Engineering Capacity September 2020 Digital Edition

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

September 2020

INDUSTRY NEWS | AUTOMOTIVE | MOULDING | MACHINED PARTS

Fibre laser and waterjet cutting services from one reliable resource - ICEE – See story on page 28

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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 Tel: 0207 241 4627 Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services.

For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company no. 10567217 ISSN 0306-0179 COMING UP IN OUR NOVEMBER 2020 ISSUE Forming & Fabrication, Aerospace & Defence, Five-axis Machining, Composites, Turned Parts, Measurement, Inspection & Testing Services 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 Covid-19 is likely to change forever the way we do many things.

Some of these are certainly negative. Reduced customer service in the banking sector is one that immediately springs to mind as opening hours are cut, more branches are closed and enquiries are filtered via automated chat robots.

Retailers are taking the opportunity to phase out inconvenient and time-consuming cash transactions and your GP is now more likely to be a disembodied voice on the phone rather than a friendly face across a desk.

Grumpy? Me? OK, it is easy to get ground down by the inconveniences of the Covid-19 pandemic, even if you aren’t currently affected by the illness itself. But if you dig deeper there are some positives to be found.

Re-imagining the way we do things gives us the opportunity to do things better and in a more sustainable way.

Some recent research by Protolabs suggests that taking a greener path in the future may be the key to the aerospace industry making a recovery after the pandemic.

The ‘Horizon Shift’ found that over three-quarters of European business leaders in the sector expect environmental credibility to be a key differentiator in the future. Nearly as many thought that new materials would be the critical factor in getting emissions down and making flying cleaner.

On top of this, nearly two-thirds thought that we shouldn’t pull back on investment in innovation despite the pandemic.

Perhaps most crucially for the subcontract manufacturing market though, 42% were now transforming their supply chains as part of the innovation drive to cut down carbon footprint.

Naturally, they want governments to back this up by providing support and stimulus packages to help them create new revenue streams, embed innovation in the supply chain and bring new products to market quickly.

Problem is, there are a lot of special cases at the moment.

Andy Sandford, Editor

Member of the Engineering Industries Association

SEPTEMBER 2020

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Contents September 2020

14 AUTOMOTIVE

News

Features

06 110 years in the family 06 Ford Engineering celebrates

13 Automotive 06 Oiling the supply chain Electrification cluster created

its longevity

19 Machined Components 06 Medical housings 40% faster

07 30,000 Mazak controls 06 Outsourcing specialist

Lend out to help out All set for productivity 5-axis targets aerospace

partners machine tool maker

08 Aerospace additive production 06 New large-scale 3D print

10 INDUSTRY NEWS 33 Waterjet & Laser Cutting 06 Cell gives dimensional flexibility

capacity

Building on a pizza base

09 Medical opportunity taken 06 Exact Group gains ISO 13485

36 Moulding 06 Meeting food industry demands Two Golds in a row

10 Prototyping joining processes 06 Welding development service launched

11 Type 26 frigate contracts 06 Five more suppliers named 4

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24 MACHINED COMPONENTS SEPTEMBER 2020

Engineering Capacity | INDUSTRY NEWS Samuel Taylor Ltd (STL) is set to invest £100,000 in two new presses to support a new manufacturing project.

The metal contact specialist says that short-term market demand has been significantly reduced, but against this backdrop it is purchasing two new Chin Fong OCP45 stamping presses as part of a project that will see the introduction of two new production lines at its Redditch-based facility.

“These are unique times in business” says Sales & Marketing Manager Carl Siviter.

“However, optimism and solid engineering remain a cornerstone to the eventual recovery of manufacturing and STL are continuing to battle through the current difficult times, whilst maintaining our commitment to a longer-term plan. The ethos of supporting strategic customers is central to this, and in this instance is evidenced by our latest investment to increase capacity.”

STL identified that in ever more competitive and global markets, cost of ownership was key to customers.

Earlier this year, the company came up with a new proposal for reducing direct cost at one of its strategic customers. The proposal was subsequently validated, accepted, and is planned to be implemented into mass production scale before the end of 2020.

Carl Siviter adds: “The project scope includes tool design and build, integrated with two new production lines which will include the 2 new Ching Fong OCP45 presses. Tools and the SEPTEMBER 2020

New production lines

production lines are in-house supported projects.”

The Ching Fong presses were purchased and will be installed as part of an ongoing partnership with Dudley-based Worcester Presses.

Russell Hartill, Managing Director of Worcester Presses said: “This latest investment is characteristic of the company’s approach and willingness to make targeted investments where required. They have developed an exceptional team of people that are empowered to be creative and develop innovative solutions for their customers.

“Over the course of our partnership with STL, we have installed more than 10 presses, feeders and coil handling systems”.

Investment in the new

production line follows a significant outlay in 2019, as STL invested £500,000 in new machinery and additional factory space in order to support both existing and new customers and as part of ongoing efforts to increase capacity and efficiency.

“We operate globally, and investment is required to ensure that we remain competitive, but it has also enabled us to broaden the services that we can offer. Between the announcement of our 2019 investments and those that we are making now, other smaller investments in new equipment have been made, such as the £30,000 purchase of a 4th wire eroder which has increased day to day production flexibility in our onsite toolroom” concludes Mr Siviter.

8 samueltaylor.co.uk www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity South Shields-based Ford Engineering has remained in the same hands for more than a century and is celebrating its 110th birthday.

Today the Group is a global specialist in the high precision machining and pressing of parts and sub-assemblies for the aerospace, industrial, and other high-technology sectors and is headed up by the great-grandson of the founder.

The company can trace its roots all the way back to 1910 – and a photograph of its founder, Robert Ford, remains proudly on display at the South Shields office.

It was formed with a £25 loan from Robert’s freemason colleagues that enabled him and two staff to set up a new manufacturing venture.

Although his business proved a success and he was able to repay the loan, the company might not have been set up were it not for an injury he sustained in 1909 while working for his former employers, Newton and Nicholson.

Robert’s hand was crushed in a pressing machine and he lost the ends of two fingers in the machinery which initially left him unable to work as a corrugated steel joints maker at the manufacturer.

Today, great-grandson Chris continues at the helm of the business keeping his greatgrandfather’s legacy alive.

He said: “My great-grandfather was only 29 years old when he was laid off from his job following the accident and he needed to make ends meet. That’s when he 6

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110 years in the family

8 Chris Ford, CEO of Ford Engineering and great-grandson of the founder Robert Ford.

Inset founder Robert Ford

decided to set up his own company making corrugated steel joints and Taylor ‘O’ rings for the steam and defence industries.

“By 1914, my great-grandfather was supporting the war effort through the steam industry as a major source of power. The company grew organically over the war years focusing on the defence industry which helped grow the business at that time.”

All in all, at least six family members have worked in the business during its long and enviable history, surviving two world wars and now a pandemic, due to the Coronavirus outbreak.

Chris said: “We have had to move with the times and have diversified over the years into other areas. We are now working in the renewables sector as well as the more traditional markets.

“Today there’s three members of the Ford family here, me and my cousins Joanne and Clare, but it doesn’t feel like it’s just the three of us. It sounds cliched but it feels like a big family here. We have a number of loyal staff with mothers and daughters, fathers and sons, and it means we all pull together when times are tough.

“It’s a fantastic business with brilliant people, Ford really does owe everything to its employees and workforce over the years and it’s testament to them that we’re still operating successfully today.”

8 ford-engineering.com SEPTEMBER 2020

Engineering Capacity | INDUSTRY NEWS Strategic manufacturing outsourcing specialists PP Control & Automation has delivered its 30,000th control system to Mazak UK. PP C & A has been working with the global machine tool builder for more than 27 years and the latest partnership has seen it play a key role in the design and production of the new CV5-500, a fully simultaneous 5-axis machining centre.

“The relationship dates back to 1993 when Japanese senior management team saw something ‘different’ in our approach and a company-wide focus on quality, resulting in the placement of the very first order,”

SEPTEMBER 2020

30,000 Mazak controls explained Tony Hague, CEO of PP Control & Automation “As the years have gone by, the relationship between the two businesses has become more interlinked, with PP C&A increasingly invited to be involved in the design stage of new machine builds to support ‘Design for Manufacturing (DFM)’ and to understand how more specification can be added easily to new models.”

He continued: “For this project, our engineers worked closely with Mazak from the outset of the concept, looking at ways in which

we can add value, eliminate unnecessary costs and standardise the build process, whilst still being able to deliver greater scope for the customer to configure machines.

“We are also now taking full responsibility for total supply chain management, including working with multiple Japanese manufactured parts to ensure that we reduce the hidden costs that can arise if the customer is having to manage this. Vendor reduction and rationalisation is a big driver.”

8 ppcanda.com

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INDUSTRY NEWS | Engineering Capacity

Aerospace additive production Latvia-based AM Craft, a contract aerospace additive manufacturer, has invested in four new large-scale production-grade 3D printers that will make it one the largest suppliers of its kind in Europe.

This is one of the largest single orders to date for supplier Stratasys and the new F900 machines will allow AM Craft to provide certifiable 3D printed parts for a much wider range of aircraft interior applications. This includes everything from aircraft seating, panelling and ducting. It will also make it much more affordable for its aerospace customers to introduce customisation within the cabin.

“In recent years, we’ve seen an ongoing demand for 3D printed production parts among major aircraft OEMs,” comments Jānis Jātnieks, Co-founder and CEO, of AM Craft. “Although COVID-19 has shocked the industry in the last few months, we are seeing efforts to return to business by remodelling passenger planes for cargo shipments, as well as projects to increase customer safety measures and improve the inflight customer experience – for example by providing mobile device charging stations and Wi-Fi infrastructures. In such cases, additive manufacturing is way 8

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ahead of slower and more costly traditional methods.

“One of the mainstay pillars that enables us to realize this business case into real-world applications is Stratasys’ highly-repeatable FDMbased 3D printing technology in conjunction with aerospace-grade materials like ULTEM™ 9085 resin.

Crucially, this gives us the capability to meet strict rules and regulations around certification that require the highest level of repeatability and traceability with every part manufactured,” he adds.

The high-performance ULTEMTM 9085 resin meets stringent flame, smoke and toxicity (FST) criteria and retains traceability required by the aerospace industry. The material is used by aircraft manufacturers such as Airbus, which has successfully standardised it for the production of thousands of flight parts for its A350 XWB aircraft. Certified to Airbus material specifications, ULTEMTM 9085 resin allows the company to produce strong yet lightweight

aircraft interior parts at significantly reduced manufacturing cost.

AM Craft’s investment will complement an existing hardware line-up of four Stratasys Fortus F450mc 3D Printers. Collectively, the battery of eight FDM-based machines will provide the core of a dedicated new additive manufacturing facility in Riga that will focus specifically on fulfilling the application requirements of the company’s customer base of aircraft suppliers and airlines.

AM Craft’s investment will see the company become one of the largest independent aerospacefocused 3D printing service providers in EMEA. The business will operate as a sister company to Baltic3D, an established 3D printing service provider that has worked closely with companies within the aerospace supply chain since 2017.

AM Craft’s Riga facility is expected to be fully operational in Q4 2020.

8 am-craft.com SEPTEMBER 2020

Engineering Capacity | INDUSTRY NEWS The Covid-19 lockdown has given the Newry-based Exact Group, the opportunity to achieve medical device accreditation.

The ISO 13485 accreditation complements the company’s existing Aerospace and Defence accreditations and awards.

ISO 13485 is a quality management system that demonstrates compliance to stringent medical device quality standards that consistently meet customer and other regulatory requirements.

Seeking this accreditation during the coronavirus pandemic helped the company to maintain its workforce and contribute to the health and wellbeing of the local community.

SEPTEMBER 2020

Medical opportunity taken Founder and manager director Stephen Cromie said, “I am delighted that we have achieved this medical accreditation, which clearly reinforces our commitment to quality and process excellence.

I would like to thank our Quality Manager, Dermot Kelly and his team, for gaining this accreditation during these challenging times.

Dermot was only appointed as Quality and Continuous Improvement Manager in February this year, several weeks before the lockdown. To quickly understand our ethos and culture, accept this challenge and succeed in this short space of time is

testament to him, his team and the Exact Group. Well done to all and thank you.”

The Exact Group’s processoriented approach to operations and their pre-existing commitment to quality were instrumental in successfully obtaining the certification and ensuring the implementation of compliance procedures.

“This medical ISO accreditation sets the company in good stead for working with the many companies in the pharma and medical sectors across the UK, Ireland and beyond,” continued Stephen.

8 exactnewrycnc.com

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INDUSTRY NEWS | Engineering Capacity A new prototyping centre will help manufacturers develop joining processes and carry out small series production for components such as EV battery trays.

In late autumn 2020 Fronius International will open a new prototyping centre to develop solutions for customers and carry out small series production.

The centre will be sited at Wels, Upper Austria, where the welding technology manufacturer will not only be working on individual solutions for customers in the field of joining technology, but also welding small series components for the prototype phase.

Trends such as e-mobility are resulting in new components and thus new challenges in production, particularly in the area of joining technology. The special systems that are required, particularly for prototype manufacturing, can pose an investment risk.

As an important strategic step towards becoming a Sheffield based steel casting and forging specialist, Sheffield Forgemasters, is manufacturing key components for a revolutionary new device for the renewable energy sector.

In a first for the company, it will supply energy giant GE’s Power Conversion Business with central components for rotating stabilisers, large turbine-like devices which work to stabilise electricity fluctuations on the electrical grid.

Sheffield Forgemasters will

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Prototyping joining processes

solutions provider, in the future Fronius Perfect Welding will be welding components for prototypes according to customer requirements.

This means the customer does not need to invest in its own prototyping centres and also has the welding knowledge of Fronius at its disposal.

Wolfgang Scherleitner, head of the prototyping centre, continues:

“We offer our customers technical support and develop the ideal welding solution for the specific component in house. If this eventually goes into series production, as a general contractor we can also supply the necessary welding systems.”

The Fronius prototyping centre will be put into operation at the start of November this year.

8 fronius.co.uk

Stabilising sustainable power initially deliver the main rotator shaft and hub for a rotating stabiliser located in Moray, Scotland which has been developed by Statkraft.

Kunal Popat, senior sales manager at Sheffield Forgemasters, said: “This is an exciting project to be involved in, we are delighted to be working with GE Power Conversion on their first rotating stabiliser reference in the UK Energy sector, an identified growth sector for

Sheffield Forgemasters.

The challenge of forging these large components and then conducting a delicate heat-shrink fit to bond the hub onto the rotating stabiliser's main shaft, is significant and our Research, Design and Technology team has had considerable input into the design of both components and the subsequent route to manufacture.”

8 sheffieldforgemasters.com

SEPTEMBER 2020

Engineering Capacity | INDUSTRY NEWS

8 Construction has begun on final unit of the first Type 26 frigate, HMS Glasgow

commitment and innovation in recent months to ensure we meet our customer commitments.”

Designed and built by BAE Systems in Glasgow, the Type 26 frigate is an advanced antisubmarine warship.

8 baesystems.com

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brings a unique capability that is essential to ensure the safe and continued progress of this nationally important programme.

It’s fantastic to see the first of class, HMS Glasgow, taking shape at our facilities here on the Clyde. She is a source of great pride for our workforce who have worked with real energy,

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SEPTEMBER 2020

Type 26 frigate contracts

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BAE Systems has awarded a further five contracts to suppliers worth more than £100m, as progress on the Type 26 frigate programme continues apace at the company’s shipyards in Glasgow.

The new contracts will support 250 jobs, with the Type 26 programme sustaining more than 4,000 jobs in total across the UK, helping to support the nation’s economic recovery by maintaining much-needed skills and capabilities. More than £1bn has been invested across the programme’s supply chain to date, with more than 100 suppliers globally.

The contract awards come as construction on the final unit of the first Type 26 frigate, HMS Glasgow, begins. All 57 units of the anti-submarine warfare ship are now under construction.

The suppliers awarded each of the five new contracts will contribute essential work to the programme as HMS Glasgow moves to the outfit phase in readiness to enter the water for the first time.

The contracts have been awarded to: Denholm Industrial Services (Glasgow) for surface preparation and painting; Malin Group (Glasgow) for vessel load out and float off; CBL (Hartlepool) for cable and associated works; Kaefer (Nottingham) for insulation products and installation services and SCA (Dorset) for access and containment BAE Systems Naval Ships Managing Director, Steve Timms, said: “Each of our new suppliers

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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 Hole filling A UK SME has developed patented technology for automatically filling the holes left by automatic nail and screw guns. It has developed a robust fully functioning prototype and created significant patent protection for the technology. It is now looking for manufacturing and/or distribution partners with established routes to market and also a brand partner to license and sell the technology.

Reference: JV1424 Closing Date: 18/10/2020 Self-repairing robot A UK SME has developed a selfrepairing industrial robot system using a patented method that eliminates downtime and system failures. It now wants to engage with partners to further develop it to a proof of concept and demonstration stage. It is also open to license agreements.

Reference: JV1425 Closing Date: 28/10/2020 CO2 laser cutting A British supplier of CO2 laser cutters used for engraving and cutting coated/uncoated metals, plastics, wood, paper, leather, card and glass seeks distributors with routes into education, sign making, printing and general engineering.

Reference: JV1429 Closing Date: 06/11/2020 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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Stephen Phipson CEO of Make UK, has been appointed to a new Trade Advisory Group which will oversee business engagement with manufacturers and help inform the UK’s ambitious trade negotiations, in particular the current and upcoming negotiations with Japan, the United States, Australia and New Zealand.

Mike Wilson has been appointed by The Manufacturing Technology Centre (MTC) as Chief Automation Officer.

Mike will lead the MTC’s drive to increase the adoption of automation throughout UK manufacturing. He will be helping companies that want to benefit from the increased application of automation.

Dyan Crowther Chief Executive of HS1, has been appointed as the new chair of The National Skills Academy for Rail (NSAR). NSAR says her experience and commitment to skills and productivity make her an ideal candidate to guide it through the COVID recovery period and beyond.

Dave Smith has been appointed as Senior Sales Manager at Eclipse Magnetics.

Some of Dave’s responsibilities will include supporting the internal and external sales teams, building new and supporting existing distributor channels and partners across all product groups.

SEPTEMBER 2020

Engineering Capacity | AUTOMOTIVE Cast metal specialist Grainger & Worrall has used its rapid end-to-end approach to fill product requirements in order to avoid costly delays to post-Covid 19 shutdown automotive production restarts.

This has enabled the company, which won a Queen’s Award for Innovation earlier this year for its innovative ‘Next Generation’ castings, to play a key role in helping to restart the automotive industry in Europe.

“We’ve been working in carefully controlled conditions throughout lock-down on areas of development, which has put us in a strong position to be able to respond as we come out at the other side,” said Phil Ward, sales director. “While it’s certainly been a very difficult period for many, we are now finding that our ability to take a component concept and turn it into a fully validated, production item ready for the line in a very short timescale is ideally suited to the requirements from manufacturers during restart.”

The award-winning company has utilised its expertise in casting design & simulation, materials development and dimensional & integrity validation to help deliver new components for vehicle product launches delayed due to Covid-19. “Our rapid turnaround and ramp-up production facilities means we’ve been able to fill gaps in the supply chain which otherwise could wreak havoc with launch timetables,” says Ward. “In one example, we’ve been able to design from concept, test, validate, produce and machine a SEPTEMBER 2020

Oiling the supply chain

cast suspension component for a major manufacturer in what would normally been seen as an impossibly short timescale.”

Grainger & Worrall has had a key role to play in new propulsion systems too, as Ward explains: “We were recently asked to respond quickly to the need for a hybrid vehicle battery casing, which of course has a completely different set of requirements to ICE castings. Here, the battery casing is expected to elongate and deform under impact to protect its contents, and we were able to validate a design and start manufacture within days of the request being received, something which was certainly a pleasant surprise to the customer.”

With its site outside Bridgnorth boasting a large, modern machining facility as well as numerous testing laboratories, including a some of the largest CT scanners in the country, Grainger & Worrall’s ability to develop and validate components looks set to play a part in metal component development throughout the recovery. Ward concludes: “It’s hard to see a long way forward just at the moment – who knows what further disruption may lie ahead? But it’s very satisfying to be in a position to help the passenger and commercial vehicle industry to start getting back into production.”

8 gwcast.com www.engineeringcapacity.com

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AUTOMOTIVE | Engineering Capacity

Electrification cluster created A new manufacturing cluster has been established to target more than £10m of electrification opportunities over the next twelve months.

Brandauer, C-MAC SMT and PP Control & Automation - all members of the Manufacturing Assembly Network (MAN) - have come together to offer a singlesource supply chain solution for electric motors, drivetrain components, battery cells, casings and housings, transfer laminations, PCB assemblies and wider infrastructure services.

The trio has also enlisted the expertise of industrial automation specialist Balluff to drive the opportunity and this joined-up approach is already reaping dividends by helping it secure in excess of £3m of off-highway automotive contracts and an order for an upwind turbine system from FuturEnergy.

“Electrification is a massive opportunity for our four businesses and we feel that by collaborating and pooling together our different, but complementary disciplines, that we can offer the OEMs and end users access to a single source solution,” explained Richard Halton, Business Development Manager at C-MAC SMT, a leading independent provider of complex, high reliability electronics and system assemblies.

“Whilst transport electrification is a natural marketplace and one that we are already picking up work in, there is a strong sense 14

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that we can also go after contracts to support the alternative energy sector and electric infrastructure work for street furniture and charging points for example.”

He continued: “Both of these markets are ramping up quickly and need partners who have a track record of delivering complex assemblies on time. This is exactly what we’re giving them with this cluster – experts in strategic manufacturing outsourcing, wiring looms, high volume pressings and laminations and electronic assembly.

Daniel Walton, Applications Engineer at Northwich-based Balluff, added his support: “We are delighted to be joining the MAN cluster so we can explore how collaboration can help us support the UK’s electrification drive.

“Our technology and solutions lend themselves directly to electric drivetrain, battery cells and modules and we already boast inclusion in a number of

automotive OEM approval lists that will be a big plus for the group.”

The MAN Group, which employs over 2000 people across 21 different factories, is working closely with Warwick Manufacturing Group (WMG) and is immersed in long-term collaborations with electrification to look at how it can aid the drive for increased supply chain capacity.

Rowan Crozier, CEO of Brandauer, concluded: “FuturEnergy is a perfect example of how we are prepared to invest in new equipment and significant R&D to deliver a solution, which in this case is a lamination that goes into an upwind turbine system designed for use in domestic homes and industrial applications.

“The cluster can work as one, two, three or all four companies and there are very few collectives who can offer our depth of expertise and, importantly, our security of supply.”

8 man-group.co.uk SEPTEMBER 2020

Engineering Capacity | AUTOMOTIVE Lotus is creating a new sub-assembly plant in Norwich to produce aluminium components for its own Evora, Exige and Elise vehicles and for other global car makers The 12,300 m2 Hurricane Way factory will be converted to a new high tech sub-assembly facility to house manufacturing of aluminium extruded and bonded aluminium components. The facility will also house the steel welding and fabrication of subframes, suspension components and other key parts for Lotus cars.

As Lotus Cars’ expansion continues under new ownership since 2017, the company has outgrown existing facilities in Worcester and Norwich, and by

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High tech sub-assemblies

moving into one, combined new location, the company will take the opportunity to further upgrade machinery and tooling in readiness for new Lotus sportscars to be launched in the coming years.

David Hewitt, Executive Director of Operations, Lotus Cars said: “By bringing the aluminium chassis and steel sub-assembly manufacturing businesses together into one facility, we can

further improve upon efficiencies and productivity for Lotus manufacturing. Being located close to Lotus’ HQ in Hethel, Norfolk where all Lotus cars are assembled, will also benefit the business as we expand further into the future.”

Lotus Lightweight Structures’ current facility in Worcester will be re-purposed by the freeholder and Lotus will relocate from the facility in May 2021. Worcestershire-based staff will be offered the opportunity to continue their roles in Norwich, where the company is recruiting for both the new Hurricane Way facility and Hethel HQ. 8 lotuscars.com

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AUTOMOTIVE | Engineering Capacity William Hughes has come to the aid of a leading automotive tierone seat manufacturer by applying its broad set of skills and advanced capabilities in the production of complex wire forms.

The order, which was for seat frames and trim wires, comprised a number of different complex parts, all of which would see use in five different vehicles types, including SUVs and saloons. In addition to bending and forming, several of the frames also required welding. The accuracy demands were such that engineers used 3D scanners and Vernier calipers to ensure the parts precisely matched the customer specifications.

“Although we had won the order a few months previously, and had turned round the prototype parts in just four weeks” explains George Cairns at William Hughes, “the customer hit a scheduling snag, which ended up with us having a very short time period in which to produce the first thousand pieces.

These had to be delivered on time to ensure the product milestones were achieved”.

Springing to the rescue

Although other companies may have the capacity to produce the numbers required, very few possess the capabilities, skillset and knowledge that would enable such a complex and large design, test, manufacturing and delivery campaign to be achieved in such a short time.

Aerospace Oil & Gas Nuclear Defence

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Automotive Electronics Hi Fi

Industrial & High Volume Machining

“Our customer is delighted!”

Cairns elaborates. “We were able to deliver 80% of the order a week ahead of schedule, which gave it enough capacity to meet the OEM’s just-in-time delivery timescales. Although scenarios like this are not good for the heart rate, it is reassuring to our customers that we can merge our capacity with the skills and capabilities to make sure that rush orders – even ones as complex as this – have the same level of well-deserved quality that more timely orders enjoy. We threw everything at this order to ensure the customer’s goodwill, and we would do it again… just give us a chance to catch our breath first.”

8 wmhughes.co.uk SEPTEMBER 2020

Engineering Capacity | AUTOMOTIVE A leading supplier to the European car market has invested in its first ever Bruderer to help it increase output for current and future models.

Xandor Automotive Canning Brett, which manufactures exterior, interior and under bonnet components, installed a refurbished BTSA 40 high-speed press and BBV 202-120 feeder three months ago and is already achieving a 400% daily increase in volumes on selected lines.

The company is using Bruderer’s control and patented ram tool guidance technology to manufacture up to 200,000 clips, fasteners and washers every day, with the flexibility of the bed size and 1200 strokes per minute capability future-proofing its investment for years to come.

“The car industry is all about achieving more efficiencies and this means constantly looking at getting the most out of your manufacturing processes,” explained Gethin Williams, Production Shift Manager at Xandor Automotive Canning Brett’s specialist metal pressings site in Swansea.

“We had identified a number of parts that could be made quicker and in higher daily volumes, whilst still retaining the same level of repeatable quality. This prompted us to look for a new press and this is where Bruderer UK came into the equation, visiting us and identifying a solution that would work.”

He continued: “They arranged for us to take a tool up to their site in Luton and run it on the actual SEPTEMBER 2020

Pressing their advantage

machine we were interested in the results were very impressive.”

Bruderer’s BSTA 40 tonne press can operate up to 1200 strokes per minute and offers a bed area of 690mm x 550mm ideal for allowing slightly larger tools to be used that do not require the extra tonnage.

The press has also been designed to provide a range of adjustable strokes (from 13 to 57mm), with the longer stroke suitable for small electrical components and a shorter stroke for more intricate formed parts.

Xandor Automotive Canning Brett, which was keen to optimise performance and reliability, also invested in a tonnage and tool protection package that has improved the tool life significantly.

Gethin went on to add: “The first few months have been impressive, with the BSTA easily the best performing machine we have at our Swansea facility, which employs 46 people.

“These production uplifts have given us the confidence to actively go out and tender for new projects

in new markets. I’m pretty certain it will not be the last high-speed press we buy from Bruderer, especially if it continues to quadruple daily output on certain parts.”

Adrian Haller, Managing Director at Bruderer UK, said: “This is the first machine we’ve ever supplied Xandor Automotive Canning Brett and we’re delighted it has had an immediate impact on its productivity and ability to cope with increased volumes.

“It all started with our desire to spend time with a potential client, look at its entire manufacturing operations and where we feel that our technology can add real value.

The answer on this occasion was a refurbished BSTA 40, which offers world class speed, accuracy and control.”

“Our technology has delivered higher quality parts with far less burr, faster tool changes to support the implementation of single-minute exchange of dies (SMED) and freed up capacity as it is doing the work of three conventional presses.”

8 xandor.com www.engineeringcapacity.com

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AUTOMOTIVE | Engineering Capacity

Getting with the programme Sarginsons Industries has joined a national automotive programme to boost its competitiveness and access funding.

The lightweight casting specialist has signed up for the National Manufacturing Competitive Levels (NMCL) Automotive Programme and has received funding of £268,000 as part of a wider £536,000 investment to complete the programme by March 2022.

NMCL Automotive was established by the Society of Motor Manufacturers and Traders (SMMT) to help boost the competitiveness of the UK manufacturing supply chain and is supported by other major trade bodies and original equipment manufacturers.

Sarginsons’ project will begin in August and will engage all employees across four work streams, which include setting the business direction and developing the capability to deliver the strategy and developing operational capability to achieve quality and delivery expectations.

Visit our website or contact us for a quote or advice

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That should lead to Sarginsons being able to win and deliver more profitable contracts and build a capable and collaborative supply chain, with the ultimate aim of the company being positioned to deliver fully finished sub-assemblies for automotive programmes.

The grant funding is provided by

the Department for Business, Energy and Industrial Strategy (BEIS) and was approved by Birmingham City Council.

Anthony Evans, managing director of Sarginsons Industries, said: "This is yet another step in our constant drive for improvement and growth.

"We have invested heavily in recent years to enhance our capabilities and to offer so much more to our existing customer base and to new clients too.

"This will provide us with an opportunity to really benchmark that and will see us working with all of our employees over the next 20 months as part of the programme.

"Ultimately, it will help us to diversify what we can offer and reach our ambitious targets for growth.”

Sarginsons recently launched its Technology Centre as well as a Design for Manufacture (DfM) white paper that offers the company’s clients the opportunity to work with the team from the outset of designing a part or product to reduce costs and improve efficiency.

Claire Wall, from NMCL Automotive, welcomed Sarginsons onto the programme.

Claire said: “This is a critical time for the automotive supply chain and we are delighted to be able to support Sarginsons in their aspiration for continued improvements in competitiveness, productivity and growth.”

8 sarginsons.com SEPTEMBER 2020

Engineering Capacity | MACHINED COMPONENTS Mildenhall subcontractor CTPE has installed a new horizontal machining centre to meet a customer’s demand for more than double the weekly production of components for critical care diagnostic equipment.

CTPE focuses on medium to large volume production of high precision components for the scientific, medical, electronics and defence sectors using 3- to 5-axis vertical machining centres (VMCs) as well as fixed- and sliding-head CNC lathes.

To expand its prismatic machining capacity, in July 2020 the company invested in its first ever horizontal machining centre (HMC), a 4-axis , twin-pallet, 40taper Averex HS-450i with nominal half-metre cube working volume from Whitehouse Machine Tools.

The purchase was driven by an uplift from 150 to 350 per week of a particular 6061 aluminium, twopart enclosure needed by CTPE's largest customer, a medical sector OEM, for the production of critical care diagnostic equipment.

There is no problem completely machining the required quantity of covers three at a time in two hits on a Japanese-built Brother Speedio S1000X1 30-taper VMC installed last April. Neither is there an issue completing Op2 on the matching housing using the same machine, which has now been fitted with an angle head to make the cycle even faster.

However, Op1 on the housing was proving too time-consuming on a 3-axis VMC to meet the increased order level and was causing a permanent bottleneck, SEPTEMBER 2020

Medical housings 40% faster

despite the running hours having been extended from 10 to 14 per day.

Alex Taylor, a director of CTPE and son of the founder, Chris, decided that an HMC would best suit the higher production volume.

The second pallet allows the next parts to be fixtured while the previous parts are being machined and automatic pallet change takes just five seconds.

Dual augers efficiently remove chips that have fallen from a cube fixture, so there is no manual intervention except to empty the swarf bin after every couple of pallet changes.

In contrast, the spindle on the fixed-table VMC was idle for 25 minutes after each cycle for accumulated swarf to be cleared and the next parts clamped for machining. A further problem

was that recutting of chips that collected within the component risked damaging the solid carbide tools.

An HMC eliminates that difficulty and is more robustly built than a VMC so vibration is lower, meaning that cutters last longer. The most significant benefit, however, is that four aluminium billets can be fixtured on a cube for Op1, so 24 housings are machined in a cycle time of 160 minutes. Formerly on the VMC, only two billets could be fixtured for machining a total of 12 components and the program ran for 135 minutes.

The figures equate to a production time saving of 40%, considerably reducing manufacturing cost per part for this operation, particularly as there is now minimal operator intervention.

8 ctpe.co.uk www.engineeringcapacity.com

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MACHINED COMPONENTS | Engineering Capacity The Pexion Group, which includes subcontractors Drurys Engineering, Claro Precision, Paragon Precision, Oxton Engineering and Rictor Engineering, has signed a multi-million pound contract for the supply of machine tools.

This new deal will see the Wellesbourne based Engineering Technology Group (ETG) become a turnkey provider to the entire group.

ETG will initially supply the subcontracting group with six new machine tools with significantly more planned in future phases of the long-term agreement.

In the first stage of the contract, ETG will deliver a new Quaser 3-axis machining

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Machine tool partnership centre and a twin-spindle, twin-turret Nakamura-Tome WY150 multi-axis turning centre to Drurys Engineering.

Oxton Engineering Ltd will receive a Nakamura-Tome WY150 turning centre, a 3-axis Quaser MV184 machining centre and a 5-axis Quaser. Completing the first phase of installations, a Nakamura NTRX300L large bed turning centre will be supplied to Claro Precision.

The Pexion Group is striving to create a uniform manufacturing platform across its businesses, as it continues to grow. The new partnership with ETG will enable it

to consolidate the service, support and maintenance of its manufacturing facilities whilst providing ETG with the opportunity to implement technology, productivity and automation advancements throughout the Group of companies.

Chief Commercial Officer at the Pexion Group, Mr Darren Turner says: “This new contract provides the Pexion group of engineering companies with a long term investment, with an initial focus on optimising our productivity and overall capabilities as a group.�

8 pexion.com

SEPTEMBER 2020

Engineering Capacity | MACHINED COMPONENTS JRE Precision was able to cope with the high demand for its services during the COVID-19 pandemic by taking up the offer of a loan machine from XYZ Machine Tools.

The machine was an XYZ TC 320LTY turning centre, with Y-axis and live tooling capability.

With extensive experience in the design and manufacture of regulators under its Presreg brand, JRE Precision found its services in high demand during the Covid-19 pandemic. As a result, its machining capability required a rapid injection of capacity.

Loughborough-based JRE Precision’s oxygen regulators feed the main circuits in hospitals, which then feed through to ventilators.

Each of these regulators allow 3,000 litres of oxygen to be delivered per minute. Typically JRE Precision would supply around 100 units/year. Covid-19 saw a major increase in demand with 70 units required in just 2-3 weeks.

“At the same time as receiving this order we were also tasked with producing a prototype of a unit that, once approved, would require production of 30,000 units as quickly as possible. Therefore, we were extremely grateful for the provision of a loan machine from XYZ Machine Tools, with no strings attached,” says John Evans, Managing Director JRE Precision Ltd. “I was overwhelmed by the support offered from XYZ Machine Tools and the speed at which they delivered and installed the machine. So that production could commence as soon as possible.”

8 jreuk.com SEPTEMBER 2020

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MACHINED COMPONENTS | Engineering Capacity Investment in tool offline presetting helps Benham Precision Engineering keep the spindles turning and boosts capacity.

The company supplies complex components and sub-assemblies to the aerospace and defence sectors for many years, operating 22 machine tools to create a range of parts such as manifolds, bodies, castings and casings.

Based across two sites in Southampton, the company’s ethos has always been one of constant improvement in terms of its technology, people and processes, particularly when it comes to driving efficiency.

To desire to increase productivity played a major role in the decision to invest in a Zoller tool pre-setting solution over ten years ago.

Benham’s Engineering Manager Neil Griggs said: “We’ve got some 76-tool change machines in our factory. It was taking us up to three hours to find the tools, put them in the machine and measure them.

That’s dead time.

“We’ve had the Zoller for about 12 years. We wanted to reduce cycle times on the shop floor – we’ve got a tool setter that builds the tools from our set-up sheet, he then puts them onto the Zoller

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All set for productivity

and measures the lengths, diameters and so on.

“All the information is stored on the back of the chip and that is then put to the machine.

Consequently, what that does is it saves time on initial set-up and probably reduces our set-up on long-running jobs with multiple tools by two hours.”

Traditional tool setting, even with advanced laser technology on a CNC machine, is unreliable as it cannot validate critical tool features such as diameters, corner radii, step lengths and run-out prior to machining, increasing the risk of costly crashes and failures.

Legacy methods are also highly

inefficient says Zoller. While a CNC machine is setting tools, the spindle is idle and is not doing the job that it was intended to do – making parts.

Mr Griggs said: “It’s about speed and efficiency. It means we’ve got more capacity on the machines and more productivity.

“The Zoller basically takes out about three hours at the front where someone else has found and built the tools and measured them.

So rather than finding the tools, building them, putting them into the machine and then measuring them, all of that’s done.”

Mr Griggs added: “We’re tied in with Mazak and basically that’s how we got onto buying the Zoller, because it’s in Mazak’s showroom.

We’ve had no reliability problems and get a service every year. We’ve had no issues with it at all.

“Benham would never be without a Zoller because it keeps the spindle running. It’s more profitable for us.”

8 benhamprecision engineering.co.uk SEPTEMBER 2020

Engineering Capacity | MACHINED COMPONENTS Eastleigh-based G W Martin called on Yamazaki Mazak to deliver a twin-spindle, twin turret mill-turning centre within four weeks following a new project win.

Established in 1959, GW Martin supplies a complete CNC machining service, providing components to the automotive, medical, electrical, vacuum and defence sectors. While the company has traditionally specialised in the production of high-volume, precision parts, it has been driving a strategy to reduce costs and increase capacity over the last five years, with investment in automated production being central to this. This was demonstrated when it purchased a Mazak Multiplex CNC turning centre with an automatic gantry loading system in October 2019.

After winning a tender to machine a specific high-precision component in large volumes, GW Martin needed to further increase its machining capacity to complete the order in time.

The new HQR-200MSY turning centre has a two-turret, twospindle set-up that allows reduced cycle times a long Y-axis stroke for high-accuracy milling. The machine is compatible with a variety of automation equipment, including bar feeders, workpieces unloaders and robots.

Following the machine’s order at the end of February 2020, Mazak’s Application Engineering team was able to quickly engineer the HQR-200MSY off-site to fit into GW Martin’s machining line. This entire process, from order to SEPTEMBER 2020

Fast movers on capacity

installation, took only four weeks and enabled the company to manufacture the volume of bespoke parts in line with the project’s demanding schedule.

“Having worked with Mazak in the past, we were aware of their reputation for supplying quality turning centres,” says Richard Blake, Business Development Manager at GW Martin. “So, when we required an automationcapable solution at short notice that could machine high-quality components in large volumes, we knew where to turn. d

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“Our previous experience with the Multiplex W-200Y meant we were fully confident that Mazak could adapt the HQR-200MSY to suit our existing processes.

“Bearing in mind the time pressures of this project, this was absolutely vital. “We really appreciate how they were able to help us react quickly to this project win, and following this success, we ordered another new Multiplex W-200Y for installation in August.”

8 gwmartin.co.ukx

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Manufacturers of High Quality Mill-Turned Parts

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MACHINED COMPONENTS | Engineering Capacity

5-axis targets aerospace BEL Engineering has expanded its capacity with a 1m cube 5-axis machining centre that is ideally suited to the production of aerospace engine parts.

The new Hermle C 62 UMT 5axis, vertical-spindle machining centre was Kingsbury and follows the company’s accreditation to AS9100 in October 2019.

Part of the British Engines Group based in the north of England, BEL Engineering operates two factories in Newcastle-upon-Tyne and Cramlington to provide project-managed manufacturing solutions, some of which involve heavy duty subcontract machining of large workpieces weighing up to 40 tonnes.

Much of the metal cutting activity involves turning on horizontal- and vertical-spindle lathes, but parts often have to be transferred to a prismatic machining platform for milled and drilled features to be added.

Around thirty 3-axis CNC mills are available for this purpose.

The Hermle joins an Italianbuilt, 5-axis mill-turn centre with travels in excess of two metres in X, Y and Z and two Japanese-built 5-axis CNC milling centres of nominal one-third metre cube capacity, one with a 10-pallet storage system.

It fits neatly between these larger and smaller 5-axis centres, extending the subcontractor's capacity.

Diversification from supplying 24

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predominantly the oil and gas industry to include serving the aerospace, defence and civil nuclear sectors is a key pillar of BEL Engineering’s growth strategy.

It is already bearing fruit, as the manufacture of fan shafts, discs and other rotational parts for aero engines, input and output shafts and bearing housings for gearboxes, and components for engine test rigs has increased the revenue from aerospace contracts from 10% of the subcontractor’s business to about a quarter.

BEL Engineering's chief production engineer Phil Westgarth commented: "We mainly process tough materials from high strength steels through titanium to nickel superalloys like Hastelloy, Waspaloy and Inconel.

So we need powerful, rigid equipment to machine them.

"A pair of similar Hermle millturn centres is being used successfully at another of our group companies, Michell Bearings, so this influenced our choice of the German machine.

"Another facet of the decision was that Kingsbury is quoting us for production solutions based on machining centres from other principals in its portfolio and we like the turnkey approach that it brings to these projects.

"In a recent exercise, its engineers supported us on-site here by helping us to adjust inSEPTEMBER 2020

Engineering Capacity | MACHINED COMPONENTS process probing cycles so that we can run the same programs in the Siemens 840D control of the Hermle as those in use at one of our aerospace customers operating the identical type of machine."

The C 62 UMT is the largest model in the German manufacturer's range. Since it was installed in Newcastle-upon-Tyne, it has operated around the clock five days a week tackling about a dozen different jobs, only two of which require no turning. When

producing input and output shafts, for example, which involves only 20% prismatic metal cutting, the machine has proved more than capable of holding 14 microns total tolerance on turned features and 30 microns positional tolerance on hole centres.

The 400 rpm torque table can turn components using the C-axis even when the Âą130-degree, dualdrive, A-axis trunnion is swung away from the horizontal. It allows shorter, more rigid cutters to

approach closer to the workpiece surface to achieve higher metal removal rates, better surface finish and longer tool life.

During non-turning sections of production cycles, the rotary axes have been used mainly to position components for 3-axis milling and drilling, with only a small amount of full 5-axis interpolation so far. Mr Westgarth pointed out, however, that they are in a good position now to bid for more such work.

8 belengineering.co.uk

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SEPTEMBER 2020

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MACHINED COMPONENTS | Engineering Capacity

Targeting aerospace primes A £1.2m investment in long-bed, fast machining of complex components will help TGM target aerospace primes.

TGM, which is part of the £43m Aero Services Global (AS.G) Group, has just completed its first parts for a MoD contract on its recently installed Zimmermann FZ33 compact milling machine.

The long bed capabilities, machine dynamics, 30,000 RPM and fast cycle times are perfect for creating complex components to the exacting standards required by the aerospace and defence sectors.

This investment will provide the company with additional capability to take on more than £2m of new work annually, as well as allowing it to tender for work on larger structural assemblies.

Sarah Stephens, Director at TGM, commented: “Traditionally we have provided 3, 4 and 5-axis machined components to aerospace tier 1s and this is still a core market, but we now have the technology, processes and skills in place to work directly with the primes.

“The Zimmermann is a fantastic machine and is the largest out of all of the 18-strong CNC machine tools we currently have at our Preston facility. An initial package of work is already in production on the Zimmermann and there are plenty of opportunities we are 26

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currently exploring that could fill up capacity.

“With this additional technology, we are hoping to double sales from £3m to £6m over the next two years.”

TGM, which became part of AS.G in 2016, specialises in the machining of both hard and soft metals, producing components and sub-assemblies for customers supplying Airbus and BAE Systems.

Continued investment in processes, upgrading operational efficiencies and upskilling of its workforce has helped it achieve world class manufacturing (99.85%) and delivery (99.16%) performance and the Bronze SC21 award for the third successive year.

The company’s core engineering skills have also been further boosted by the

introduction of CATIA V5 CAD design packages and inspection software to ensure a total end-toend solution for the customer.

Sarah added: “The first package of work for the Zimmermann is worth £1.4m to our business over two years and is the type of contract we are now looking to secure.

“It’s all about positioning TGM as a strategic critical partner to the primes and ensuring we can add value at every part of the process. This wouldn’t have been possible three years ago, but a combination of the investment, industry approvals and a track record of quality and delivery has paved the way.

“Covid-19 has brought its own challenges, but we feel we are in a good position to come through the pandemic and proactively establish our new position in the supply chain.”

TGM’s parent company, AS.G also includes Arrowsmith Engineering, B&H Precision Tooling, Datum, Ludolph, TGM and AMF Precision Engineering.

8 tgmeng.co.uk aeroservicesglobal.com SEPTEMBER 2020

SPONSORED FEATURE

ABRASIVE WATERJET CUTS IN 2D AND 3D WITH NO HAZ The abrasive waterjet offers designers and specifiers a number of major advantages, such as cutting most materials including composites, no formation of heat affected zones (HAZ), no molecular change or hardening of cut edges, a deep depth of cut, and cutting in both 2D and 3D - all on one machine, in one efficient operation. Chris Arnold of manufacturing contractor ICEE Managed Services reviews this highly advanced and versatile production process.

There are several ways to cut sheet and plate materials.

Obviously, which method depends on the design specification and material choice in relation to production requirements. The most widely chosen method is fibre laser because much sheet metal production is centred on thin materials. Quickly, accurately and at low cost it will produce a wide variety of profiles, holes

and slots. Abrasive waterjet cutting will do all that, but in addition handle practically any material, from super-tough exotic alloys and tool steel, through to glass, plastics, composites and stone. It is not as fast as fibre laser, but because it is a cold-cutting process, for some critical applications it may be a safer option.

No HAZ with waterjet Cold cutting is an important distinction. Whether sheet material is thick or thin, hotcutting processes produce oxides that form on cut edges – ‘heat affected zones’ or HAZ. In many cases this may not be important, but does matter if a part or panel has to be welded to another, typically edge-to-edge, to form a large structure. If not cleaned off, oxide may become included or embedded within the weld. This contamination can weaken the joint, leading to the risk of fracture under load or catastrophic failure.

Instead, using the cold-cutting waterjet process, clean-cut panel edges require no oxide removal, eliminate the risk of contamination and help ensure welds meet required standards. Moreover, the molecular structure of the material being cut is not changed or compromised by heat. Again, this has safety implications, the material is not at risk of heat-induced embrittlement or reduction of strength.

Another advantage is the

narrowness of kerf and depth of cut possible. A customer of ours wanted three sizes of plain brass bearing and was machining each from three sizes of bar. Exploiting the two features above ICEE accurately and ingeniously cut three bearing shells or blanks out of a single brass bar stock measuring 150mm diameter by 100mm thick.

Nesting each within the other, once cut by waterjet, the shells could be precision-machined to create finished parts. Instead of holding three bar sizes with associated processing, only one item of stock was required and cut in one session, with less waste than before. This achieved big time and cost savings for the customer.

Waterjet features a narrow kerf or cutting path, typically 0.28mm wide. This means parts may be nested closely together, generating less waste (and if appropriate, several sheets stacked together so one cut produces several copies). With other processes, such as milling or routing, the cutting path may be anything between 5-10mm wide, depending on the material being cut. This can be wasteful, especially if the material is costly, like titanium.

Mention of titanium raises another major advantage. Using other methods besides waterjet or fibre laser, cutting titanium is hard on processing tools. The waterjet cutting tool – a mixture of water and abrasive garnet

Chris Arnold, Key Account Manager, ICEE Managed Services Ltd.

SPONSORED FEATURE

Abrasive waterjet cuts a three-dimensional impeller from thick aluminium plate Inset: Finished part, straight off the waterjet cutting machine, no finishing required

particles delivered in a 2.8mm diameter jet at an aggressive 80,000 psi - never wears out and is always perfect.

The above demonstrates the versatility of waterjet cutting, as practically any material – sheet, plate and thicker stock - may be either cut or profiled. We have processed granite blocks over 200mm thick and the waterjet retains high accuracy over this depth. There can be some deflection of the stream or ‘taper’ effect, but the software changes the cutting speed and makes other adjustments, so the customer’s specification on tolerance is met.

Complicated parts are possible with 3D abrasive waterjet cutting

2D cutting and 3D forming on one machine Sophisticated control is demonstrated even more today as advanced waterjet technology permits cutting in not only two but three dimensions – all on one machine and in one seamless operation (good for productivity and throughput). Thanks to 5-axis CNC, this feature enables threedimensional blanks or finished parts to be cut from thick plate, providing an often less costly alternative to casting, moulding or machining processes.

With 2D and 3D cutting, the CNC software calculates and runs the machine to take account of many parameters, input before cutting, such as type of material, depth or thickness, and other factors. It will run the machine faster for straight cuts but slow up for

curves, or adjust for ‘tapering’. A perpendicular cut is the shortest, but as soon as the head tilts to cut in 3D, the depth of cut lengthens, so the software makes adjustments.

On a 3D CAD system with design for manufacture software, many possibilities may soon be explored, from modelling a truncated conic blank for a toothed bevel gear, to a finished impeller rotor that would otherwise be costly to make another way.

Selecting fibre laser or waterjet cutting depends on a number of factors, but it always helps to talk to a contractor that offers both processes, together with sound advice and balanced judgement. Based on years of experience, ICEE Managed Services can supply that. Besides parts manufacture, our core business is offering a complete package covering the design, manufacture, installation and maintenance of equipment enclosures and structures.

Please see our website for more details.

8 For more information please contact: ICEE Managed Services Ltd. 20 Arnside Road, Waterlooville Hampshire PO7 7UP Telephone: 02392 230 604.

Email: sales@icee.co.uk Web: www.icee.co.uk

MACHINED COMPONENTS | Engineering Capacity Ayrshire-based NPI Solutions has installed two new vertical machining centres and a new Doosan cobot to replace to older machines.

The machines – a Doosan DNM 4000 and a DNM 6700 supplied by Mill CNC – were installed at the company’s 46,000 square foot facility in the first week of July and replace two older machining centres that had served the company well but which had seen better days.

The Doosan M1013 cobot, the company’s first investment in a robotic automation system, was delivered and installed in late July.

The decision to invest in new machine tool and automation technologies was made during the height of the pandemic in April.

Says Kevin Priestley, NPI’s managing director: “We are a company that’s committed to continuous improvement and, as such, regularly monitor and review our performance.

“We had become aware earlier in the year that two of our older machining centres were creating a ‘pinch point’ in our operations and were affecting our productivity and efficiency.

“We decided that we wanted to replace the two older machines and approached Mills CNC to discuss a way forward.”

The company has been using Doosan machine tools since 2011 and in addition to the latest machines has three other Doosan machining centres and three Doosan lathes.

The new DNM 4000 is a compact machining centre equipped with a 30

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Machining capacity update

18.5kW/12,000rpm direct-drive spindle, a 20-position quick-change ATC and, inline with NPI’s preference, the Fanuc 0iMF control.

The DNM 4000 is similar to the larger Doosan DNM 6700 machine which is equipped with a 18.5kW/8,000rpm direct-coupled spindle, a larger ATC (30/40position), grease-lubricated LM roller guide ways and thermal error compensation system that ensures high-accuracy over long machining runs.

Explains Kevin Priestley: “We machine high-precision components - from prototypes and small batch series through to larger volumes - for a growing number of UK and international customers.

“To meet their quality and lead time demands we need access to reliable, high-performance machine tool technologies. The new Doosan machining centres are a case in point.”

The company’s commitment to continuous improvement and willingness to invest in the future was the driving force behind its first collaborative robot investment.

Says Kevin Priestley: “We are

always looking to improve and recognise the power and potential of automation.

“In discussions with Mills’ sales and technical consultants we began exploring the benefits we could gain from integrating a cobot with our Doosan DNM 350-5AX (5-axis) machining centre acquired in 2016.”

“The ability to run the machine and cobot unattended was particularly appealing and would help us really take advantage and exploit of the DNM 350-5AX’s onehit machining capabilities.

“Lights-out operations is a desired state. The cobot investment is a first step in getting there.”

8 npi-solutions.com

SEPTEMBER 2020

Engineering Capacity | MACHINED COMPONENTS Two precision engineering specialists were recognised for their commitment to quality and delivery performance as the Farnborough International Airshow went ‘virtual’.

Arrowsmith Engineering and TGM, both part of the £43million Aero Services Global Group (AS.G), were given the SC21 Silver and SC21 Bronze awards respectively for their ongoing ability to manufacture complex components to customers supplying some of the world’s largest airplane manufacturers and primes.

These awards are a critical performance indicator for the sector and has helped the two manufacturers secure over £3.5m of new contracts during the last twelve months.

Jason Aldridge, Managing Director of precision turning, milling, thread rolling and grinding specialist Arrowsmith Engineering, commented: “This is a great moment for our business as it marks four years of us performing to SC21 Silver standards – one of the few companies in the world to achieve this.

“Over the last twelve months, and despite all of the economic shocks and turmoil of Covid-19, we have still managed to record 99.5% right first time quality and 97.55% delivery on-time and these are parts for aerospace engines and braking systems for the likes of Rolls-Royce, GKN, ITP, Incora and Meggitt.”

Sarah Stephens, Managing Director of TGM in Preston, added her thoughts: “It’s great to play a small role in the first ever virtual SEPTEMBER 2020

SC21 at virtual Farnborough

Farnborough International Airshow and a massive lift for our staff to be recognised for our SC21 Bronze Award for the third consecutive year.

“We specialise in long-bed CNC machining and, traditionally, have supplied into tier 1 customers in aerospace and increasingly defence. Working towards these globally recognised standards helps open doors and gives us confidence to aggressively push our strategy of moving up the supply chain and actively securing work with the primes.”

The Aero Services Global Group has made a commitment that all of its companies will work towards some form of SC21 involvement and this decision will immediately see the recently acquired AMF Precision Engineering start the journey and German-based Ludolph target the SC21 Operational Excellence Award.

Phoenix CNC, renowned for its

8 Arrowsmith Engineering achieved SC21 Silver for the fourth year in a row

Aircraft on the Ground and speed shop support, will join Arrowsmith Engineering on the SC21 Competitiveness and Growth programme, the ADS-backed intensive booster programme.

Simon Weston, Managing Director of AS.G, concluded: “We were founded in 2015 with the aim of developing a highly specialist group, which could help a global customer base to consolidate their supply chains through innovation, efficiencies and excellent value for money.

“SC21 has been a fantastic vehicle for helping us deliver on our promise and we want to ensure that all relevant companies we own are operating to the highest possible standards when it comes to quality and delivery.”

8 arrowsmitheng.co.uk tgmeng.co.uk www.engineeringcapacity.com

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SPONSORED FEATURE

More and more manufacturers are discovering the benefits associated with the adoption of automated robotic processes.

Though when initially scoping the potential for automation, robot periphery is often a key consideration that is overlooked.

Ensuring that not only can the robot or robots physically satisfy the task within any given application, any automated robotic system must be sufficiently supported by a competent robot controller; essentially a computer that keeps the robot moving.

The brain of the robot, the controller is an essential part of the automated solution, and can be networked to other systems, so that the robot is able to work together with other machines, processes, or robots, ensuring maximum performance, connectivity and flexibility.

The KR C5 and KR C5 micro KUKA robot controllers integrate seamlessly into existing infrastructures and immediately deliver added value through more efficient performance, in all application areas.

Compact, high-quality and with low energy consumption, the KUKA KR C5 controller offers possibilities for space savings, delivers highly efficient performance, and at the same time conserves resources. To this end, it can be seamlessly integrated into heterogeneous automation landscapes, and almost all KR C4 applications are still supported, thanks to the current system software which is functionally compatible with the KR C4 and has

32

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Don’t overlook robot controller

identical software applications and technologies - more applications with maximum cost-effectiveness.

The KUKA KR C5 micro small robot controller offers maximum performance, connectivity and flexibility in a minimum of space.

The compact, open and flexible platform of the robot controller for small robots can integrate seamlessly into existing automation environments. Various KUKA software products enable a wide range of applications to be implemented quickly. The KR C5 micro also supports current field bus standards for cell and line integration.

KR C5 micro is also equipped with the necessary hardware resources and flexible IO ports to enable it to quickly adapt to future tasks and standards - future-oriented for highest performance and availability.

The development of the KR C5 micro, has been significant, when compared to its predecessor, the KR C4.

• A volumetric reduction of some 70% delivers valuable space savings.

• UPS (uninterruptable power supply) ensures that valuable robot data is preserved in the event of sudden power failure.

• Battery packs have been moved, external of the control unit, contributing to volumetric and weight reductions. Developments dictate that now; three controllers can operate off one KUKA battery.

• Both the KR C5 and KR C5 micro operate using KRL (KUKA robot language) specific to the KUKA hardware.

The production environment of the future is smart, and with the KRC5 and KR C5 micro it is moving to a completely new level. The latest platform for robot controllers from KUKA offers possibilities foe space savings, whilst delivering highly efficient performance and conserving resources.

To find out more, please contact sales.uk@kuka.com or call us on 0121 505 9970

SEPTEMBER 2020

Engineering Capacity | WATERJET & LASER CUTTING

Cell gives dimensional flexibility A new cutting cell at GF Laser gives it the flexibility to switch quickly and easily between 2D and 3D cutting.

The Trumpf TruLaser Cell 5030 5-axis CNC laser-profiling machine is the first such machine in the UK and has boosted throughput speed at the company’s Dudley headquarters and manufacturing centre.

Founded in 2006, GF Laser supplies laser-cut parts to sectors such as automotive, yellow goods, construction, architecture and general fabrication. The company, which is ISO 9001:2015 accredited, has grown its turnover from £2 million to £3.5 million in the past three years, and today runs a 24/7 schedule over three shifts.

The new fibre laser cell complements an existing Trumpf CO2 5-axis machine.

“Since installation, the TruLaser Cell 5030 has been busy processing a multitude of different parts,” states Director Simon Tregillus. “Not only have we been using it as a 5-axis machine for profiling 3D components, we’ve also used it extensively for flatbed cutting, which was one of the main reasons behind its selection.

It’s been doing everything from the trimming of automotive pressings, spinnings and extrusions, through to components for the fire-retarding industry. It has probably been in 5-axis configuration 60% of the time, reverting to flat-bed format for the remaining 40% whenever SEPTEMBER 2020

we reach capacity on our existing trio of Trumpf 2D laser cutters.”

On a regular basis, the 4kW TRUMPF TruLaser Cell 5030 is processing parts from materials that include mild, galvanised and stainless steel, as well as aluminium. The company is also using the machine to profile pressings and spinnings made from yellow metals such as copper and brass. The machine, which offers a bed size of 3000 x 1500 mm, can also be used to process formed and straight tube, as well as box and angle section.

“Most of the parts we process on the TruLaser Cell 5030 are up to 5 mm in thickness, while typical batch sizes are circa 500,” says Mr Tregillus. “However, we can handle batches as small as 1 or 2-off as the machine is quick and easy to set up.”

By adopting fibre-based 5-axis laser profiling, the company has made significant gains in the speed of its output in comparison with CO2 technology. The faster speed of the machine’s electronic doors has also contributed to shorter cycle times.

“The big thing for us, however, is the flexibility of the TruLaser Cell 5030,” states Mr Tregillus. “The ability to use it as a flat-bed machine is hugely beneficial to a subcontracting business such as ours, which can never be entirely certain what will come through the door tomorrow, and in what quantity.

We need to be flexible and fastmoving for our customers, so the TRUMPF TruLaser Cell 5030 is proving ideal.”

8 gflaser.co.uk www.engineeringcapacity.com

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WATERJET & LASER CUTTING | Engineering Capacity Starting as a pizza pan importer over 30 years ago, Alphin Pans has transformed itself into a business where 70% of its work is in subcontract spinning, pressing, profiling and forming.

Its latest investment is in two Timesavers deburring and surface finishing machines from Ellesco.

Alphin began life in a garage in 1989 importing and selling pizza pans. For its first 20 years the company was happy to simply buy and sell pizza pans and associated equipment, building solid foundations and counting the leading UK pizza supplier as a key customer.

“We had been happy to operate as an importer/wholesaler of products for 20 years, but when faced with supply problems we investigated manufacturing in the UK, and found, to our surprise that this could be done competitively,” says Alphin Pans Managing Director, Matthew Sykes. “Having made an initial investment in 2009, we took the decision to relocate and invest further in 2011, which brought pressing and flat-bed laser capability in-house. Initially this capability was for our own pizza pan production, but over time we recognised the potential to offer this to others as a subcontract service.”

Success quickly followed and the business is now split 70/30 in favour of subcontract metal spinning, pressing, profiling and forming, with customers from across a range of industries including industrial lighting, tier two nuclear, construction and more general subcontract work.

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Building on a pizza base The Timesavers machines are a 42-1350Rb and a 22-900-W, the former being initially purchased to meet the requirements of one particular customer. While the laser produced a perfect edge, for health and safety reasons that edge required some finishing.

Exchanging ideas with the customer, who already used Timesavers, the decision was taken to purchase the 42-1350Rb machine with its rotating brushes that provided the exact edge preparation that was required.

“The Timesavers 42 series machine is a fantastic piece of kit that we use purely for edge finishing and we have run hundreds of thousands of parts through it without any problems,” says Matthew Sykes.

The second Timesavers machine was introduced to eliminate the

need for hand graining of 5mm thick aluminium parts.

“The impact the 22 Series machine has had is significant as we have saved hundreds of hours since its introduction. With hand graining these parts would take at least five minutes, where with the Timesavers 22 series and its 900 mm wide abrasive belt these same parts are processed in seconds to a consistent standard.

“From both machines the added value that we now present to the customer is a positive and they were also impressed by our proactive approach to meeting their requirements. The result is that we have gained more work, with indications that volume work is also being on-shored back to us thanks to willingness to invest and react positively to challenges.”

8 alphin.co.uk/manufacturing SEPTEMBER 2020

Engineering Capacity | WATERJET & LASER CUTTING Grenville Engineering says that what customers really want and need is a service that adds value.

It says that in basic terms the definition of “value-added” describes the delivery of an enhanced product or service a company provides before offering to its customers.

In the manufacturing world of fabrication there are many companies offering standalone services such as laser cutting and metal forming which can benefit select industries. However Grenville says the real value add is having a complete offering which encompasses not only capabilities but intangible benefits such as specific skills in welding, accreditations to back up processes with ISO9001:2015 as standard, history of a company and the sectors it operates in, good levels of customer service and delivery performance.

Adding value to a customer’s supply chain requirements is a defining factor in maintaining healthy long-standing relationships.

Grenville says that customers consider a range of factors when selecting a supplier rather than just the cost saving benefits.

One of these is to have a single source contact. Having a single point of contact, such as an Account Manager, can help to speed decision making and reassurance that the manufacturing problem will be dealt with.

Trust is a vital component in any relationship. Customers want transparency and to get the best out of the customer/ supplier relationship.

SEPTEMBER 2020

Value-added manufacturing

A customer will also look for specialised skills and capabilities and will want to deal with a fabrication company that has the relevant skills and accreditations for making their product – such as a dedicated stainless steel facility, CE marking accreditation, traceability and so on.

Bespoke projects require a partnership approach from both the customer and supplier as this often involves in-depth conversations and drawing iterations to maximise on the product quality/performance.

Finally, of course, technical expertise is key as customers look for in-house knowledge that can adapt and improve design for cost-saving and manufacturing efficiencies.

Grenville Engineering says that a customer-centric is at the heart of it does: “We collaborate with our customers ensuring that we produce the most cost effective solution without compromising on quality. We have a combined experience of over 100 years within the industry, which is invaluable for our customers, supporting them in the best solution for the design to manufacture process.

“Our partnership approach towards our customer relationships has been our differentiator and strengthened our long term relationships.”

8 grenville-engineering.co.uk www.engineeringcapacity.com

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MOULDING | Engineering Capacity

Meeting food industry demands Following the trend towards larger mould tools for increased productivity, Pattern Forme has expanded its deep hole machining capabilities.

For over 30 years, Tauntonbased, Pattern Forme Ltd has specialised in the in design and manufacture of thermoforming mould tools. The company specialises in producing tools for thin gauge work, mainly in the food industry and thick gauge work for applications, such as, signage. However, the key focus of the business is the food sector where its success has stemmed from a willingness to partner with customers. By offering its experience and being pro-active it can take projects from initial concept to finished mould tool, often with lead times as short as 2-3 weeks.

The food industry is fast-paced and constantly changing, therefore Pattern Forme has continually invested in machining technology allowing it to keep pace. More recently, the trend has been for larger mould tools to increase productivity, this led to a need to drill deeper holes.

Typically, these holes would range in size between 6 and 10 mm diameter, with depths up to 1000 mm. The traditional solution would be to purchase a dedicated deep hole drilling machine or subcontract the work. The former would require a significant investment, whereas the latter brings logistical problems and 36

www.engineeringcapacity.com

lack of control over production.

XYZ Machine Tools was able to propose and deliver a quicker and more cost-effective solution.

“It was a chance conversation with XYZ Machine Tools, who have supplied us with several machines, where I mentioned that we needed this extra capacity. They immediately suggested modifying one of its XYZ 1000 LR vertical machining centres to give the extra z-axis capability we required.”

“The simple and cost-effective solution was to add a 1050 mm riser block to the machine, which would allow us to drill these holes from either end using the 500 mm z-axis of the machine,” says Paul Wilkins, Managing Director, Pattern Forme.

By reconfiguring the machine, XYZ Machine Tools was able to increase the minimum distance from spindle nose to table to

1050 mm and with the standard z-axis stroke making the maximum distance 1550mm which was more than enough to accommodate Pattern Forme’s components.

“This machine has been purchased purely for deep hole drilling and, considering the modifications, it is proving to be of excellent value with the capital cost alone around 80 per cent less than a dedicated deep hole drilling machine. Efficiency will also improve as we can transfer work from what previously had been done on manual machines to a fully CNC controlled operation.

A further advantage of this capability from the XYZ 1000 LR is the reduction in lead times, which is crucial if we are to maintain existing and win new business,” states Paul Wilkins.

8 patternforme.co.uk SEPTEMBER 2020

Engineering Capacity | MOUDLING Medical, pharmaceutical and commercial plastic moulder and thermoformer TEQ has rebranded its business into one operation.

It was previously been known as Plastique across Europe, and TEQ Thermoform Engineered Quality more widely.

The business, which was recently acquired by Sonoco, is now able to offer a complete range of cleanroommanufactured and injectionmoulded packaging to the medical, pharmaceutical and commercial sectors.

Alongside TEQ, which operates two European sites, in the UK and Poland, Netherlands-based Sonoco Plastics produces millions of injection-moulded parts with high optical properties for use in diagnostic and clinical chemistry instruments.

In the US, TEQ has three thermoforming facilities and one extrusion operation. With more than 50 locations across the world, TEQ, a Sonoco Company is now part of a truly global packaging business.

“With 75 years of combined experience and operating more than 30 thermoforming lines, TEQ has world-class facilities that will see us continue leading from the front in innovative packaging solutions,” says Anne-Sophie Belamine, TEQ’s European Sales Director.

As customers work to address critical health requirements associated with Covid-19, TEQ continues to offer a range of high-quality medical packaging solutions.

SEPTEMBER 2020

Breaking the mould

The company’s specially commissioned Class 7 and 8 cleanroom facilities in Nottingham, UK and Poznan, Poland are both certified to ISO 13485: 2016. This enables TEQ to meet medical device and pharmaceutical manufacturers’ most rigorous packaging requirements.

TEQ’s medical packaging range includes clamshells, dosage cups,

trays, tubs, lids and sterile barrier blisters. The company also manufactures custom thermoformed handling trays, including dry powder inhalers, auto-injectors, injection-moulded components, pre-filled syringes and pharmaceutical bottles.

The company also produces recyclable, moulded-pulp-fibre packaging under the Fibrepak brand for commercial customers.

“At the heart of our business is a team of talented experts all driven to exceed our customers’ expectations in everything we do,” adds Belamine. “From our stateof-the-art technology, to our many years of experience, to the quality of the partners we work with, we have what it takes to deliver on time, on budget, and with unequaled precision.”

8 teqnow.com

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

Tel: 0118 978 6573 Email: sales@simpsonsprings.co.uk

www.engineeringcapacity.com

37

MOULDING | Engineering Capacity Carrickfergus-based IPC Mouldings has achieved the SC21 Gold Performance Level for the second consecutive year.

The SC21 international programme promotes the continuous improvement and acceleration of the competitiveness and capabilities of the Aerospace and Defence Supply Chains worldwide.

The tool manufacturing and injection moulding company joined the programme in 2015 and is one of few companies to reach gold standard in the space of four years.

Managing Director of IPC, Joanne Liddle said, “I am delighted that we have secured the SC21 Gold Performance Level for Operational Excellence for the second consecutive year. This reinforces our commitment to providing high quality service and products to the aerospace supply chain and other customers.

“Our team has worked extremely hard to implement a culture of continuous improvement, ensuring all processes and standards are met and I’d like to thank each and every one of them, as without their hard work, this achievement would not have been possible.”

Joanne continued, “I would also like to give thanks to Stuart McKee and the team at Collins Aerospace Kilkeel for continuing to sponsor IPC Mouldings through the SC21 Programme. To have their support is a great honour and we look forward to continuing this SC21 association going forward.”

Collins Aerospace Managing Director, Stuart McKee, said, “Well 38

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Two Golds in a row

done to Joanne and the team at IPC Mouldings for achieving the SC21 Gold Performance Level for the second consecutive year. At a difficult time in the market, it’s important that supply chain performance continues to improve and the exceptional standards that Northern Ireland companies are known for is maintained.”

Dr Leslie Orr, Director at ADS Northern Ireland shared his delight saying, “IPC Mouldings has once again demonstrated the quality excellence required by global aerospace primes. This award will continue to strengthen the company’s relationship with their customers, as well as adding to the strength of Northern Ireland aerospace – a trusted supply chain.

Well done to Joanne [Liddle] and all the team.”

Colin Hart, Chair of the SC21 Programme also passed on his congratulations. Colin said, “Congratulations to IPC Mouldings

on their Gold Award Success for the second year running. We’re extremely proud of the many organisations that are representing the UK globally in terms of the high level of service they provide and it’s great to see IPC among them. Well done!”

The SC21 programme is the primary route on the improvement ladder and companies that participate see achievements of 99.00% delivery and 99.90% quality performance, the reduction of supply chain risk and implementation of leaner production methods.

Companies that have secured the recognition, whether bronze, silver or gold, go through rigorous assessments which are designed to accelerate the performance and competitiveness within the sector.

Throughout 2019, IPC Mouldings achieved 99.93% quality and 99.90% delivery ratings.

8 ipcmouldings.com SEPTEMBER 2020

BTMA MANUFACTURING MEMBERS | DIRECTORY

ACSL Precision Engineering sales@acsleng.co.uk www.acsleng.co.uk

Currie & Warner Ltd tonyfox@curriewarner.com www.curriewarner.com

H P C Services Ltd sales@slidinghead.com www.slidinghead.com

Atkinson Engineering sales@atkinson-engineering.com www.atkinson-engineering.com

Davromatic Precision Limited sales@davromatic.co.uk www.davromatic.co.uk

Haydon Precision Turned Parts Ltd haydontool.co@btconnect.com www.haydon-precision.co.uk

Auto Turned Products (Northants) Ltd shad@autoturned.co.uk www.autoturned.co.uk

Dawson Precision Components Ltd. sales@dpc.co.uk www.dpc.co.uk

Herve Engineering Ltd sales@herve-engineering.com herve-engineering.com

Batchflow Engineering info@batchflow.co.uk www.batchflow.co.uk

Dawson Shanahan (Wales) Ltd info@dawson-shanahan.co.uk www.dawson-shanahan.co.uk

JCF Engineering Limited john.felton@jcfengineering.co.uk jcfengineering.co.uk

Cambion Electronics Ltd sales@cambion.com www.cambion.com

DKW Engineering Ltd karl@dkwengineering.co.uk www.dkwengineering.co.uk

M&M Turned Parts Ltd sales@mmturnedparts.co.uk www.mmturnedparts.co.uk

Cambridge Precision Ltd sales@cambridgeprecision.com www.cambridgeprecision.com

Falcon Engineering Productions Ltd sales@falconengineering.co.uk

Machined Component Systems sales@machinedcomponent.com www.machinedcomponent.com

CK Precision Engineering Ltd Info@ckprecisionengineeringltd.com www.ckprecisionengineeringltd.com

GS Brown (Precision Engineers) Ltd malcolm@gsbrown.com www.gsbrown.com

Manton Engineering (Bedford) Ltd sales@mantonengineering.co.uk www.mantonengineering.co.uk

CTN Group Ltd charlie@ctn-group.co.uk www.CTN-GROUP.co.uk

G W Martin and Co Ltd sales@gwmartin.co.uk www.gwmartin.co.cuk

MaS Precision Engineering Ltd sales@masprecision.co.uk www.masprecision.co.uk

SEPTEMBER 2020

btma.org

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DIRECTORY | BTMA MANUFACTURING MEMBERS

Muller England Limited sales@muller-england.co.uk www.muller-england.co.uk

Quantamatic info@quantamatic.co.uk www.quantamatic.co.uk

Thomas Brown Engineering Ltd info@thomasbrownengineering.co.uk www.thomas-brown-engineering.co.uk

NC Precision Ltd sales@ncprecision.com www.ncprecision.com

Rodmatic Ltd enquiry@rodmatic.com www.rodmatic.com

TKM Engineering Ltd Sales@tkmengineering.co.uk www.tkmengineering.co.uk

Neida Products Engineering Ltd sales@neida.co.uk www.neida.co.uk

Rowan Precision Limited sales@rowanprecision.co.uk www.rowanprecision.co.uk

Trust Precision Engineering Ltd info@trustprecisionengineering.co.uk www.trustprecisionengineering.co.uk

Normec (Manchester) Ltd sales@normec.co.uk www.normec.co.uk

Salcey Precision Engineering Ltd info@salceyprecision.co.uk www.salceyprecision.co.uk

Plastic turned Parts Ltd sales@plasticturnedparts.co.uk www.plasticturnedparts.co.uk

Swissmatic Ltd info@swissmatic.co.uk www.swissmatic.co.uk

Wealdpark Limited sales@wealdpark.co.uk www.wealdpark.co.uk

Precision Component Services Ltd shane@precision-components.co.uk www.precision-components.co.uk

Techfore Turned Parts Ltd info@techfore.co.uk www.techfore.co.uk

Wharf Engineering Ltd sales@wharf-engineering.co.uk

Precision Products (Brighton) Ltd ian@precisionproducts.co.uk www.precisionproducts.co.uk

Tenable Screw Co Ltd nigel@tenable.co.uk www.tenable.co.uk

Wilco Manufacturing Ltd sales@wilcomanufacturing.co.uk www.wilcomanufacturing.co.uk

Qualiturn Products Ltd sales@qualiturn.co.uk www.qualiturn.co.uk

Tercet Precision Ltd Alex.Burns@tercet.co.uk www.buyturnedparts.com

Yorkshire Precision Engineering Ltd info@ypel.co.uk www.ypel.co.uk

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SEPTEMBER 2020

BTMA TECHNICAL MEMBERS | DIRECTORY

Arno (UK) Limited sales@arno.de www.arno-tools.co.uk

Filtermist Systems Limited sales@filtermist.com www.filtermist.co.uk

The Amodil Group tkd@amodil.co.uk www.amodil.co.uk

Floyd Automatic Tooling Ltd sales@floydautomatic.co.uk www.floydautomatic.co.uk

Badger Anodising (Birmingham) Ltd sales@badgeranodising.co.uk www.badgeranodsing.co.uk

Bowers Group sales@bowersgroup.co.uk www.bowersgroup.co.uk

PSL Datatrack engcap@psldatatrack.com www.psldatatrack.com

Smiths Metal Centres info@smithmetal.com www.smithmetal.com

Kumi Solutions simon@kumi-solutions.com www.kumi-solutions.com

Star Micronics GB Ltd sales@stargb.com www.stargb.com

LNS Turbo sales.uk@lns-europe.com www.lns-europe.com

Ceratizit UK & Ireland Ltd info.uk@ceratizit.com www.ceratizit.com

Matsuura Machinery Ltd imichie@matsuura.co.uk www.matsuura.co.uk

Citizen Machinery UK sales@citizenmachinery.co.uk www.citizenmachinery.co.uk

Engineering Technology Group sales@engtechgroup.com www.engtechgroup.com

SEPTEMBER 2020

Stelstocks Ltd info@stelstocks.co.uk www.stelstocks.co.uk

Tornos Technologies UK Ltd sales_uk@tornos.com www.tornos.comk

Optimum Oils cliff.thrussell@optimumoils.com www.optimumoils.com

Wieland-Nemco Ltd. sales@wieland-nemco.com www.wieland-nemco.com

btma.org

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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

42

www.engineeringcapacity.com

PRECISION ENGINEERING 8

Qualiturn Products Limited

PRECISION ENGINEERING 8

Top Gear House, Bletchley Road Heaton Mersey Industrial Estate Stockport SK4 3ED Tel: 0161 432 0222 www.minigears.co.uk

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

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

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

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

dpc.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 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.

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.

Mini Gears (Stockport) Ltd

REPETITION TURNED PARTS 8

JFL Broaches and Broaching

MACHINING (5 AXIS) 8

BROACHING 8

DIRECTORY | Engineering Capacity

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

SEPTEMBER 2020

TURNING (CNC) 8 Subcontract mill turned parts up to 65mm in diameter from bar and 300mm billet work.

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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 business machinist suppor million parts subcontract The Manufa t initiative. some 1.5 eted ches dispat Programme cturing Growth g from compl lies (MGP), funded ssemb a year – rangin European and sub-a Regional Develo by the assemblies ned castings and Fund (ERDF) pment to large machiparts – and is Economic and delivered by 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 cantly ing £1 techniques, signifi tant, nal to vestm exceed positio 359 ’ often most impornstivity.” expected to single return-on-in setters to investment and an ‘open-liaison times and be Further once -up l produc ongoinne year has s createdfrom freeing g project keeps the million a from the improve overalcomple machi are which comes y new tasks and ted.machi By thenes people strategto date on the He says the£1.6m end July, m other time for each up of grant ium of perfor 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 beMarch 1MSY and which manuf automation cutting and manag logy turnin and Lorrain ion can techno of the BNE-5 s to come ge of ement, R&D, lean ityacturer le e Holmes, cycle.2019. operat and see production manufacturin it is capabforward The flexibil Chiefe me the shorta er, milling Execut how turn-milling s asthey productivity g, can take ed in oneive Officer its succes toadvant helps to overco require. Howev ofaverag that EGS, produc and capacit key is with three age explain is of would cuttingthe ed: “We are has systems and ve bonus at y, quality assista cycle pped we still need offer. nce skills we A massi part way above of single It’s never on targets tant that sly overla the 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 and the Martin Coats, there is a rt and by to grow our ends oftacan bar up toscope of real appetit both suppor from SMEs nt suppo Operations be tailored our Director at and using e exact for time, to the through consta to maximise EGS, continu needs ofter. support that targeted business same in order the busine firms come so ed: “When diame can bar and training, help The main ss.” to them grow. 51 mm Manufa “The differen 15 kW vestment what eadcturing strategic reviewus they receive a Progra return-on-in we support and kW The fixed-h mme programme ce with our is 7.5Growth from one of was set MGMs that two-ax is that it is upwith our the void e and improve how customers.” to fill determ spindl by deliver both left manufacturin e, Manufa ines what by the o r to ed barriers are spindl Advicedary g experts we delive n to the new Miyan d in the way secon Service (MAS) understand s of 5,000 cturing support is and what the challen who y ordere In additio by tage of 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 network of followed by ement’, logy) and experie LFV (LFV bringin ‘Enviro techno 2017 specialists nced manuf BER ‘Marke nment cutting on specific g in acturin SEPTEM ting and Market al’ and growth manag vibration ange M16-V will bring g issues are facing 14. ers (MGM) Knowledge’ ations to they’re or opportunities they to industr top-of-the-r (12% each). y specialists , access Citizen install looking initial stage Once the and the opportunity the total has She continu to explore.” to we then bring been completed, ed: “1000 m average grant apply for an acity.co benefic ringcap of £1400, rising iaries is just works with in an expert who maximum the manag the start. www.enginee to a to £3,500 14 ement team address these Support can . be used for 8 manufacturin issues.”

SEPTEM BER 2017 programme.c ggrowth o.uk

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