts as no further fixing methods or materials are used. The materials are dissimilar, preventing a true fusion weld, however a spotweld through the HDPE into the PP

moulding at two strategic points creates a mechanical locking action of sufficient strength to retain the assembly until it is finally presented to the vehicle on the production line. Telsonic UK supported MGS Technical Plastics Ltd at all stages of the project. This included the in-house sub-contract manufacture of pre-production assemblies whilst the production machine was being built. 8 mgsplastics.co.uk

SEPTEMBER 2017

Engineering Capacity | MOULDING

€4m European investment at Proto Labs Rapid prototyping and on-demand manufacturer Proto Labs has announced its largest European infrastructure investment since the UK business was established in 2005. The business has financed a spend of around ¤4 million on new manufacturing technology and facility renovations; primarily in Telford, UK and also its other locations across Europe. The investment is in response to current and projected customer demand for Proto Labs’ advanced manufacturing services from across Europe. During June and July 2017, Proto Labs, digital manufacturing service providers in 3D printing, CNC machining and injection moulding, confirmed their largescale purchase of Haas CNC machines and ARBURG injection moulding machines. “Proto Labs offers a supremely fast and reliable service,” said Lee Ball, Proto Labs General Manager in the UK. “Because customers today across all industries require fast turnaround, especially in product development. Our continuous investment allows us to meet the ever-growing needs of our thousands of customers across all industries.” The new Haas machines will be configured for either mould making or component machining, with both of these services growing at a rapid pace. Including the new machines, Proto Labs UK’s inventory now totals 130 CNC SEPTEMBER 2017

machining and 57 injection moulding machines. “We are seeing demand for moulded parts increase across the board yearover-year, from both longstanding and new customers, for a range of products and industries. To meet predicted levels of growth, a critical leverage is this investment in new technology.” said Lee Ball. Demand for the Proto Labs’ industrial 3D printing service, which operates from two sites in Germany, is also growing. Daniel Cohn, Managing Director of the 3D printing business Proto Labs GmbH in Feldkirchen, Germany, said: “The rapid increase in order intake is being fuelled by more customers, across varied industry sectors, now realising the extensive possibilities to prototype parts

with complex geometries cost-effectively using 3D printing technology. For certain parts, the only possible option is to manufacture using this technology.” This recent capacity growth is reinforced by business expansion across Proto Labs’ European locations. Since 2015, the business has supported annual growth in excess of 20 percent in manufacturing and engineering, sales and administrative functions. “Additional space will be required within the next 18 to 24 months to accommodate our projected level of growth, both to our office space and manufacturing capacity,” said Lee Ball. A similar expansion plan is also in development to support expected growth in the company’s German facilities at Eschenlohe and Feldkirchen. 8 protolabs.co.uk www.engineeringcapacity.com

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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HEAT TREATMENT 8

Qualiturn Products Limited

Flame Hardeners Ltd Bespoke surface heat treatment processors. Gears up to 4.5m dia. Shafts or rollers up to 1.5m dia. and 7.5m in length. Machine beds up to 6m lengths. Wheels up to 2.3m dia. We have over 75 years of experience.

MANAGEMENT SYSTEMS 8

Shorter Works, Bailey Lane Sheffield S1 3BL Tel: 0114 276 8167 www.flamehardeners.co.uk/ MACHINING (5 AXIS) 8

GEAR CUTTING – GENERAL 8

CNC PRECISION COMPONENTS 8

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

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.

Kirkham Engineering Co Ltd 13 - CNC Sliding Heads up to 1”; 14 CNC Twin Turret Fixed Heads up to 65mm; 5 - Twin Turret Twin Spindle; 5 - Twin Turret with Sub-Spindle and 4 - Twin Turret; 4 - CNC Single Turret Fixed Heads up to 6” Billet. Centreless Grinding & T/rolling. All materials - Stainless Steel; Nickel Alloys and other exotics a speciality. Prestwood Place, East Pimbo, Skelmersdale, Lancashire WN8 9QE Tel: 01695 727401 www.kirkhamengineering.co.uk

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

PSL Datatrack PSL Datatrack, a flexible production management system for small/ medium size manufacturing businesses, helps to manufacture quality parts, on time and at the right price. PSL Datatrack provides vital information to management and shop floor. Lily Hill House, Lily Hill Road, Bracknell, Berkshire RG12 2SJ Tel: 08456 345931 www.psldatatrack.com

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

PRECISION ENGINEERING 8

JFL Broaches and Broaching

GRINDING CENTRELESS 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

SEPTEMBER 2017

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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

Rotatech Ltd Specialists in reconditioning and rebuilding of all makes of precision machine tool spindles. Spindles rebuilt in purpose built clean room. On-site removal and re-installation available. 20 Cavans Way, Binley Industrial Est, Binley, Coventry, W. Midlands CV3 2SF Tel: 02476 452600 www.rotatech.com

SEPTEMBER 2017

TURNED PARTS 8

Accredited to AS9100 Rev C

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

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Saws (UK) 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

SPINDLE REBUILD 8

SAWING MACHINERY 8

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

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