Engineering capacity jan 2018 digital

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January 2018

INDUSTRY NEWS | MACHINING | ELECTRONICS | CASTING

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6th – 8th February 9.30am – 4.30pm (3.30pm close Thurs)

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

2018 celebrates the event’s 20th Anniversary with a move to the brand new FARNBOROUGH venue

Pre-register online now for your free entry badge and show preview at

www.industrysouth.co.uk

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FOR BUYERS OF CONTRACT MANUFACTURING SERVICES

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

For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company number 10567217 ISSN 0306-0179 COMING UP IN OUR MARCH 2018 ISSUE Turned Parts, Forming & Fabrication, Aerospace & Defence, Heat & Surface Treatments, MACH Preview Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website

Editor’s View Did you know that BSI has just launched a new specification for greyhound kennels in residential areas? No me neither, and I wouldn’t have done if they hadn’t sent me a press release.

I get a lot of bizarre emails in my editor’s inbox, probably because it is easier to send something to everyone in the media database rather than focusing on the relevant targets. It doesn’t work, by the way.

It just means that the next email from that sender will be deleted without even being looked at.

At least it isn’t spam in the classic sense – they do at least know that I publish a magazine and there is no malicious intent.

It’s a different story in my personal email where, due to a broken spam filter, I get hundreds of suggestions every day of new ways to get conned.

Recently, among the invitations from Russian dating agencies, dodgy pharmaceutical companies and online gambling companies, I have been getting more and more invitations to invest in Bitcoin ‘get rich quick’ schemes.

You’ve probably heard of Bitcoin, a ‘cryptocurrency’ which has created a massive amount of media coverage and an ever expanding bubble.

Despite the hype, even organisations such as Goldman Sachs are starting to take Bitcoin seriously. But it is the technology behind it, known as blockchain, that is likely to be one of this year’s industry buzzwords.

Essentially, a blockchain is an online ledger of transactions that are linked and secured using advanced cryptography so that everyone has access to details of every transaction and which is updated every time a new transaction is made.

The distributed nature of a blockchain makes it incapable of being changed without leaving a record and it can be applied to any multi-step transaction where traceability and visibility is required.

This makes it an ideal tool for supply chains – so expect to hear a lot about it and its potential as a disrupter.

Andy Sandford, Editor

Member of the Engineering Industries Association

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

Tel: +44 (0)23 9267 7747

JANUARY 2018

Email: info@dkwengineering.co.uk

1969 - 2014

45 years

www.dkwengineering.co.uk

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Contents January 2018

30 HEAVY ENGINEERING

News

Features

06 Comprehensive marking service 06 Start-up offers types of

14 Machined Components 06 Brothers add more Brothers Defence strategy pays off

laser marking

08 Registration open for MACH 06 Time to sign up for the UK's manufacturing technology show

19 Laser & Waterjet Cutting 06 Sweet dreams are made of this

14 MACHINED COMPONENTS

25 Training & Education 06 Supporting tomorrow's

09 Sally takes the helm 06 New MD for Precision Products

engineers

26 Southern Manufacturing Preview

11 Red Arrows Aston keeps its cool 06 High tech coating for

30 Heavy Engineering 06 Sculpture hits the high notes

limited-edition supercar

12 In trim for electric SUV 06 Borough Plating tools up for new model 4

www.engineeringcapacity.com

22 Casting & Forging 06 The power of partnership

31 ELECTRONICS

31 Electronics 06 Make or buy?

JANUARY 2018

Engineering Capacity | INDUSTRY NEWS Photo etching specialist Precision Micro helped artist Russell Marshall create unique artworks of Elvis, Hendrix, Bowie and Sid Viscious for a charity auction.

The Hepatitis C Trust is a charity which aims to eliminate the disease as a major health concern by 2030 and its ‘Art on a Postcard’ initiative raises money for the trust through so-called ‘postcard lotteries’ which occur throughout the year.

The main event is a secret auction held in London each November where more than 400 world-renowned artists contribute postcard-sized original artworks — the creator of each piece is kept secret until after the purchase.

The auctions have so far raised in excess of £400,000.

This year's participants included: Sir Peter Blake, Harland Miller, Rowan Newton, Jeremy Deller, Ceal Warnants, Gavin Turk, Vanessa Jackson RA, Sara Pope, Maggie Hambling CBE, Antony Micaleff, Shezad Dawood, Ben Eine, Daisy Cook and Hayden Kays, Adam Koukoudakis and Adam Bridgland.

One contributor who joined this illustrious list was Russell

Sand casting acquisition Expromet Technologies Group has acquired Hampshire-based Haworth Castings. Expromet already owns Ilfracombe-based investment casting company Investacast.

JANUARY 2018

Rock stars etched in metal art

Marshall, an award-winning artist based in London whose work reflects his 25 years in the British tabloid newspaper industry. Marshall has worked with Precision Micro on previous artworks etched onto

stainless steel. The pictures, usually celebrity ‘mug shots’, are depth-etched onto one-metre long sheets using the halftone process — a reprographic technique that uses dots varying in size and space to produce a gradient-like effect.

Marshall's contributions to Art on a Postcard were mug shots of Sid Vicious, David Bowie, Elvis Presley and Jimi Hendrix, etched and donated by Precision Micro.

As the only artist using a combination of metal and photo etching, the postcards stood out from the other contributions using paper as the chosen medium.

The broad spectrum of styles coupled with the high profile artists involved in the event ensured its success. The total raised at this year's auction was £53,000 — a great result, and one that Precision Micro is delighted to support.

8 precisionmicro.com

Haworth Castings operates from an aluminium- and copperbased sand foundry in Romsey and a precision machining facility in Basingstoke. The business specialises in producing fullymachined, tested and finished sand castings and gravity-die castings for defence, aviation, marine, medical, energy, automotive and other

safety-critical applications, providing a fully-owned and controlled single-source solution for customers.

Haworth Castings employs 40 people across two sites in Romsey and Basingstoke. Andrew Haworth, managing director of Haworth Castings, will continue in his role following the acquisition.

8 investacast.com

Sid Vicious, David Bowie, Elvis Presley and Jimi Hendrix etched in steel

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INDUSTRY NEWS | Engineering Capacity A new start-up in Oxfordshire offers an extensive range of lasers for all types of subcontract laser marking.

ES Precision offers laser processing to industries such as medical device, Formula 1, aerospace, electronics and general engineering.

The business has got off to a good start, says Managing Director Tim Millard, with its six staff busy running jobs on the eight laser workstations at the company’s premises at Kingston Business Park between Oxford and Swindon.

“Turnover for the first quarter is well ahead of expectations and we’re going to go into the Christmas break with a very solid start,” he said.

“We’ve taken on some part-time staff locally in addition to our six permanent staff to meet the demand peaks. We’ve met delivery expectations 100% so far as a result, which is crucial when a new

Comprehensive marking service company is building a reputation.”

The lasers include a 200W CO2 galvo-delivered source which can drill and cut organic materials at very high speed. There is also a lower power CO2 laser with automatic reel-to-reel feeding which is used to mark label data onto any shape label required (because the laser also cuts the label profile – no kiss-cutting dies required). Labels are tamperevident, high temperature and weather-resistant, so customers use them for tracking and traceability as well as outside use.

They can have incrementing barcodes, ID Matrices or human-readable characters and cannot be removed without destroying. Most people will have seen the material on their cars – such laser-marked black labels are ubiquitous showing fuel type by the petrol fill-up

JJ Churchill looks to the future at 80 Engineering firm JJ Churchill is celebrating eighty years in business by recruiting the highest number of apprentices in its history. The company was founded on Christmas day 1937.

Based in Market Bosworth, Leicestershire, the company, which employs 129 people, makes high precision gas turbine components for the aerospace industry as well as high horsepower diesel engine components and assemblies.

The firm recruits new

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apprentices most years and the majority of its workforce has an apprenticeship background.

Taking on four new engineering apprentices, following the largest recruitment drive in the company’s history, Chief Executive of JJ Churchill Ltd, Andrew Churchill, spoke about why the firm continues to invest in apprenticeships year on year: “We couldn’t have been so successful for the past eight decades without the hundreds of apprentices who’ve come through

cap and tyre pressure on the door interior.

“We’ve also got UV, fibre and Vanadate lasers with galvo delivery, so that we can optimise marks on virtually all materials – all metals, most plastics as well as coated materials” explained Tim. “We have a tool room to fabricate fixtures so that repeat customers are guaranteed consistent results. The business model needs customers who have a regular permanent identification or decorative need for their products, so ensuring every customer is happy with our service is of course essential.”

ES Precision still has capacity to take on more work and can work with volume customers on a development and prototype contract basis to get the right sort of finish on components.

8 esprecision.co.uk our doors and gone on to be great engineers. Most are local – we’re part of the community in Leicestershire and we’re proud that we could invest in the region and give people a great career in engineering.

We could bring people in with the skills already, but giving young people those opportunities instead is important to us.”

8 jjchurchill.com

JANUARY 2018

WE’RE SHAPING THE FUTURE OF COMPOSITES From tooling design and component production to surface finishing, you can trust Pentaxia to deliver a complete composite solution under one roof. With total project management control, we promise to deliver on time, every time.

Our expert team is known across the automotive, motorsport, aerospace, defence and rail sectors for high quality, fast turnaround and genuine customer service.

www.pentaxia.com

enquiries@pentaxia.co.uk

+44 1332 574 870

INDUSTRY NEWS | Engineering Capacity Visitors can now register for their Fast Track Entry Pack for MACH 2018, which runs from 9 to 13 April in its new home on the Atrium side of the NEC in Halls 17, 18, 19, 20, 6 and 7.

This is the first move of the show since relocating to the NEC when it first opened in 1976 and reflects the changing technologies the show covers. Visitors are invited to register early.

James Fudge, Head of Events at the Manufacturing Technologies Association (MTA), which organises the exhibition on behalf of the industry, said, “MACH prides itself on attracting top quality visitors with real buying power and the ability to invest in new equipment. The new hall layout will help create a brand new visitor experience which is easier to navigate, showcasing all the different technologies in action under one roof. It will be a more interconnected show, just as we have a more interconnected industry.”

Mr Fudge continued, “For MACH 2018, we have worked hard to provide visitors with a new way to connect with exhibitors. Our smart badging system provides every visitor with an interactive badge, allowing them to collect information from exhibitors in a quick and effective manner, without the need to carry lots of cumbersome documents. Data is transferred live to the visitors’ online portal, ready to download as soon as they leave the show.

This investment by the MTA in smart badging reflects the digital nature of the advanced technology 8

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Registration open for MACH 2018 MACH prides itself on attracting top quality visitors with real buying power and the ability to invest in new equipment . . .

It will be a more interconnected show, just as we have a more interconnected industry

‘‘

on show at MACH, where a key feature will be a unique presentation produced in partnership with the AMRC to demonstrate cost effective adaption of Industry 4.0 Technologies.

This will demonstrate up to six separate manufacturing cells that replicate familiar manufacturing environments that have been integrated with Industry 4.0 Technologies.

James Selka, CEO of the MTA,

said, “The show will be 2018’s biggest display of live, working technology. At the core of the show, exhibitors will showcase the latest developments in metal cutting, forming and finishing along with tooling, CAD/CAM and laser technology. The number of companies displaying additive manufacturing technology has grown considerably and exhibitors tell us they will be focusing on the digital factory, with more automation and connected manufacturing processes on display than ever before. New for 2018 is a specific IT for Manufacturing Zone, where companies offering connected solutions for the fourth industrial revolution will be on hand with practical displays and demonstrations.”

8 machexhibition.com JANUARY 2018

Engineering Capacity | INDUSTRY NEWS

Vacuum forming protects precision springs Precision spring manufacturer William Hughes has expanded its range of specialist products for the aerospace and hydraulic industries with the introduction of a range of standard size and bespoke vacuum formed trays.

The trays are designed to protect high value, precision manufactured parts against physical damage or contamination from foreign bodies during transportation and storage and are particularly useful with products supplied to William Hughes for ultrasonic cleaning.

The stackable trays also help customers maintain accurate inventory control as part of a lean manufacturing programme.

The standard range is available in clear (0.5mm thick), white or black (2mm thick) high impact polystyrene up to 56 x 81cm in size with a clear top available if required. Recyclable materials are used wherever possible and there is a choice of pocket sizes and configurations to suit a wide range of applications.

For unusual or complex shaped components, bespoke trays can be manufactured to customer’s specifications and these can be supplied in small batch quantities.

Alternatively, William Hughes can design suitable trays using examples of the components to be stored. Where there is the need to protect special finishes or threaded components, caps and JANUARY 2018

diaphragms can be supplied to ensure components are in pristine condition when they are required for use.

Vacuum formed trays are part of an extensive range of precision components available from William Hughes for the aerospace and hydraulic industries. For example, springs manufactured

by William Hughes are being used in vital items of aerospace equipment including oxygen systems, access hatches and the solenoid valves used to control the hydraulic and cabin pressure systems. The company offers its customers a rapid design and prototyping service which is particularly suited to the aerospace industry where small quantities are often required for prototypes. Quality systems to ISO 9001:2000, ISO/TS 16949:2002 and AS9100 - the quality management system standard for aerospace companies, ensure consistency and accuracy of supply.

8 wmhughes.co.uk

Sally takes the helm Sally Thorley, who has been employed by Precision Products for nearly 30 years, has taken over the position of Managing Director from Brian Owen, who remains on the board of directors as Chairman.

Further senior appointments at the precision turned parts subcontractor include Ian Jenkins, who has moved across from production to become Commercial Manager; and Jason Bullen, who joined the company at the start of 2018 as Production Manager.

The end of 2017 marked 18 months since Precision Products consolidated its business into its factory in Rustington, West Sussex, and dispensed its satellite unit in Hollingbury.

It operates 22 Citizen and Miyano CNC automatic turn-milling lathes.

Mrs Thorley said: "It has streamlined our operation, reduced overheads and helps us keep down the prices we charge, making us more competitive. As a result, we have been able to increase the number of long-term partner relationships we have with customers, leading to stable contracts that benefit both them and us.�

8 precisionproducts.co.uk

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INDUSTRY NEWS | Engineering Capacity

Element adds more NDT Element has expanded its immersion ultrasonic testing capabilities with the acquisition of NDT Limited NDT Limited, headquartered in Sheffield, UK, is a UKAS and Nadcap accredited laboratory that offers a comprehensive range of NDT, mechanical testing and metallurgical testing including ultrasonic immersion inspection, ultrasonic contact inspection, dye penetrant inspection, magnetic particle inspection, radiographic inspection and eddy current inspection.

Tim Elwell, Managing Director, NDT, commented: ‘’Since 1986, NDT Ltd has held a strong reputation and market position and through Element’s Engaged Experts and innovation in advance testing solutions, the acquisition is an ideal fit in terms of further enhancing our capabilities to our customers.’’

8 element.com d

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Irish aero cluster gets its wings Irish Government agency Enterprise Ireland has created the Emerald Aero Group, a new aerospace and aviation cluster which is forecast to increase turnover at precision engineering, composite, plastics and metal fabrication companies by over 25%.

Formed from 15 indigenous manufacturing companies, the aim of the company is to increase aerospace manufacturing revenues and employment, developing opportunities for Irish aerospace companies in the UK and further afield.

Based on the average sector turnover, the goal of this new subcontracting alliance is to increase collective aerospace exports from £13.2million in 2016 to £30.1million in three years. This will also lead to the creation of 200 new jobs across individual members by 2019.

The Emerald Aero Group will act as a catalyst in allowing these

to

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Manufacturers of High Quality Mill-Turned Parts

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smaller industry companies to join forces, forming clusters and sharing widespread industry knowledge and technical expertise in a bid to win greater contracts against contending larger companies across the aerospace sector.

Valued at €4.1bn, Ireland’s aerospace and aviation industry is on the rise, creating a growing need for increased business collaboration, so smaller, more niche companies can benefit.

The creation of the Emerald Aero Group will also give these newly formed alliances a competitive advantage when contending with larger players, while helping mitigate risk.

Members, located throughout Ireland, are all owner-managed indigenous SMEs, with expertise in sectors such as precision engineering, metal treatments, plastic injection moulding & thermoforming, 3D Printing, composites and fabrication.

Increased ‘cluster’ mentality and business collaboration is vital in enabling these groups to collectively reach new heights and secure these larger contracts through shared skillset as well as industry and technical expertise.

Sean Long, Senior Market Adviser Engineering, Electronics at Enterprise Ireland, said: “The creation of the Emerald Aero Group will provide increased opportunities for small companies looking to expand their presence internationally.

8 emeraldaerogroup.com JANUARY 2018

Engineering Capacity | INDUSTRY NEWS A highly durable ceramic coating from specialist heat management company, Zircotec Group, is being used to treat the exhaust tailpipes of a special Aston Martin Vanquish S Red Arrows edition.

The limited-run vehicle, of which only 10 have been made, uses Zircotec’s Ultimate Range coating technology.

“Zircotec is delighted to be associated with this project, which combines the visual and dynamic thrills of the latest limited-edition Aston Martin and the aviation legends of the Red Arrows,” says Zircotec Group Sales Director, Graeme Barette. “The use of our ceramic coating not only provides an aesthetically attractive finish, but through advanced thermal management of exhaust temperatures protects the custom Éclat red paint finish and expensive carbon fibre diffuser that encases the exhaust tips.”

The exclusive Aston Martin uses Zircotec’s Ultimate Range coating, which is specifically formulated for use on vehicle exhaust tailpipes to withstand extreme heat. In this instance, the coating was applied using an automated process, which ensures a high quality, consistent finish. Its automated capabilities allow the company to cater for large volumes, up to 100,000 parts a year, with additional programmes in place to increase this further.

“The quad exhaust tips are a focal point of the rear of the car, so the finish has to perfect not just when it leaves the factory but in 10 years’ time too,” continues Barette.

“The quality of coating on an A JANUARY 2018

Red Arrows Aston keeps its cool

Class surface component has to be very high, particularly for a tailpipe, which is subjected to salt, moisture, stone chips and high temperatures.

The proprietary way we apply the coating and our state-of-the-art automated process enables us to achieve this. Aston Martin and the Red Arrows are two of the most iconic marques in British history, so they expect the best."

Further benefits of the Zircotec Ultimate Range that make it the ideal tailpipe coating for the Q by Aston Martin Vanquish S Red Arrows edition, include resistance to flame and heat, corrosion protection, defence against staining and weather damage, and the ability to maintain aesthetics without flaking, pealing or chipping.

The Aston Martin Vanquish S Red Arrows editions are one of the most exclusive Aston Martins ever built. Each car is uniquely paired with a Red Arrows jet, including matching military serial numbers throughout. Red 10 has

been donated to the Royal Air Force Benevolent Fund and has been raffled off to raise money for the organisation.

Zircotec Group is a specialist heat management company that was formally part of the UK Atomic Energy Authority, based near Oxford. Its expertise in thermal barrier technologies was originally developed for the nuclear industry and many of its scientists and engineers have remained with Zircotec since its nuclear origins.

The company’s products include: proprietary plasmasprayed thermal barrier coatings; exhaust system coatings; inlet manifold coatings; heat shield materials; wear resistant, anticorrosion and aesthetic coatings; ceramic coatings and metal coatings for carbon composites and high-temperature plastics; and specialist plasma-sprayed ceramic products.

8 zircotec.com www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity Borough Plating has installed a new Engel 400 Twin Shot injection moulding machine to support the production of chrome plated interior trim parts for a new allelectric SUV vehicle from one of the world’s leading marques.

The company, which is a leading plastic injection moulder and chrome platers of plastics, revealed the high-tech piece of equipment after announcing it had recently secured new contracts worth around £9 million.

The new machine creates parts injection moulded using two different plastics to allow them to be selectively chrome plated in-house, so fixing lugs remain flexible.

The Engel 400 will be central to the production of at least twelve different interior trim parts and will further increase Borough’s capacity to support the UK automotive supply chain, indicating sector growth amid post-Brexit uncertainty.

David Brereton, Sales Director at Borough Plating, said: “Although

In trim for a new electric SUV

there has been a lot of discussion about the challenges the UK manufacturing and automotive sectors are facing at this moment in time, developments like these shows there’s still a lot of potential for growth and cause for optimism across the sector.

“From our point of view, the opportunity to be involved in the production of a revolutionary allelectric SUV with one of the world’s most recognised

Moulding investment at Stroud Group The Stroud Group, which purchased Cotsworld Plastics in 2016, has invested heavily in a range of new injection moulding machines – replacing existing equipment and making strategic investments in new capacity.

The Group of Companies which includes Stroud Metal Company, a high-volume manufacturer of deep drawn metal pressings, has in place an

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on-going program of plant renewal and capital investment, ensuring customers receive cost efficient and quality products.

The recent investment has included a 60t, 90t and a 150t range of Haitian Zeres presses. The Haitian presses are tremendously flexible hybrid moulding machines based on electric technology and equipped with integrated energyefficient hydraulic units.

automotive manufacturers is an exciting prospect that indicates the respect we have from the biggest names in the industry.

“The scale of investment demonstrates our ongoing commitment to manufacturing only the highest quality injection moulded components, designed specifically for selective plating to ensure the interior of a top marque car is a nice place to be.”

8 borough.co.uk Further additions include 160t and a 320t Haitian Mars Series 2 machines. The group has also replaced 25t and 35t machines for smaller components.

Cotsworld Plastics has over 40 years’ experience in the injection moulding sector, with a reputation for complex, high end technical parts, miniature mouldings, metal insert components and lead frame over-mouldings.

8 stroudmetal.co.uk

JANUARY 2018

Engineering Capacity | PEOPLE

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

Charles Corner managing director of a Malton Laser has graduated from the prestigious Goldman Sachs management training programme which provides small business leaders with the skills and tools they need to effectively grow their companies.

Simon Hiiemae has joined specialist thermal management company, Zircotec Group as Technical Director from a leading international surface solutions company. His role will support the company’s recent investments into the development of a new R&D facility.

Solder alloy and solid wire A UK based company seeks foundries or smelters for the preparation of solder alloy and manufacturing of solid wire under a manufacturing agreement. The company offers patented tin-based soldering alloys, which offer an innovative and unique solution for bonding carbon-based components to other carbon or metal components.

Reference: JV1189 Closing Date: 13/02/2018 Mexico - Plastic and aluminium injection machinery A company wants plastic and aluminium injection machinery and tools Reference: 30222 Deadline: 29/03/2018 Russia - Component manufacturers A large vehicle Original Equipment Manufacturer (OEM) is looking for component manufacturers Reference: 30223 Deadline: 31/03/2018

Stephen Phipson has joined EEF as Chief Executive.

He was formerly Head of the Defence and Security Organisation within the Department for International Trade, responsible for providing Government export support to the UK defence and security industry.

JANUARY 2018

Christopher Greenough Commercial Director of Salop Design & Engineering, a manufacturer of pressings and assemblies based in Shrewsbury won a regional Leadership Award in the EEF Future Manufacturing Awards and now goes on to the national final.

Turkey - Embedded steel plates An energy company is looking for embedded steel plates for its combined cycle power plant Reference: 30474 Deadline: 28/02/2018 For more information please email head.office@eia.co.uk quoting reference number.

Please remember to use due diligence in responding to Trade Leads. Engineering Capacity provides you with the above information in good faith, but is unable to accept any responsibility or legal liability arising from any use of these leads.

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MACHINED COMPONENTS | Engineering Capacity

Brothers add more Brothers Anthony and Michael Pateman, the brothers that run zinc and aluminium high-pressure die casting specialist RD Castings, have invested in two new Brother high-speed machining centres The company has used the Japanese-built high-speed, twin-pallet machining centres since 1989 and currently has nine of in two machine shops in Mildenhall, Suffolk.

Since the mid-90s, the 30-taper machines have replaced manual milling, drilling and tapping, which was both labour intensive and subject to quality variation.

The first machine ordered was a Speedio R650X1 with Nikken rotary 4th axis and another identical machine was ordered within six months.

The machines are particularly applicable to machining light castings because of the speed.

Workpiece changeover is completed entirely within the 3.4second rotation of the twin-pallet Quick Table, as the 21-pocket magazine’s 0.9 second tool change time, 50 m/min rapids in X Y and Z, and rotation of the 4th CNC axis are carried out simultaneously.

The first tool is ready to cut the next component immediately it arrives in the machining area and little time is wasted on each subsequent exchange of the cutter due to the rapid tool-to-tool time and spindle acceleration from zero to 16,000 rpm in 150 milliseconds, with similarly fast stop time.

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Anthony Pateman said: “There is a trend towards larger castings these days and we have just installed a 500-tonne casting machine to meet the requirement.

In order to machine them, the ability of the R650X1 to swing our 400 mm diameter parts in the rotary axis means that we are often able to finish these bigger castings in one hit and save on a second set-up operation, which hugely

decreases cost of production.”

For example, a larger part that used to need a second operation but is now machined in one 4-axis process, saving 70 pence per part.

Simon Hale, CNC machine shop manager, stated that productivity of another part – an aluminium die cast housing for the rail industry – has been nearly doubled using the larger machine compared with the other Brother models with similar tool carousels. 17 castings per hour were drilled and tapped using 12 tools on the latter machines, whereas using a trunnion fixture on an R650X1, 32 parts per hour come off the machine after each pallet rotation and just eight tools are needed.

JANUARY 2018

Engineering Capacity | MACHINED COMPONENTS The increase in output is partly because, by routing coolant at the uprated 30-bar pressure on RD Castings’ latest machines through an indexable-insert drill rather than employing a twist drill, it is possible to produce larger holes above 18 mm diameter in one spindle movement, rather than having to spot and then peck drill the holes multiple times.

Michael Pateman says that manufacturing costs are

increasing in Asia while the lower pre-Brexit value of the pound is helping UK competitiveness.

He said: “By employing ultra-high-speed machining techniques on 30-taper rather than 40-taper machines, with extensive use of polycrystalline diamond inserts clamped in dynamically balanced tool holders, the cost of producing a casting is now about the same in Mildenhall as it is in China –

and we are winning back business as a result. “The latest Brother Speedios with their larger working envelope have added considerable versatility to our shop floor, as they can economically machine anything from the simplest, smallest casting up to the largest and most complex. Productivity is also up due to the faster control and by allowing more flexible production planning.�

8 rdcastings.co.uk

Wealdpark Limited Stand number 5126

Subcontract Capacity #.# MILL TURN FACILITIES USING SLIDING AND FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER -IYANO FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER (URCO VERTICAL MACHING CENTRE 03, $ATATRACK MANAGEMENT SOFTWARE

BS EN ISO 9001:2008. Approved by BSI since 1991.

Company Contact Details Phil Smith, Director, Wealdpark Limited Sutton Road, St. Helens, Merseyside, WA9 3DJ Tel. 01744 22567 / 732083 Fax. 01744 451339 E: sales@wealdpark.co.uk www.wealdpark.co.uk

JANUARY 2018

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MACHINED COMPONENTS | Engineering Capacity

Defence strategy pays off Following recent investment in its Rotherham facility, Newburgh Precision has won its first contract direct with the MOD. Newburgh Precision’s commitment and determination to grow in the defence sector is highlighted by the recent installation of a new £500k CNC gantry machining centre. The Kafo KMC-4140 double column gantry was purchased to meet the demand of a defence contract awarded in the first quarter of 2017.

Lee Townsend, Sales Director said “The machine strengthens our already extensive capacity, although the machine was purchased with one contract in mind we have had the opportunity to utilise spare pockets of capacity to prove out new work which has led to orders being placed with Newburgh.”

David Greenan, who has been

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Managing Director for the last 5 years and has 43 years with the business, takes up the position of Vice Chairman, taking over Chairman, Vince Middleton’s duties whilst he focuses on other projects.

David has also become a Director of Sizer Ltd, pelleting solutions manufacturer, who have recently moved into new premises after being based within the Newburgh Precision factory in Rotherham.

Danny Gibbons, Operations Director has after 15 years with the business taken up the role of Managing Director.

Lee Townsend, Sales Director and Matthew Jewitt, Business

Systems Director remain in their current roles. To continue to support the current business growth Jack Pickford, CNC Programmer has become Sales Engineer.

8 np-ltd.co.uk

Ten machines for aero-engines Reginson Engineering has installed ten Hyundai Wia vertical machining centres and CNC lathes to meet the demands of an ever-increasing order book for aero-engine components.

The six turning machines (four two-axis L210A models and two E200s with c axis) and four vertical machining centres (F400 models), were available from stock from Ward CNC. The new machines are being used to perform milling, drilling, boring and turning operations on a variety of workpieces including elbows and T pieces in materials such as stainless steel and Inconel.

8 reginson.com JANUARY 2018

Engineering Capacity | MACHINED COMPONENTS FT Gearing achieved Nadcap approval for EDM machining after bringing the process back in-house on three new Makino machines.

Aldershot-based FT Gearing supplies the global defence and aerospace sectors with gears, miniature gearboxes and safety critical components for wing surface actuators, engine controls, instrumentation and fuel pumps. Many years ago, the manufacturer tried broaching the bore profiles in steel worm shafts to transmit the drive to thrust reversers, but the length-todiameter ratios were too high and the tools broke frequently.

So the company put the work out to a wire-type EDM (electric discharge machining) subcontractor in the Midlands.

The service was expensive, partly because the firm needed to have Nadcap approval, a requirement of primes such as Boeing and Airbus as well as tier-one aerospace companies, all of which FT Gearing supplies.

The situation has been turned on its head following the arrival over an 18-month period of three Makino wire EDM machines at an FT Gearing satellite facility close to the company’s main factory.

The machines were supplied by NCMT, UK agent for the Japanese machine builder.

Within six months of the first machine arriving, FT had gained Nadcap approval, while the latest EDM machine installed mid-2017 provides capacity for internal development projects and offering a subcontract wire EDM service.

JANUARY 2018

Gearing up for Nadcap

Managing director Graham Fitzgerald, who started the business with his father Des in 1978, commented, “We chose U3 wire eroders from Makino after we employed a skilled EDM machinist that has a lot of experience operating machines of the same make and rates them highly.

“He says that ISO programming on the Fanuc-based control is far easier than on some other EDM machines that employ two languages, macros are simpler to create and operations like rotation and mirror imaging are straightforward.

“From my perspective, quicker programming leads to higher productivity. The machines are also reliable, and their build quality means they sit well alongside top-end, 4- and 5-axis machining centres in our Unit 19, which we recently opened.”

The Makino’s advanced technology is brought to bear on FT Gearing’s S106 and S82 aircraft steel worm shafts to produce bores of square, double-D, hexagonal and other shapes that provide the drive to the reverse thrust flap. Dimensional tolerance is to within 10 microns and cycle times range from one to three hours.

There is spare capacity to wireEDM other components as well, such as internal gears, splines and keyways. Mr Elwick said, “Usually they require special gear cutters that can take up to 16 weeks to be delivered, but they can be put straight onto a Makino U3 without delay. Although machining takes a little longer, parts can be processed in their hardened state, so distortion and potential rework are avoided.”

8 ftgearing.com www.engineeringcapacity.com

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MACHINED COMPONENTS | Engineering Capacity

Software streamlines service When Newtech High Speed Turning decided to move to better premises, it also decided to streamline its operations and service with PSL Datatrack production control software.

“It had been on the cards for a while,” says Director Alan Riley, “and with the relocation we knew it was the right time to make the investment. I wish we had made it years ago!”

Newtech had been using a combination of accounting software and spreadsheets, resulting in too much re-entering of information, too many mistakes and too much time spent on re-quotes.

“These were all issues that I guess any small subcontract precision engineering business can face and at some stage they have to be addressed. Our move was the perfect time for us, so we could start afresh. We wanted to ensure Tridan Engineering is taking delivery of new one-hit Mazak machines that will dramatically increase its workload capacity.

The machines are a Mazak Quick Turn 200MSY and Mazak Variaxis i500 SmoothX, with a six pallet Palletech system.

The Quick Turn 200MSY will give over 90 hours of extra capacity a week. It offers improvement in efficiency using a second spindle to produce components in ‘one-hit’ along with full Y-axis

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that our customers could see for themselves how we were trying to live up to our motto of applying professionalism, giving high customer service standards and having a continuous investment strategy to deliver products to them that we are proud of,” says Mr Riley.

Initially, Newtech has used PSL Datatrack modules to focus on the key areas relating to improving customer service.

The company produces turned parts in one-offs through to batches of 20000 for a vast range of customers in industries

as varied as defence, electronics, automotive, food processing and fabrication.

Many of the customers' orders are repeats or have slight changes in terms of material specifications or quantities. These can now be dealt with much more easily as PSL Datatrack gives them the facility to call up previous orders and quickly make the required changes before quoting.

The shop floor now knows precisely what has to be made and when - including what time has to be allocated on individual turning or milling machines. “This helps us immensely in keeping to our delivery promises and as an added benefit we can produce order acknowledgements for our customers so that they are fully aware of when their delivery will be made,” says Mr Riley.

8 newtechhighspeedturning.com

One-hit Mazaks boost capacity capability performing complete milling cycles. This will reduce cycle times and, with manual intervention between operations no longer required, will minimise non-conforming parts.

The Variaxis i500 SmoothX, with a six pallet Palletech system, offers 5-axis capability for contouring of complex parts and ‘one-hit’ machining of more conventional parts.

Components that might previously have required three

to six operations on 3- and 4-axis machines will be finished in one setup.

8 tridan.co.uk

JANUARY 2018

Engineering Capacity | LASER & WATERJET CUTTING The rapidly expanding precision laser cutting specialist FC Laser has reached a major milestone by achieving a monthly turnover of £½m.

This follows the recent announcements of a record year that saw the company's sales grow by 30% over 12 months and customer activity increase by 20% in a single month.

FC Laser, which celebrated five years of operation in 2017, aims to be known for combining the finest quality laser cutting with unrivalled customer service.

As a result of its increased turnover and activity, the company is moving to larger and more ecofriendly premises so that it can continue to meet customer demand for its services.

The expansion and the move will also generate a significant recruitment drive which is expected to see FC Laser take on up to nine new members of staff.

FC Laser believes that its record growth and level of customer activity are due to the company offering the best service in the industry to existing customers while attracting increasingly high levels of new business.

The company recently extended its suite of Bystronic laser centres with the addition of three 10kW fibre machines automated with the latest ByTrans material loading and unloading system that increases production efficiency and handles materials and parts more gently, creating better quality.

FC Laser's General Manager Steve Connolly said: "Achieving a turnover over £500,000 in a single JANUARY 2018

£500,000 monthly turnover at FC Laser

As a result of increased turnover and activity, FC Laser is moving to larger premises. Managing Director Danny Fantom watches the latest Bystronic laser centre being installed

Achieving a turnover over £500,000 in a single month is quite simply phenomenal but it is no surprise to us because we have worked tirelessly over the years to satisfy customer demand and to generate new business

‘‘

month is quite simply phenomenal but it is no surprise to us because we have worked tirelessly over the years to satisfy customer demand and to generate new business. So much of this growth and success is down to the company's ethos on how it treats its customers and how it supports its employees, who can pat themselves on the back for reaching this incredible milestone."

FC Laser's Managing Director Danny Fantom added: "The most advanced machines in the laser cutting sector, the best customer service in the industry, total dedication to quality from initial consultation through manufacturing to delivery these are the reasons we are going from strength to strength.

The new factory will enable us to go even further, satisfying current customers and taking on new business, and we can't wait to get started."

FC Laser's new 20,000 sq ft factory is expected to be up and running by the end of 2017 and an open day will be held in June 2018 on the occasion of the company's sixth anniversary.

8 fclaser.co.uk www.engineeringcapacity.com

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LASER & WATERJET CUTTING | Engineering Capacity

Sweet dreams are made of this Malton Laser has delivered six giant large stainless-steel hoppers that will be filled with molten chocolate to create sweet treats for supermarkets across the country.

The large metal vats each measure 1.5m wide by 1.6m high and sit in 2.2m high frames to dispense chocolate at one of Britain’s biggest listed food companies. After drawing up the designs from a sample provided by the client using the latest CAD technology, Malton Laser cut the shapes required out of sheets of stainless steel using its advanced laser cutting machinery. These laser-cut panels were then pressed and rolled in Malton Laser’s press

£3m invested at laser cutter 5750 Components, a specialist laser cutting division of engineering and fabrication company WEC Group, has invested £3m in new premises and equipment.

The new 33,000 sq ft factory is on the Knowsley Business Park in Merseyside, just 528 yards from the old facility, but boasts more shop floor space and larger offices.

In addition to the new factory, the £3m investment includes a 4m x 2m fibre laser cutting machine which will enable 5750 to cut larger sheets of metal

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department, before being welded together to create the final form.

Charles Corner, managing director of Malton Laser, said: “This project was a really exciting one, as the chocolate hoppers we manufactured will be used to create products sold in the majority of UK supermarkets.

“We continually strive to create the highest-quality products at

cost-effective prices, along with providing unrivalled service. As this project proves, we truly are a one-stop-shop for reliable, innovative sheet metalwork.”

Malton Laser specialises in providing a full sheet metalwork service, from laser cutting and pressing to fabricating, powder coating and assembly.

8 maltonlaser.com

and maximise productivity across the entire parts spectrum, as well as two additional press brakes to complement the new machinery line up.

The 8KW 5040 Trumpf TruLaser comes fully fitted with automated handling and is now the fastest laser cutting machine out of the 24 within the Group, offering high speed nitrogen cutting on a large range of materials as well as the ability to cut up to 40mm stainless steel, 25mm mild steel and aluminium.

Michael Fitzgibbon, Director at 5750 Components, said: “The investment in the new facility and state-of-the-art technology will enable us to take on more business and improve our service and lead

times to customers.

“Our new factory will also give us more assembly space as well as creating additional welding capacity as we continue to recruit more welders.”

5750 has recently recruited three new sales estimators to enable the company to offer quicker quotes and turnaround times.

Mr Fitzgibbon added: “It’s extremely important for us to respond to our customers quickly and to offer competitive turnaround times as we continue our growth in the industry. Taking on more engineers and staff in sales will help us to achieve this goal.”

8 wecl.co.uk

JANUARY 2018

Engineering Capacity | LASER & WATERJET CUTTING Sheet metal fabrication specialist, Concept Metal Products Ltd, has invested in its second Kimla fibre laser system following substantial production gains from its first machine.

Supplied by laser cutting and metal fabrication equipment specialist, MBA Engineering, the new 6kW machine complements the 10m x 2m Kimla Powercut 4kW Fibre Laser installed in early 2017.

Concept Metal Products was impressed with the speed and precision of the machine, and the resulting cost savings, and so ordered the second system – a Kimla Powercut LF2040 6kW. The manufacturer says that the technology in its machines can provide substantial advantages in

6kW fibre laser at Concept Metal terms of performance, efficiency and cost when compared to other laser systems.

Kimla claims its machines are among the most efficient fibre laser systems on the market, being up to 50% faster than competitor models. They also have a small footprint, saving valuable factory floor space and reducing costs per square metre.

The machined can cut to an accuracy of 0.03mm.

Speaking about the new installation, Dean Barnard, general manager at Concept Metal Products, said: “Following the success of this first machine, the obvious choice for us was to install

a second system to further enhance our capacity and production capabilities. On top of the machine, the service we’ve received from MBA Engineering has been outstanding. The engineers are on hand 24/7 to assist with any queries we’ve had – they’ve very much felt like a part of the Concept Metal Products team.�

All parts and consumables for the Kimla fibre laser machines are manufactured in-house, resulting in lower repair costs for customers. In addition, the Kimla team can repair 85% of problems remotely, resulting in faster repair and reduced monetary losses.

8 conceptmetal.co.uk

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Telephone: 0115 944 3428 Email: sales@fclaser.co.uk www.fclaser.co.uk

www.engineeringcapacity.com

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CASTING & FORGING | Engineering Capacity

The power of partnership A unique collaboration between a world-leading UK precision casting business and a motorsport engine icon created ‘the world’s most reliable motorsport engine’.

In an increasingly globalised world, collaboration is integral if engineering companies are to continue to push boundaries in their respective fields. Multiple teams of experts, working seamlessly and bringing cutting edge technologies and processes together can overcome even the most difficult engineering challenges and deliver true innovation.

That’s particularly true in the case of Grainger & Worrall (GW), a business which has a long heritage of developing high performance automotive castings, structural 22

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castings, and EV powertrains, through the adoption of emerging technologies and processes. On their own, these solutions are highly effective but when coupled with the high-performance race engine expertise of Gibson Technology, a truly unique solution is developed; an engine that not only took first place in its class at Le Mans in 2017, but one which set a new precedent for reliability.

A Gibson LMP2 engine had never previously led a race at Le Mans or taken a podium overall. That all changed in 2017, when Jackie Chan DC Racing, run by Jota Sport, took second and third on the podium in their Oreca-Gibson #38 and #37 cars, respectively. The Gibson / GW engines also helped the cars

achieve first and second places in the LMP2 class.

While this represented a huge victory for the LMP2 teams, it validated the importance of longterm partnerships in engineering.

It was also testament to the skill and use of the latest technology by GW to produce engine castings that have delivered almost 144,000 kilometres (89,477 miles) without a single failure.

Tomorrow’s technology While GW is well known for its use of traditional sand casting techniques, there’s nothing old fashioned about the way it manufactures engine heads, blocks and structural castings that are used in F1, high performance cars, JANUARY 2018

Engineering Capacity | CASTING & FORGING

aerospace and the emerging EV market. The Bridgnorth business is a pioneer in the use of 3D sand printing, which it originally used exclusively for F1 clients to achieve world-class tolerances and the most complex internal geometries.

Now operating three sand printers – each operating at 90% plus capacity – this technology is being used across the vast majority of GW projects, on everything from hyper cars to electric vehicles, and even helicopters!

Another technology that GW is using to push traditional casting into new performance milestones is modelling and computer simulation. Technical director at Grainger & Worrall is Keith Denholm. He explains: “We’re using tools that model the flow and solidification of liquid metal; the processes that define the quality of the casting.

“We have to obsess about defects in castings. Defects have no strength and have to be eliminated.

The mechanical and thermal demands our customers place on these castings requires consistency at every level so process controls and testing on the shopfloor are of critical importance. This is why we deploy compositional spectrometry in every melt preparation and the use of digital x-ray and CT is mandatory at Grainger & Worrall.

JANUARY 2018

“When this is done correctly, you get a very high-tech, high performing product at the other end. The markets we operate in – prototyping, motorsport and prestige or niche marques such as sports car manufacturers – exemplifies the opportunities that are here today and will continue for some time, helping push forward various castings technologies.”

It’s a people thing While GW’s adoption of the latest casting technologies was a key component of Gibson’s Le Mans success, the importance of collaboration should not be underestimated.

John Manchester, Gibson Technology’s operations director, said: “Completing Le Mans with a total of seven of the top ten positions was a massive achievement for all concerned.

While the drivers and race teams did an amazing job to take on some of the biggest names in endurance racing, the sheer resilience and reliability of the GW cast engine was a major contributing factor that cannot be overstated.

“Our collaboration with GW goes back years and demonstrates how UK engineering businesses can

work together in true partnership to deliver world-class results. Without our shared ‘can do’ cultures, commitment to new technologies and close co-operative ethos, we could never have created an engine that has proven so remarkable.”

Last year saw the largest ever number of Gibson engines on the LMP2 grid at Le Mans, record 25 cars powered by Gibson engines, in total supplying and supporting 19 different teams. This is an amazing achievement for the UK manufacturer, with its GK428 engines making their Le Mans debut.

During the world-famous endurance race, the performance of the Gibson engines was unprecedented, with reliability second-to-none, especially given the extreme temperatures and conditions. An impressive 21 out of the 25 Gibson-powered LMP2s finished the 24 hours, with the four retirements unrelated to engine issues.

Throughout Le Mans race week, and during the 24-hour race itself, Gibson engines covered a total of 143,440.03 kms (89,129 miles), equating to an impressive 719 hours and 27 minutes.

Founder of Gibson Technology, Bill Gibson, added a final note on the reliability of their engines. “During Le Mans, our engines travelled the equivalent of three and a half times round the world without any issues, demonstrating how incredibly reliable they are. This was made possible through engineering excellence and the power of collaboration, setting a new precedent for motorsport engines.”

8 gwcast.com www.engineeringcapacity.com

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Engineering Capacity | TRAINING & EDUCATION

Supporting tomorrow’s engineers To support the brightest of tomorrow’s aerospace engineers, APT in Leicester runs a scheme of work placements for students. The latest to join APT is Sam Down, who is studying engineering at the Sir Frank Whittle Studio School in Lutterworth.

The school is a progressive and dynamic place to learn, it focuses on both academic and workrelated education in keeping with APT’s emphasis on work-based training for its own engineers.

Named in his honour and inspired by the work of Sir Frank Whittle, the inventor of the turbojet engine, the school specialises in engineering and develops the students’ self-reliance and determination to succeed in the work place.

Sam has a particular interest in pursuing a career in either aerospace or automotive.

Aged 16, he applied for a placement with APT knowing that it would nurture his interest in these sectors. Sam joined APT in October and during his placement he will be able to work in every department on the site. He has already had the opportunity to learn about turned parts as well as inspection and quality control systems. Sam has also been marking parts for the aerospace sector.

He is looking forward to help designing components with the latest CAD modelling software and seeing how raw materials are selected and parts are produced.

The aerospace products APT JANUARY 2018

manufacture can be found in a wide variety of equipment, from planes landing gear to emergency breathing apparatus.

Outside of his Level 3 B-Tech studies, Sam is a keen and determined sportsman, swimming at county level and enjoying a friendly game of football. He has always been interested in cars and how things work. The experience at APT has confirmed to him that he wants to pursue a career in engineering and that he can turn something that he has a passion for into a full-time job. His placement experience has made him want to follow the apprenticeship route.

This is Sam’s first work placement and he has been surprised at the variety of products that APT makes, the wide range of raw materials used and the extensive knowledge of all

their engineers. APT not only supplies the aerospace industry but manufactures parts for the oil & gas, medical and security. He has been made to feel a valued member of the team and enjoys the welcoming attitude of the people who work here, “They have all made me feel so comfortable”.

APT says that running this placement scheme is a perfect fit with its ethos: all its engineers go on a 4-year in house training scheme. It believes that its engineers should be an expert in every aspect of the manufacturing process and APT’s comprehensive work placement scheme reflects this. It is important to the company to be able to offer a realistic insight into an engineering career for young students and to inspire the brightest future talent.

8 aptleicester.co.uk www.engineeringcapacity.com

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SOUTHERN MANUFACTURING & ELECTRONICS PREVIEW | Engineering Capacity

Southern Manufacturing & Electronics returns to Farnborough from February 6th to 8th 2018 for its 20th anniversary event. Over two decades the show has established itself as a firm favourite amongst engineering firms across the South, and more latterly, the whole of the UK and continental Europe.

While its impressive longevity, enduring popularity and the steadfast support it has enjoyed may be great cause for celebration, it has been somewhat upstaged by a second major landmark achievement in 2018, and one which has been causing not a little excitement amongst its regular visitors and exhibitors.

From its earliest beginnings at Thorpe Park, through to its move a decade later to its present site in Farnborough, the show has been housed in a purpose-built temporary structure. However from 2018 the show moves into a new permanent home, which now graces its former site. The brand new £30m Hall 1 development at Farnborough is a 20,000m² stateof-the-art exhibition centre, featuring world-class facilities, easy access, on-site parking for 3000 cars and comfortable modern surroundings.

Situated at the birthplace and epicentre of the UK’s massive 26

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A new look for a familiar favourite £20bn+ aerospace and defence industry, Hall 1 looks set to become one of the most important showcases for UK manufacturing expertise and the diverse supply chain that supports it. Southern Manufacturing will be the first major event to be held in Hall 1, and, given the show’s well-established profile as a favourite with manufacturers and industrial buyers, it’s difficult to imagine a more appropriate inaugural event for the largest exhibition venue development in the UK for 20 years.

Subcontracting is a key focus area for Southern Manufacturing.

As the largest annual engineering show in the UK, attracting buyers from all over Europe, Southern is one of the top marketplaces for engineering services and the

selection of expertise on show is also impressively wide.

The show’s location at the centre of one of the most important regions for aerospace, automotive and medical technology, means that precision engineering services are particularly well represented.

Free seminar programme Colin Cater of TriTech 3D will be one of the expert speakers presenting as part of the show’s free technical seminar programme. Colin’s case studyillustrated talk on the seemingly boundless possibilities of 3D print is one of no less than 34 sessions running in two theatres over all three days of the show.

Two of the most perennially popular speakers return for 2018.

JANUARY 2018

Engineering Capacity | SOUTHERN MANUFACTURING & ELECTRONICS PREVIEW With examples from manufacturing, service and warehousing, Tim Scurlock, Director of ALC, will guide delegates through the benefits of Lean, include eliminating waste from existing processes, together the problems and pitfalls in bringing Lean into their organisations. Ailsa Carson of Onsite Insights shares the best practice methodologies and key activities that have made some of the world’s greatest manufacturers so successful.

Using real world examples, the sessions look at how top firms remain innovative and produce the best quality product in terms of design, cost, performance, quality and delivery.

Business management and strategy also comes under the spotlight for 2018. The General Data Protection Regulations come into force on 25th May 2018 affecting all personal data, and introducing new requirements and huge fines for transgressions.

Dave Smith of Corpdata shares the essential knowledge to help keep your organisation compliant and safe. In two separate sessions

by Andrew Mackenzie of Cleveland Scott York, and Kelda Style of Page,White & Farrer, delegates can gain a comprehensive overview of the various aspects of IP law; what can be protected and what tangible value IP protection adds to businesses. In total, the seminar programme for Southern Manufacturing & Electronics 2018 includes an impressive 34 sessions, all of which are completely free to both visitors JANUARY 2018

and exhibitors. Visitors registering online also receive a free comprehensive show guide,

containing full details of what’s on show.

Farnborough Exhibition and Conference Centre offers free on-site car parking and is easily reached by road, air or public transport.

Southern Manufacturing & Electronics 2018 opens from February 6th to 8th. Admission to the show is free. More information and tickets are available from 8 industrysouth.co.uk. ➠

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SOUTHERN MANUFACTURING & ELECTRONICS PREVIEW | Engineering Capacity What to see at the show: 8 Machining metals, ceramics and plastics Services offered by Jota Engineering (Stand G255) include CNC milling, using three, four and five-axis milling machines.

Components can be manufactured across all types of materials, ranging from ferrous and nonferrous metals to ceramics and plastics. Haas UMC-750 machines provide simultaneous five-axis machining with a 762 x 508 x 508mm working envelope, allowing for production to precise tolerances and excellent repeatability at a commercially viable cost, says the company.

8 Plastics and 3D printing Established in 1969, Industrial Plastic Fabrications (Stand F140) has amassed a wealth of expertise in engineering plastics, and more lately 3D Print. Its EOS SLS 3D printing uses powdered nylon 12, to build 3D printed parts with high strength and stiffness, and detail resolution. The company is also an exponent of fused deposition modelling (FDM), a technique yielding parts with good geometric accuracy, durability, stability and strength, for concept models, functional prototypes, end-use parts and manufacturing tools.

Alongside CNC machining, milling, plastic fabrication, laser processing and diamond tip polishing, other specialities include diffusion bonding, a technique for the molecular bonding multiple layers of pre-machined acrylic components to create flawless, 28

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void-free permanent joints without adhesives. The technique is used in applications such as the manufacturer of micro-fluidic medical manifolds, multi-layer manifolds, medical imaging devices and light guides.

8 Latest AS9100 accreditation Precision Products (Stand D70) has recently become one of the first contract machinists in the UK to be accredited to AS9100 Rev D, the latest revision of the quality management system standard for the aviation, space, and defence industries. Precision Products is a long-established, second-tier supplier to the aerospace sector, which accounts for around 20% of the subcontractor's turnover. The latest accreditation will be promoted on the company's stand.

8 Video marketing for manufacturers Aro PR and Marketing (Stand D110), a specialist agency for composites, engineering and scientific companies, is launching two new video services at Southern Manufacturing and Electronics 2018. The two styles of video are: traditional high quality, corporate video, showcasing capabilities with high production values, and more informal videos, which can be deployed in social media, as well as on company websites, and are shorter and more energetic in presentation.

The launch of this new capability closely follows Aro’s new SEO and Awards Applications services, both of which have received positive feedback and good uptake. These

complement Aro’s existing offering which includes: PR, marketing, media relations, profile boosting, digital marketing, social media, graphic design, web design and build, and copywriting. aroprandmarketing.co.uk

8 Parts with an extra gleam NC Precision (Stand C200), a leading CNC Sliding Head subcontract machining company, has recently invested in a top of the range Citizen L20-XII featuring B and Y-axis control on both the main and sub spindles. Driven tools feature B-axis operation, allowing the machining of angled features and contouring with simultaneous 4-axis control.

Another recent investment is a magnetic deburring machine that gives parts an extra special gleam and perfect finish.

NC manufactures miniature, high precision components and complex parts from a wide range of materials and provides additional services such as heat treatment, electroplating and anodising.

8 Cable looms and harnesses Cable looms and harnesses maker, Convert Ltd (Stand A155) is at Southern Manufacturing for the first time.

It follows an extremely successful year in which the Kentbased electrical engineering JANUARY 2018

Engineering Capacity | SOUTHERN MANUFACTURING & ELECTRONICS PREVIEW company worked on a range of innovative projects including: designing a 250-metre loom for the first UK trials of an autonomous grocery delivery vehicle; designing a miniature grommet to house the wiring for a lamp unit on a luxury British sports car and winning a prestigious Bright Sparks award.

Convert specialises in the automotive, public transport and scientific/medical sectors, manufacturing cable harnesses for car head and rear lights, passenger gates at railway stations and a range of scientific equipment.

Convert will be sharing its stand with SK Electronics, a Manchesterbased PCB assembler, with whom it works in partnership.

8 Supply chain and components Liberty Speciality Steels (Stand L195) represents the Aerospace Service Centre and the Advanced Machining Centre. The Aerospace Service Centre located in Bolton, UK offers a fully accredited (AS9100, AS9120, IS0 14001) integrated mill-backed supply chain. This is from stocking material through to sawing and packaging for just in time delivery requirements or servicing of long term agreements.

The Advanced Machining Centre (AMC) located in Sheffield, South Yorkshire can deliver a completely integrated supply chain, which reduces the complexity of component manufacture by delivering from concept to finished component. This is for key clients in industries such as aerospace, automotive, general engineering and energy supply.

JANUARY 2018

8 All types of metal part Qualitetch (Stand B135) offers a wide range of manufacturing process methods to aid in the manufacture of metal components, including, photo and chemical etching, metal stamping, punching, wire erosion, CNC machining, tool-making, laser cutting and associated services

such as: 3D component forming, spot-welding, finishing and plating, soldering, spark drilling and assembly work.

Lead-times start from same day and the company has particular expertise within highly-regulated industries or those with critical or high-tolerance requirements.

Supporting your sales Boost your company profile with strong PR and effective digital marketing.

For a free consultation phone 01752 894 786 or email info@aroprandmarketing.co.uk

www.aroprandmarketing.co.uk

www.engineeringcapacity.com

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HEAVY ENGINEERING | Engineering Capacity

Sculpture team hits the high notes Conceived, engineered and fabricated in the UK, the Arches of Oman, a 12metre high water and steel sculpture, has been unveiled at the Royal Opera House in Muscat, Oman.

It is anticipated that sculpture, by artist Giles Rayner, will become an iconic symbol not only in Muscat, but in the wider Middle East. At its location, next to The Royal Opera House, the country’s premier venue for musical arts and culture, the new sculpture offers unique views from all surrounding approaches.

Its stunning design includes purpose built gardens, a purpose-built pool, 70 water jets, a subterranean plant room and 2km of hydraulic hoses.

The sculpture's jets provide four distinct patterns of water that project out of the piece and into the pool below. The sculpture is formed from duplex stainless steel, a material specified for extreme environments.

Julian Glyn-Owen, the Commission Director for the artist, commented “Duplex provides enormous structural surface strength for the sculpture, the surface finish Giles and the client desired, and anti-corrosive properties needed in this coastal environment.”

In their design engineering role, Generative Parametrics, based in Melksham, played a key part in the story of The Arches of Oman.

The double curvature of the sculpture required their highly 30

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specialist 3D modelling and design engineering skills. The company took Giles Rayner's concept and developed it for fabrication, designing all components from the flat and curved surfaces, the nozzle housing and all other elements within the sculpture. Their modelling methodology was also used throughout the development and construction of Arches. Their parametric modelling techniques were central to the complex interrelationship of the 69 water jets and brackets, access hatches, and the 1km of internal hose housing.

The fabrication of the designs alone required 12-months work.

M-tec, a specialist division of WEC Group, worked from two sites, in Darwen and then at a second group subsidiary

MTL, based in Rotherham.

The sculpture, once complete in the UK, required a significant shipping and logistics project to move to Oman. The total weight of all elements shipped was in excess of 50 tonnes consisting of specialist sculpture shipping jigs, water display pumping system and alignment rigs. Charles Kendall Packing and Freight managed the packing and delivery of the piece in five separate consignments over a ten-month period to Oman. Freight was moved as specialist wide-load escorted haulage down from Rotherham, then shipped out of Southampton and trans-shipped into Sohar, Oman before being moved 250km to Muscat.

Truck Oman North, an Oil and Gas drilling rig location business assembled the sculpture once it was on Omani soil. Five cranes were used in the horizontal assembly of the piece, before it was lifted to the vertical and moved into position for fixing down.

An 11-tonne framework jig was used to align the sculpture’s main components and lift it into place.

8 archesoman.com JANUARY 2018

Engineering Capacity | ELECTRONICS Rockford has been awarded a multi-million-pound contract to deliver aircraft electronic panels to a world-leading defence aircraft manufacturer.

In a move that simplifies a fragmented supply chain, Rockford will now deliver complete electronic systems to the aircraft manufacturer, rather than the customer building it themselves and relying on many businesses to deliver individual parts.

Rockford will source various components such as switches, metallic structures, sensors, wiring and interconnect and integrate these into a final tested panel assembly. Rockford will then ship this complete unit to the customer, who will install it into the air platform.

The work involved in winning the contract started many months ago with supplier development activities to validate the supply chain. This ensured all relevant conditions were flowed down, capacity was available and competitive pricing for the life of the programme had been achieved.

The next stage was to validate the build by developing and building the first off prototype panel. The first off panel was built utilising highly skilled operators, supported by production engineering technicians.

As part of this process, Rockford developed an idea of what the future manufacturing cell would look like. All details were covered, including set-up, flow, capacity, number of stations, floor space, line balancing of standard operations, build instructions, JANUARY 2018

Multi-million-pound aircraft panel contract build jigs, line side stocking, automated equipment such as laser wire marking, cut and strip machines, electrical test cables and equipment, quality care points, handling equipment, KPIs (key performance indicators), final inspection and packing. These ideas were collated and developed into a 3D working model of the manufacturing cell, which has become a visual tool to validate both the build and production rate, and also provides the companies involved with a 3D video for engagement and feedback.

Rockford Sales & Marketing Director Chris Parsonage explained that their approach to system solutions helps defence customers deliver complex platforms by integrating technology. Meanwhile, this mitigates risk for customers by offering a one-stop-shop for all electrical requirements, simplifying complex, and often

fragmented, supply chains.

Chris says, “We’re really excited to be working on this new project.

Rockford is traditionally known for its cables and harnessing products, so this complex electrical panel allows Rockford to showcase its skills in electrical, electronic and mechanical systems and also further highlight our design and integration capabilities. The Rockford team is very proud to be working with a world leading defence aircraft manufacturer on a project of this magnitude�.

Rockford continues to grow its business by acquiring new customers and developing projects with existing customers.

These strategies combined with the launch of the new system solutions capability for defence, commercial air and industrial markets have laid the foundations for Rockford to achieve its 2022 growth targets.

8 rockford.co.uk www.engineeringcapacity.com

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ELECTRONICS | Engineering Capacity Every growing company faces a quandary when it reaches a certain size – expand in-house production or outsource it to a reputable electronics subcontractor. Steve Marshall, Managing Director of Offshore Electronics has good reasons for recommending the latter.

Successful electronic manufacturers typically start out by manufacturing their own products before experiencing growing sales and therefore, an expanding manufacturing operation.

However, rapidly growing companies can very quickly a victim of their own success.

There will come a time when production is at full capacity and a new order comes in. These successful manufacturers then face a critical decision – should they further expand in-house production, or outsource to a reputable sub-contractor?

According to the Institute of Manufacturing at Cambridge University, getting this decision right is crucial to the future of a business: “Today’s global competition forces manufacturing companies to re-evaluate their existing processes, technologies, manufactured parts and services in order to focus on strategic activities. However, companies have finite resources and may not be able to afford to have all activities in-house.

“This has resulted in an increasing awareness of the importance of the make-orbuy decision, the dilemma organisations face when deciding between keeping technologies/ 32

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Electronics: make or buy? processes in-house or purchasing them from an outside supplier.

The ability to make such decisions in a structured and rational manner is likely to improve a company's overall performance.”

Offshore Electronics has discovered that, when making this type of decision, businesses tend only to examine the cost of materials without fully taking into account that investments must be made in factory space, machinery, and extra staff.

As a contract electronics manufacturer (CEM), our company provides outsourcing over internal expansion. Indeed, outsourcing makes sense in so many ways. Of course, letting go can be hard; for a company that is self-sufficient with an intimate knowledge of its products, the notion of handing it over to somebody else can be daunting.

Indeed, these fears can be wellfounded. Intellectual Property (IP) – a concept or product that has

been uniquely created by you or your company, and has the potential to add value to your brand and product range by creating more revenue or brand awareness – is exceptionally valuable.

A recent government report revealed that IP theft resulted in a combined loss of £9.2 billion in 2016. With such staggering statistics, manufacturers need to be sure they have the correct procedures in place to safeguard their IP. It is therefore vital to properly vet potential contract manufacturers before you start working with them and make sure they are honest and trustworthy.

Guernsey-based manufacturers, such as Offshore Electronics, have to follow strict rules when it comes to IP protection and our longstanding partnerships with world class customers are further proof that we are a company that can be trusted with your most valuable assets.

The New York Times summed JANUARY 2018

Engineering Capacity | ELECTRONICS up the benefits of employing a CEM as including: • Greater efficiency, giving your firm an important competitive advantage.

• Lower labour costs, allowing your human resources to be redistributed where they are most needed.

• Reduced risk, outsourcing providers use their expertise to manage all aspects of specialised production, from compliance with governmental regulations to specialist industry standards, ensuring all products are safe to use A CEM partnership also enables electronics companies to concentrate on what they’re good at – designing, marketing and selling electronic products.

A progressive CEM will enhance its host company’s reputation by adopting a laser-like focus on manufacturing: it will have the specialist staff and machinery, manufacturing capacity, buying power and – crucially – expertise in compliance to ensure that the final product is top class.

Although CEMs are perceived as being best suited to large companies, they work closely with many small and medium enterprises (SMEs). Indeed, a CEM can lend credibility to small electronics producers. If they are working in a small facility, making products by hand, they may not be getting the repeatability and product quality needed.

They may also be too small to handle ISO accreditations, or meet evolving compliance. Regulations are becoming more of a challenge, JANUARY 2018

especially for small, design-led companies. Because CEMs have economies of scale, we can handle all this and more – everything from buying components, assembling the products, testing and shipping the final product.

Electronics manufacturing and the machinery needed to achieve it tends to work on a large scale. A company buying, for example, a surface mount line, would be unlikely to use its full capacity. A far better idea would be to subcontract out that portion of work to a CEM who has that capacity.

And a good CEM does more than just ‘follow orders’. For example, we are often presented with printed circuit board layouts that are over-engineered, expensive and difficult to produce.

So, we offer a prototyping service that helps designers remove complexity and cost from a project.

The lowdown on Contract Electronics Manufacturing A CEM such as Offshore Electronics, that is purely a contract electronics manufacturer will have no products of its own; rather it makes other companies’ products as a manufacturing partner, specialising in industrial and scientific machinery, such as industrial controllers and medical equipment.

We recently invested more than £500,000 to expand our capabilities, including a new surface mount production line with screen printer, precision placement machines and reflow oven capable of up to 56,000 placements per hour. The new line complements two existing lines, giving the company extensive production capacity.

Compliance is a huge learning curve, and achieving an ISOapproved facility like the one operated by Offshore Electronics takes time and money; the company works to IPC 610 Class 3, which is considered the ‘gold standard’ of electronics assembly.

8 offshore-electronics.co.uk

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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

Hewitt & Topham Ltd Precision gear cutters since 1938.

Standard and non standard cutter pitches and pressure angles. Gears from 2.5-6mm diameter. Northern England leading gear specialist through quality and commitment.

Royd Way, Keighley, West Yorkshire BD21 3LG Tel: 01535 602587 www.hewitt-topham.co.uk

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MACHINING (5 AXIS) 8

Qualiturn Products Limited

PRECISION ENGINEERING 8

Bespoke surface heat treatment processors. Gears up to 4.5m dia.

Shafts or rollers up to 1.5m dia. and 7.5m in length. Machine beds up to 6m lengths. Wheels up to 2.3m dia.

We have over 75 years of experience.

Mini Gears (Stockport) Ltd Mini Gears is a subcontract manufacturer of machined components, gears and racks.

Winner of 17 Industry Awards, it has a global customer base, 35,000 sq. ft. facility and over 100 machines.

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

PSL Datatrack PSL Datatrack, a flexible production management system for small/ medium size manufacturing businesses, helps to manufacture quality parts, on time and at the right price. PSL Datatrack provides vital information to management and shop floor.

Lily Hill House, Lily Hill Road, Bracknell, Berkshire RG12 2SJ Tel: 08456 345931 www.psldatatrack.com

Dawson Precision Components Precision CNC milling and turning.

Machining centres, CNC Turning centre and multi-axis sliding head machines. Full in-house machining service with additional laser marking and kitting capabilities.

Greenfield Lane, Shaw, Oldham, Lancashire OL2 8QP Tel: 01706 842311 www.dpc.co.uk

Shorter Works, Bailey Lane Sheffield S1 3BL Tel: 0114 276 8167 www.flamehardeners.co.uk/

MANAGEMENT SYSTEMS 8

GEAR CUTTING – GENERAL 8

CNC PRECISION COMPONENTS 8

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

Flame Hardeners Ltd

PRECISION ENGINEERING 8

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

DKW Precision Engineering Celebrating our 47th year supplying CNC Turned and Milled Components to all Sectors in both UK and Export markets. From 1 off to Volume, 1-450mm diameter turning, 1x1mtr milling, fast turnaround.

Quartremaine Road, Airport Service Estate, Portsmouth PO3 5RD Tel: 023 9267 7747 www.dkwengineering.co.uk

PRECISION ENGINEERING 8

JFL Broaches and Broaching

HEAT TREATMENT 8

BROACHING 8

DIRECTORY | Engineering Capacity

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

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

Hurco vertical machining centre.

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

JANUARY 2018

Specialists in reconditioning and rebuilding of all makes of precision machine tool spindles.

Spindles rebuilt in purpose built clean room. On-site removal and re-installation available.

20 Cavans Way, Binley Industrial Est, Binley, Coventry, W. Midlands CV3 2SF Tel: 02476 452600 www.rotatech.com

JANUARY 2018

TURNED PARTS 8

Accredited to AS9100 Rev C

•

Precision T Turned urned P Parts arts Subcontract Machining Surface T Treatment reatment CNC Machined Components Parts P arts Assembly Design & Engineering Support Service A AS S 9100 & ISO 9001

Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk TURNING (CNC) 8

• •

South Easts leading specialist metal cutting machinery and blade supplier. Agents for Fabris, Pilous, Alligator, Comet, Forestor, Carif and many more.

Unit 8, Wealden Business Park, Farningham Road, Crowborough, East Sussex TN6 2JR Tel: 0844 8804511 www.sawsuk.com

Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts

• • • •

Saws (UK) Ltd

Rotatech Ltd

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

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

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

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

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

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

WATERJET CUTTING 8

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

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

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

SUBCONTRACT CNC TURNING 8

Kirkham Engineering Co Ltd

SPRING MAKING 8

SPINDLE REBUILD 8

SAWING MACHINERY 8

REPETITION TURNED PARTS 8

Engineering Capacity | DIRECTORY

ICEE Comprehensive fabrication facilities offering complete turnkey solution.

Design, Precision Engineering, Sheet Metal Fabrication and Welding.

Prototypes, one off or batch work.

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

Aluminium Alloy Specialists.

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

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FARNBOROUGH | Hants | GU14 6XL 6th – 8th February 2018 9.30am – 4.30pm (3.30pm close Thurs)

The UK’s must-attend event for every industrial engineering and manufacturing professional Meet over 800 national and international suppliers under one roof in the brand new Farnborough venue next February at Southern Manufacturing & Electronics (inc AutoAero) 2018.

2018 celebrates the event’s 20th Anniversary with a move to the brand new FARNBOROUGH venue FREE SEMINARS FREE PARKING

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

Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February.

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

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

Register here with your smartphone