Engineering Capacity May 2021 digital edition

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

March 2021

INDUSTRY NEWS | AEROSPACE | INSPECTION | TREATMENTS

TREATMENTS: Fixturing biggest brazing furnace

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Automated injection moulding _cost efficient manufacturing

Automated applications within the plastic injection moulding process minimize manual interventions which afford several benefits; from productivity gains, to health and safety considerations, consistency of product integrity to waste reductions. Manufacturers are leveraging these benefits in order to dynamize their solution offering, future proof operations and streamline production, maximising returns on investment through process optimisation.

www.kuka.com 0121 505 9970 sales.uk@kuka.com

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 MAY 2021 ISSUE Laser & Waterjet cutting, Medical, Moulding, Additive Manufacturing, Machined Components 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 Those of you who follow this kind of thing will have noticed that this is the time of year when I generally dust off my ‘green shoots’ comment column. Last year was a notable and understandable exception, but I think we are ready for another outing as the literal and metaphorical green shoots seem to be appearing again.

Literally, the garden is coming to life again. Buds are swelling, the grass is growing and it’s time to think about which tomato seeds to sow.

Metaphorically, I can sense a lightening in the national mood as the days get longer and more and more of us get our jabs.

So where does manufacturing fit in with the green shoots scenario? In our January issue we wrote about the latest Contract Manufacturing Index, which showed that the subcontract market remained depressed, with projects on hold due to uncertainty and shortages.

In this issue, both the Cast Metal Foundation’s (CMF) Business Impact Survey (page 20) and the Manufacturing Barometer (page 5) give more cause for optimism.

The CMF reported that the mood remained positive among members, and that, on average, they expected to return to 2019 capacity levels within the next ten to twelve months.

The Barometer reports that 31% of companies have seen sales increase over the past six months, with 44% expecting further growth between now and August.

The Barometer also reports that despite the fact that we are still working our way through the knotty problems of Brexit, there is a growing belief that it could deliver new reshoring opportunities as OEMs look to move their supply chains closer to home.

One contract has already come home for H V Wooding (page 18) that will see it produce 28 million parts a year for tamper-proof products for the airline sector. So they are flying high, even if we can’t.

Andy Sandford, Editor

Member of the Engineering Industries Association

MARCH 2021

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Contents March 2021

11 INDUSTRY NEWS

News

Features

06 Engineers Thrive at Work 06 A&M EDM invests in staff

14 Aerospace & Defence 06 Ejection seat contract renewed Pressing ahead with reshoring

wellbeing

08 Casting and machining expansion 06 Expromet acquires

20 Casting & Forging 06 Foundries resilient and optimistic

Metaltech Precision

09 Autumn dates for Southern show 06 Southern Manufacturing

14 AEROSPACE

29 Forming & Fabrication 06 UV light for disease-free air

returns to Farnborough

Faster laser cut car panels

10 Blockchain traceability for quality 06 Technology validates NDT data 11 Remastered Mini all wired up 06 Convert supplies cabling for updated classic

39 BTMA Directory 4

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22 Inspection & Testing Services 06 Digital drive for testing

32 Heat & Surface Treatments 06 Fixture for biggest brazing furnace Building back to original specs

30 FORMING & FABRICATION

37 Plastic Moulding 06 Diversifying automated moulding MARCH 2021

Engineering Capacity | INDUSTRY NEWS

Brexit pains, reshoring gains Brexit challenges threaten to hold back England’s SME manufacturers as they recover from the effects of COVID, but reshoring opportunities are opening up.

The latest Manufacturing Barometer, which is produced by SWMAS (the South West Manufacturing Advisory Service) and the Manufacturing Growth Programme (MGP), reveals almost two thirds (65%) of companies have seen negative price changes within their supply chain since leaving the EU, with the availability of raw materials an issue for 56% of firms.

Of the 284 national respondents, more than half cited complications with exporting (54%) and importing goods (56%) since December 31st, causing potential short and long-term hits on volumes and new opportunities.

This survey, the largest of its kind in the UK, also highlighted that less than a third of SME manufacturers feel they are getting the right support and guidance from Government on how to navigate changes caused

by Brexit, underlining the need for better communication and additional tailored support.

On a more positive note, 21% of businesses believe Brexit could deliver new reshoring opportunities as firms look to bring their supply chains closer to home.

“SME manufacturers have had to deal with unprecedented levels of change over the past 12 months and it is encouraging to see some MARCH 2021

green shoots of how the sector has adapted throughout this difficult time,” explained Nick Golding, Managing Director of SWMAS. “However, despite signs of an initial recovery, firms have a new set of issues to contend with now the Brexit deal is done. Price hikes in the supply chain have been immediate, and we are hearing tales of lead times being extended on raw materials.

“Almost two thirds of respondents aren’t convinced that the Brexit guidance they have already received from the government is adequate and SMEs are asking for more clarity on key issues, such as logistics or freight forwarding (54%), sourcing components/services overseas (51%) and product markings (50%), including a CE replacement.

These challenges need to be addressed and quickly.”

He continued: “Reshoring has been spoken about as a potential opportunity and there is some

confidence from manufacturers that new purchasing trends might drive increased sales to the UK. We would love to see more made of this and perhaps even a co-ordinated campaign to promote the benefits of locating production back home.”

Away from Brexit struggles, the latest Manufacturing Barometer paints a more optimistic picture of industry slowly starting to bounce back from COVID-19.

Results show that 31% of companies have seen sales increase over the past six months, with 44% expecting further growth between now and August, both up 3% and 4% respectively on the previous report.

“Nearly a third of firms are planning to take on staff going forward, whilst 39% are planning to spend more on new machinery and capacity as they look to replace sales volumes lost in previous months,” added Martin Coats, Managing Director of MGP. 8 swmas.co.uk www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity A&M EDM is the first engineering company to be accredited on a new Midlands-based scheme aimed at improving employee health and wellbeing.

Thrive at Work is a free workplace wellbeing awards programme that is transforming workplaces around the Midlands, by boosting productivity and reducing staff sickness absence.

Employers that gain accreditation to Thrive at Work, are recognised among an esteemed network of organisations committed to excellence in employee mental health and wellbeing.

West Midlands based A&M EDM specialises in the rapid manufacture of high value, low volume components and precision tooling for automotive, aerospace, Formula 1, marine and other engineering sectors.

A&M participated in a West Midlands Combined Authority (WMCA) Thrive at Work pilot to maximise workforce potential by reducing sickness absence, improving staff retention and increasing the productivity of happier, healthier staff.

Melvin Wingfield, A&M director Bradford-based precision engineers Produmax and Andover-based MRT Castings were both recognised at the recent Make UK National Manufacturing Awards.

Produmax was announced as SME Manufacturer of the Year, while MRT Castings won the national Manufacturing Matters

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Engineers Thrive at Work

said: "Thrive was the catalyst for A&M to enhance the wellbeing of our most valuable asset, our 70 employees. We have a traditional manufacturing workforce, who participated in activities to improve their awareness of mental health, healthy eating and exercise.”

A&M used the Thrive toolkit to raise staff awareness of mental, musculoskeletal and physical health and encourage healthy lifestyles through diet and exercise. The programme ran from 2019 into 2020 with extensive evidence gathered of staff engagement using discussions, online materials, newsletters,

posters and sampling new diets and exercise for themselves.

Initiatives included a new staff forum, an in-house gym and access to a confidential mental health counselling service.

Sean Russell Head of Thrive at WMCA said: "We wanted Thrive at Work to target manufacturing SMEs, with a majority older male workforce and a traditional working-class culture, which could be resistant to change. We knew this type of business would be the most difficult culture to influence and yet we believed would benefit the most from our programme.”

8 amedm.co.uk

National awards for SMEs award, a special category introduced this year to recognise companies who have contributed to the national effort to deal with the pandemic.

MRT Castings pulled out all the stops to meet a five-fold increase in demand for die-cast, machined

and painted components for critical care ventilators. It installed a new die-casting machine, put on extra shifts, recruited more staff and bought two new machining centres.

8 produmax.co.uk mrt-castings.co.uk

MARCH 2021

INDUSTRY NEWS | Engineering Capacity

Casting and machining expansion UK precision casting and machining group Expromet Technologies Group has acquired Chard-based Metaltech Precision Ltd. Metaltech manufactures precision components for industries including energy, scientific instruments, pump and valve, aerospace, defence, rail and marine. It employs 70 people and has extensive capabilities and experience in CNC turning, milling, fabrication and welding.

Alistair Schofield, CEO of Expromet, commented, “We are delighted to welcome Metaltech to the group and to extend the portfolio of precision engineered solutions that we are able to provide to our diverse customer base. The acquisition of Metaltech is the next step in the development of Expromet and the business represents a strong fit with our existing casting and machining operations.”

“I would like to thank Steve Hill and the team at Metaltech for A robot cell installed by CNC Robotics at Autodesk’s Advanced Design & Manufacturing Facility in Birmingham was used to manufacture part of the hull for a 3D-printed boat.

With a striking design that includes wave-inspired sides and a finlike form that tapers toward the stern, MAMBO (motor additive manufacturing boat) is a boat like

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working with us, over what has been an incredibly challenging period, to make this transaction happen. I look forward to working with Steve and his colleagues in the future as we continue to develop the business within the group.”

Steve Hill, Managing Director of Metaltech, says, “Joining Expromet will strengthen our position as a leading precision machining and fabrication supplier by giving us access to a wide range of resources, expertise and investment that will benefit the business and its

customers. We look forward to working together.”

Metaltech was founded in 1973 and operates from a 50,000ft² factory on its 4-acre site in Chard, Somerset. It offers high quality precision CNC machined components and fabrications used within demanding markets such as energy, scientific instruments, pump and valve, aerospace, defence, rail and marine.

Expromet Technologies Group is a privately-owned precision engineering group that also owns Investacast, a leading global supplier of investment castings, pressure die castings and forgings, with a manufacturing base in Ilfracombe, Devon, and a network of supply chain partners throughout the world; and Haworth Castings, a specialist in manufacturing fully-tested, machined and finished sand and gravity die castings, located in Romsey and Basingstoke, Hampshire.

8 expromet.com

Robots print boat hull no other, both in its distinctive looks and in the way in which it was manufactured from fibre-reinforced plastic by 3D printing.

Milan-based Moi Composites collaborated on the design of the boat with Autodesk, which provided its Fusion 360 and Netfabb software. Sections of the hull were constructed in

Birmingham and Milan using continuous-fibre manufacturing with robots on both sites. This 3D-printing process gives greater durability and performance, while also saving material. In addition, the boat's design is no longer restricted by the manufacturing process.

8 cncrobotics.co.uk

MARCH 2021

Engineering Capacity | INDUSTRY NEWS

one of Europe's newest exhibition venues. Its non-urban location, ease of access by private transport and fresh air ventilation system make it a relatively lowrisk environment, ideally suited to running Covid-safe events.

8 industrysouth.co.uk

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Manufacturing & Electronics Show will take place on the 6 & 7 October 2021 and 8, 9, 10 February 2022.”

Safety of both visitors and exhibitors is clearly of paramount importance. Farnborough International Exhibition Centre is

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MARCH 2021

Autumn dates for Southern show

–A

Southern Manufacturing & Electronics 2021 will go ahead as a two day event on October 6 and 7 at the Farnborough International Exhibition Centre.

The show had previously been postponed from the spring due to the ongoing Covid-19 crisis. In a further announcement, the organisers have confirmed that the 2022 show will return to its usual dates in early February next year.

Throughout the ongoing crisis, the show organiser, European Trade and Exhibition Services has been in close contact with both exhibitors and visitors, many of whom had indicated their continuing strong support for the show.

Show director Phil Valentine commented: “Based on the feedback we've received it is clear that everyone is keen to get back to normal business, providing the circumstances permit and most importantly, it is safe to do so. The kind support and understanding we have received in these difficult times for the event sector has been humbling. The value of faceto-face meetings at shows and events cannot be overestimated as human interaction is undeniably the cornerstone of any successful business relationship.

“The option of staging the event in October 2021 followed by a return to our normal February timeslot in 2022 received sufficient interest for us to work alongside Farnborough International to identify a realistic and achievable timescale.

Consequently, I'm delighted to announce that the Southern

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INDUSTRY NEWS | Engineering Capacity

Bilbao show returns for 20th time Subcontratación, the biennial subcontracting trade show that is held in Bilbao, will return on 26 to 28 October for its 20th event.

Running as part of the Industry+ group of events, Subcontratación is Spain's only trade show featuring manufacturing processes and equipment for SME outsourcers and as a benchmark event for advanced manufacturing.

This year's edition will once again combine an exhibition space with large-scale B2B encounters at the 19th European Subcontracting Meeting, organised by the Barcelona Chamber of Commerce, the Bilbao Chamber of Commerce and Bilbao Exhibition Centre, working together with the Spanish Outsourcing Network. At the 2019 event, more than 1000 interviews were held, allowing subcontractors and buyers to forge links and strike deals.

QA/QC inspection specialist for the energy sector, Fulkrum, is collaborating with Steeltrace to ensure blockchain-based protection for inspection data.

SteelTrace utilizes blockchain technology to manage all aspects of the steel supply chain. FTR will use the platform to service its global customers, utilizing SteelTrace for product certification with fully digital and blockchain secured inspection reports.

Fulkrum Technical Resources (FTR) is a global provider of

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The exhibition area at Subcontratación 2021 will feature companies from a broad spectrum of manufacturing processes, including foundry, part machining, and moulds, as well as specialists in surface treatments and coatings and prototypes. A wide range of companies will take part, showcasing essential processes, cutting-edge technologies and everything in between, including complete manufacturing processes.

The event offers the added

attraction of being held as part of +Industry, one of the leading industrial platforms held at Bilbao Exhibition Centre. Along with Subcontratación, another six trade shows will run concurrently at BEC - Industry Tools by Ferroforma, Addit3D, Pumps&Valves, Fitmaq, Maintenance and BeDigital, making +Industry the country's biggest Smart Manufacturing meeting point.

8 subcontratacion. bilbaoexhibitioncentre.com

Blockchain traceability for quality technical personnel specializing in QA/QC, inspection and vendor surveillance services to the energy industry. The new collaboration will ensure another level of protection when safeguarding traceability and digital secured inspection reporting for its clients.

Andrew Bethel, Director at FTR, commented on the partnership: “SteelTrace’s use of revolutionary blockchain technology, bringing security and transparency of data,

was one of the key reasons for forming this partnership and we’re delighted to be working together.

“This new product allows Fulkrum to guarantee that our active and archived data inspection reports cannot be changed, tampered with or replicated without smart contract validation which is an advancement not yet seen in the industry.”

8 fulkrum.com steeltrace.com

MARCH 2021

Engineering Capacity | INDUSTRY NEWS

MARCH 2021

Remastered Mini all wired up

Photo credit: David Brown Automotive

Cable loom and harness manufacturer, Convert Ltd, is working with David Brown Automotive to supply full car-sets of cable harnesses for its Mini Remastered model.

Mini Remastered by David Brown Automotive pairs the original, unmistakable body of the classic Mini with modern luxury touches such as LED headlights, an infotainment system and engineered and hand-crafted interior and exterior details.

After some months of careful review and development of plans to prove the quality of Convert’s parts and manufacturing process, the production of samples and performing quality checks, the first production ready cable harnesses have been fitted into the latest Mini Remastered cars to leave David Brown Automotive’s build facility in Silverstone, Northamptonshire.

The next year could see Convert produce harnesses for over 100 Mini Remastered models with 200 Mini Remastered vehicles predicted to be produced in the following year.

The cable harnesses will be fitted across the entirety of Mini Remastered, from engine control, through all the model’s interior, and to the boot harnesses and rear lights. In total, there will be around 500 metres of wiring with 650 multi-branched connection points, across 9 individual harnesses.

Dave Lord, managing director of Convert said: “When we were approached by David Brown Automotive to help with their Mini Remastered model, we knew that we could apply our sharp technical expertise to such a

bespoke project. The classic Mini is such an iconic British car that everyone at Convert was very excited to get stuck in to design and prototype production.

“David Brown Automotive’s manufacturing is so precise and authentic to the original Mini; so much so that the wiring is the exact same colour as when the first car came off the production line in the 1960s.”

Rikki Dillon, Operations Director at David Brown Automotive said: “Convert’s highly precise engineering capabilities, partnered with their particular care and attention to detail was something

that appealed to us when choosing a supplier. This is something that encompasses our ethos in creating each Mini Remastered.”

Operating predominantly in the automotive, public transport and scientific/medical sectors, Convert manufactures wire cables and harnesses for prestige automotive headlamps and rearlamps, heavy plant & machinery vehicles, passenger control systems for the rail & air industry, transmission and driveline systems and a range of scientific equipment.

8 convertltd.co.uk davidbrownautomotive.com

Aerospace Oil & Gas Nuclear Defence

Automotive Electronics Hi Fi

Industrial & High Volume Machining

PRECISION ENGINEERING www.thomas-brown-engineering.co.uk Tel: 01484 548903

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INDUSTRY NEWS | Engineering Capacity

Private equity buyer for Formaplex Lightweight component specialist Formaplex has been acquired

by UK Private Equity fund Elaghmore.

The company is an integrated manufacturer and supplier of lightweight component solutions to the global automotive, motorsport, aerospace, medical and defence markets.

The business started as a specialist tooling partner for the F1 motorsport sector before adding injection mould tooling and moulding to its skillset and developing expertise in composite components.

Formaplex employs over 500 employees, and, following the acquisition, the business will continue to be led by Mike Bryant, CEO. 8 formplex.com

Visit our website or contact us for a quote or advice

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Castings technology MBO

Castings Technology International Ltd (CTI), which provides manufacturing, technology, expertise and services to the cast metals sector has completed a management buyout from the University of Sheffield.

The company has casting capabilities in almost any type of metal alloy and has a 1,200kg titanium vacuum melting capability, which ranks it as one of the largest in the world. In conjunction with customers’ design teams, CTI is casting complex components supplied into the aerospace, defence, chemical nuclear and marine markets.

CTI has completed a £2m fundraising.

The funding raised will allow the company to expand more rapidly by investment into further product development, alongside sales and marketing infrastructure and resource, to expand throughout its world-class manufacturing facility, which is based at the University of Sheffield Advanced Manufacturing Research Centre (AMRC).

The management team is led by Richard Cook, Managing Director and Kevin Parkin, Chairman.

Kevin Parkin said: “This is a unique opportunity to develop and grow this highly efficient manufacturing capability now that the equipment, processes and quality systems have been fully developed and accredited.

Working alongside our AMRC neighbours, together with the superb research and development initiatives provided by the University, will give CTI an enviable position in the global supply chain.”

8 castingstechnology.com MARCH 2021

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 India: BSVI (Euro 6) sensors A company requires sensors for BSVI (Euro 6) emission standards.

Reference: 34824 Closing Date: 31/12/2021

John Atkins has joined Hampshire precision engineering business RHH Franks as Sales Director. From an early career in engineering to more than 20 years in business management and sales, John has extensive experience across a range of sectors, including defence, aerospace and technology.

Tony Sexton has been appointed Group Sales Director at Nasmyth Group. He joined the Group in 2007 as Managing Director of IEC and has more recently held the position of Director of Systems and Defence for both the Nasmyth IEC and Nasmyth CE businesses.

MARCH 2021

Phil Brown has been appointed as a rail industry consultant by Salamander Fabrications to strengthen its position in the transport sector and secure large-scale project work. He has 30 years’ experience and has worked with OEMs, Tier 1 companies, SMEs and trade associations.

Colin Maver has joined offshore engineering and fabrication specialist R&M Engineering as Managing Director and will help capitalise on strong growth opportunities. He was Group Director of Dron & Dickson for 16 years, gaining extensive market experience in UK, Brazil and UAE.

Poland: Cable assemblies Polish manufacturer of electric wire harnesses, cable assemblies and power cords is looking for a manufacturing agreement for power cords with overmoulded plugs and assembly services for electric elements.

Reference: JV147 Closing Date: 19/02/2022 Spain: Recycled plastics A Spanish university has developed a procedure for the decontamination of recycled plastic materials, improving their quality to be used in high added value applications. It is looking for licence agreements and techical cooperation.

Reference: JV1469 Closing Date: 03/10/2021 Ukraine: Paper from leaves A Ukrainian research and production company which developed a technology for production of pulp and paper made of fallen leaves is looking for partners to establish joint venture or license agreement.

Reference: JV1471 Closing Date: 30/06/2021 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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AEROSPACE & DEFENCE | Engineering Capacity The maker of an advanced modular jet trainer for the RAF, which could create 3800 supply chain jobs, has joined NDI, the defence, security, space and aerospace division of Make UK, the manufacturers’ organisation.

AERALIS is building the world’s first modular military aircraft involving a common fuselage and a range of alternative wings and engines to optimally deliver a range of military missions that previously required a range of different aircraft types. The company is looking to revolutionise the way that flying training is delivered, and will seek to support the UK’s future Combat Air System programme.

In the long term, the project anticipates supporting 200 new highly skilled design and manufacturing jobs, and a further 3800 jobs in the supply chain at a time when the aerospace sector has been hit hard. The project will also support the Government’s levelling up agenda with jobs being created across the UK. Designed to win global market opportunities, AERALIS anticipates the project could be a big player in the global defence market, with the opportunity to promote the UK’s engineering expertise around the world.

Andrew Kinniburgh, NDI’s Director-General said: “AERALIS are a such an important business to the UK’s Defence Aerospace Sector, both domestically and for future export markets. We are very proud to have them as members and to work closely with their team”.

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Modular aircraft maker joins NDI

Tristan Crawford, AERALIS’s CEO and Founder said: “NDI membership has been enormously useful in helping us to approach and understand key stakeholders in the Ministry of Defence and Government more widely. Their honest and insightful advice and consistent support for SMEs in the industry is really important to us as a business.”

NDI is a key partner with the MoD and works across the supply chain, especially with SMEs on some of the UK’s most critical defence, security, space and aerospace projects. In particular it acts as a critical interface with the major OEMs in these sectors. It has recently become the lead Trade Association for the MOD’s new

Small and Medium Sized Enterprise (SME) Working Group, which has an important role in improving engagement between the MOD, major Primes and the SME Supply Chain. MOD wants to spend around 25% of its total budget with SMEs by 2022.

NDI is a division of Make UK, The Manufacturers’ Organisation, one of the UK’s major business bodies and the representative voice of UK manufacturing, with offices in London, Brussels, every English region and Wales.

Collectively it represents 20,000 companies of all sizes, from start-ups to multinationals, across engineering, manufacturing, technology and the wider industrial sector.

8 makeuk.org MARCH 2021

Engineering Capacity | AEROSPACE & DEFENCE Stratasys has been awarded a contract extension for the production of 3D printed polymer Airbus cabin interior components.

While the initial contract with Stratasys was focused on production parts for the A350, this contract extension expands the range of parts printed for Airbus to include replacement and spare parts for maintenance, repair, and overhaul (MRO) as well as parts for aircraft platforms (such as A300, A330, A340 and A320) in addition to the A350.

This builds on the company’s long-term relationship with Airbus as a technology, material, and part supplier.

In the aerospace sector Stratasys produces 3D printing solutions for flight parts, tooling and prototyping. The company’s

M E TA L S & P L A ST I C S

More 3D print parts for Airbus

industrial FDM systems and materials provide the performance and manufacturing repeatability required by space, commercial aviation and military customers.

As it recovers from pandemic slowdowns, the aviation industry is expected to increasingly turn to

additive manufacturing for strong yet lighter weight parts and consolidated assemblies, while digital inventory of 3D-printable spare parts promises to make MRO operations more agile and cost effective.

8 stratasys.com/aerospace

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AEROSPACE & DEFENCE | Engineering Capacity

FAC prepares for sector take-off Farnborough Aerospace Consortium (FAC) has added four new members this year as the sector prepares for a post-lockdown take-off.

FAC represents companies in aviation and aerospace and the associated supply chain – mainly centred in the south and south east but with an international membership.

Since the industry was hit hard by the reduction in passenger traffic it has been lobbying the government on behalf of the sector.

The latest companies to join FAC are Oxfordshire-based business consultancy kc4business Ltd, US-headquartered software specialists CGTECH whose UK base is in Sussex, Global Shop Solutions, the software giant headquartered in the US with a Sussex branch, and Adaptix Ltd, an Oxfordshire-based 3D imaging company.

Chief executive of FAC David Barnes said: “Never has the sector been through a more difficult time. Aerospace and aviation have been among the hardest hit of all industries.

“Many companies have suffered greatly but their resilience has been astonishing.

“We initially saw them diversify to help the battle against Covid by making ventilators and other equipment.

“Since then they have diversified to gain entry into different markets in a bid 16

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to keep trading. And we’ve seen extra focus on research and development.

“Aerospace is one of the country’s genuine world class industries and it has to be ready to spring back when allowed.

“Those within it understand that sticking together is the best way for us to maintain that worldleading position post-Covid. That is why we have seen more companies join us.

“We offer great benefits, but it is the power of one voice representing hundreds of businesses and thousands of workers that attracts new members.

“We welcome the new

companies to FAC and would urge others to join us as we prepare for the sector to be opened up.

“While this could take time, there really is light at the end of the tunnel. Communication between our members is the key to success.

“The nature of the sector means any re-opening requires a global solution and we must be poised to react as soon as lockdowns are eased.”

The country’s aerospace industry pre-Covid provided more than 120,000 skilled jobs with an annual turnover of £35 billion – most of which was generated by exports.

8 fac.org.uk MARCH 2021

Engineering Capacity | AEROSPACE & DEFENCE Martin-Baker Aircraft has renewed its supply agreement with composites specialist Pentaxia for the long-term supply of high-performance, lightweight components and assemblies on a multi-year basis.

These parts are fitted to MartinBaker’s latest generation of ejection seats and subsequent global fighter jet programmes.

Tim Ollier, Sales Director of Pentaxia, said: “Pentaxia is delighted to renew our supply contract with the team at Martin-Baker. We share many company values and pride ourselves on producing world class components. Working collaboratively with our colleagues at Martin-Baker, our highly talented team are able to ensure quality and consistency in every component we deliver.

This new agreement not only demonstrates our customer’s confidence in working with us, but provides an international platform for British engineering.

It is a pleasure to continue our working relationship.”

Andy Patrick, Programmes and Commodity Supply Chain Manager at Martin-Baker added: “Martin-Baker is pleased to enhance its working relationship with Pentaxia through this agreement on a commodity that is expanding its usage in the next generation of escape systems” Pentaxia produces all advanced composite components in-house and will supply Martin-Baker and its international aerospace partners with legacy and latest generation composite components.

MARCH 2021

Ejection seat contract renewed

Martin-Baker has been the world leader in the design and manufacture of ejection and crashworthy seats for over 70 years. A family-run business at its d

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core, its seats have saved over 7,638 lives since the company was founded and over 17,000 seats are currently in service.

8 pentaxia.com

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Manufacturers of High Quality Mill-Turned Parts

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AEROSPACE & DEFENCE | Engineering Capacity

Pressing ahead with reshoring Investment in a high-speed press is helping HV Wooding deliver a significant aerospace contract that has been reshored from Spain.

The Kent-based company, which offers laser cutting, wire erosion, busbars, motor laminations and presswork to customers all over the world, has invested over £120,000 into new tooling and the installation of a Bruderer BSTA 25H to produce more than 28 million precision parts every year.

The contract will utilise the press’ repeatable bottom dead centre accuracy and 1500 strokes per minute capability.

Components will be used in a number of tamper-proof products for the airline sector and should account for 60% of the machine’s capacity, leaving the other 40% for new opportunities in electrification and green energy.

“This is the second Bruderer we’ve installed, after inheriting our first when an electrical client outsourced its press shop,” explained Paul Allen, Sales Director at HV Wooding.

“There are few machines in the world that can offer the speed and accuracy in such high volumes and this is going to make a major difference to our ability to meet the requirement of our aerospace customer.”

He continued: “The material we are using is really thin gauge and tolerances are within microns that’s why we decided on the BSTA 25H. The RAM Guidance System 18

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eliminates the possibility of movement during the stamping process, prolonging the tool life and giving us consistent repeatable quality, something the customer wasn’t getting overseas.

“It was a real partnership approach, with the Bruderer experts working with us to identify the right machine and then planning the timeline so that we could manage the install without disrupting production. This meant running the initial parts off at its Luton factory whilst we were putting the machine in place.”

Simon Stewart, Technical

Manager at HV Wooding, went on to add: “We have been really impressed with the performance of the BSTA 25H and are already looking at ways where we can standardise the set-up process to move other projects on to it.

“There is also the potential to target new opportunities, with the 1500 strokes per minute speed giving us plenty of capacity to take on high volume electrical, lamination and motor orders.”

8 hvwooding.co.uk

We have been really impressed with the performance of the BSTA 25H and are already looking at ways where we can standardise the set-up process to move other projects on to it

‘‘

MARCH 2021

Engineering Capacity | AEROSPACE & DEFENCE Precision engineering company RHH Franks has unveiled its newly expanded factory in Hampshire, which will increase its manufacturing capacity for the global aerospace, defence, nuclear and marine industries by over 25%.

Following a successful application to the Solent Local Enterprise Partnership (LEP), the business was awarded more than £97,000 towards its investment to acquire and equip an additional 6,600 sq ft of unit space at its premises on Gore Road Industrial Estate, New Milton.

It takes the total manufacturing site up to over 30,000 sq ft.

The expansion project, which was completed in January 2021 – RHH Franks’ 60th year of trading – is part of the business’s growth strategy to substantially increase turnover in the next five years.

The extension includes a dedicated and improved Nadcapaccredited heat treatment facility, increased machining and fabrication workshops and storage provision, allowing for all other departments to expand within the existing premises.

New technology worth more than £150,000 has been purchased, including a third heat treatment oven and four-axis CNC machine which will increase manufacturing capabilities at RHH Franks from 130,000 components per year currently to more than 160,000.

Managing director Elsa Hogan said: “As part of our intense growth strategy which we have launched to mark our 60th year, we are thrilled to unveil our newly expanded premises.

MARCH 2021

Expanded capacity unveiled

“They will significantly increase our manufacturing output to meet the growing demands of our clients and their supply chains.

“Over the past 10 months our team and contractors have worked extremely hard to create a modern and fully-equipped facility, despite the operational challenges, that provides our skilled engineers with a positive and productive working environment, improving capacity and lead times.

“When circumstances allow, we are looking forward to welcoming clients to our new facility.”

Founded in 1961, RHH Franks has grown from a modest sheet metal workshop to a sizeable endto-end subcontract manufacturer providing a complete range of services from CNC milling and turning to fabrication and Nadcapaccredited welding, chemical processing, heat treatment and dip and torch brazing.

Clients include Leonardo Helicopters, Eaton Aerospace, Cobham Mission Systems, SEA Ltd and QinetiQ. Honeywell Aerospace is one of

8 RHH Franks managing director Elsa Hogan

the firm’s longest standing clients, having worked with RHH Franks since 1967.

Based in New Milton, Hampshire, RHH Franks employs over 40 skilled engineers from the Hampshire and Dorset area and is committed to inspiring the next generation of young engineers through its apprenticeship and work experience offering.

Brian Johnson, chair of the Solent LEP, said: "I am delighted to congratulate New Forest-based business RHH Franks for completing their 60th year of trading; and also to look back to see how the LEP's Local Growth Fund has been put to such good use within the manufacturing sector in the region.

“RHH Franks is one of many innovative and high performing manufacturing businesses based in the Solent who are providing much needed innovation and jobs that will support our economic renewal."

8 rhhfranks.co.uk/ www.engineeringcapacity.com

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CASTING & FORGING | Engineering Capacity

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Foundries resilient and optimistic UK foundries report that there is hope for a return to pre-Covid capacity utilisation levels, despite the impact of the 2020 lockdown measures and the resulting decline in production activity. This is the finding of the Cast Metals Federation (CMF) Business Impact Survey – 2020 Summary Report.

Courtesy Castings PLC

Despite the negative impacts of the pandemic including a fall in demand, the need to pause business operations for a short period and make additional investments to make workplaces Covid-secure, and prolonged supply chain disruptions, the mood remains positive amongst CMF members, with most reporting optimism for 2021.

With 2019 resulting in a significantly better year than recent years for the UK foundry sector, a decline in order books was anticipated during the early part of 2020, with concerns surrounding the outcome of ongoing Brexit trade deal negotiations. By March, the industry was also faced with responding to the global coronavirus pandemic and has subsequently responded with agility and resilience. The rapid change in volumes for the automotive and aerospace sectors saw order books plummet, specifically in the diecasting and investment casting sectors. Two lockdowns and the practicalities of operating facilities under imposed government social distance restrictions – reduced workforce, additional health & safety measures in working and common areas, supply chain disruptions etc. – have taken their toll.

The impact on business has been significant. Throughout the summer order books remained short, but by the autumn business levels were picking up, with the foundry sector well placed to respond. However, a resurgence in infection rates resulted in a

8 Robotic fettling

second lockdown and a slowdown in demand as the year closed.

To counter the negative effects of the pandemic, CMF members have drawn on the assistance made available by various government schemes, such as CBIL loans for additional finance, deferred VAT payments and the coronavirus job retention scheme (CJRS).

By the middle of 2020, the average percentage of employees on furlough was 30%. This lifeline enabled Members to retain staff and meet customer demand, playing to the sector’s strength in terms of skills and responsiveness.

The scheme has allowed companies to maintain production levels when required, most notably in the latter half of the year particularly quarter 4 when orders increased. There were however some redundancies, but the levels were low compared to other sectors.

As expected, business disruption has taken many forms and is not merely confined to a downturn in customer demand. At the start of the crisis, many members significantly reduced or paused production to reorganise workplaces and implement social distancing measures, to enable operations to resume in a safe and efficient manner. In addition, procedures had to be adapted to accommodate operating with a reduced workforce to meet government guidelines and to support the shielding of vulnerable employees.

By the middle of the year, the industry had adapted to the new working procedures, but supply chain disruptions continued thanks in part to the lack of production capacity throughout the supply chain and logistical challenges. This was compounded by significant increases in costs MARCH 2021

Engineering Capacity | CASTING & FORGING for waste disposal, energy supplies (specifically in quarters 3 and 4) and insurance.

In some instances, customers also sought notable price reductions with the foundry industry thus squeezed at both ends.

Despite all of this and as the economy mounted a tentative recovery during quarters 3 and 4, CMF members reported improvements in order books.

There are of course exceptions and those businesses considered to be in an ‘essential’ supply chain – 40 per cent of foundries and 15 per cent of foundry suppliers – had a busy year, often with increased demand and the specific challenges that poses.

Towards the end of the year and the end of the Brexit transition period, a large proportion (73 per cent) of members said they were prepared for a new way of working as the UK exited the European Union. There was concern over the late timing of the publishing of final detailed guidance, but there is also “hope” that there would be increased opportunities for local content in supply chains.

Notably, despite a very testing year, no member has reported the need to close or scale-down operations in the longer term. Members also reported that on average they would return to 2019 capacity levels within ten to twelve months.

Speaking about the results of the Survey, CMF CEO Dr Pam Murrell FICME said: “Our sector has faced an enormous challenge during the past year and CMF members have responded as they always do, with remarkable resilience. Their optimism and robust handling of what has been a challenging year for all industries and society is a reflection of their competence and abilities. With industry gearing up throughout the Brexit transition period and awaiting trade deal news, 2020 was set to provide certain complexities, but nobody could have predicted a global pandemic and what that would throw into the mix. However, the wheels of industry continue to turn and CMF members have an important role to play in contributing to the UK’s GDP and they haven’t disappointed. Our sector has ‘dug deep’ and found solutions during the harshest of conditions and we can be particularly proud of that.”

Contact: Dr Pam Murrell FICME, Tel: +44 (0) 121 809 3500, email: pammurrell@cmfed.co.uk 8 www.cmfed.co.uk MARCH 2021

The Cast Metals Federation is the single voice for the UK castings industry, the Trade Association that represents the interests of foundries and foundry suppliers.

CMF members come from every part of the industry and produce around 85% of all castings output in the UK. With over 120 foundries, ranging from global foundry groups to small jobbing foundries, our members supply precision finished parts and assemblies in a range of sizes, metals and processes to the UK and global markets. A strong casting sector requires and supports a successful chain of equipment and consumables suppliers, over 40 of whom are important part of CMF’s membership.

As a proactive trade association, the CMF undertakes activities beyond the resources of individual members that drives the whole industry forward competitively, technically, environmentally and legally. When it comes to dealing with national or European governments, legislation, health and safety and a wide range of other topics, we can represent members’ best interests.

For manufacturers across the world seeking the

the CMF provides a single point of contact, whether for sourcing castings for every application and market sector or general information on the activities of the UK foundry industry.

www.castmetalsfederation.com To find out more or apply for membership please contact:

National Foundry Training Centre, ECMS, Tipton Road, Tipton, West Midlands, DY4 7UW Tel: +44 (0) 121 809 3500 Email: admin@cmfed.co.uk

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21

INSPECTION & TESTING SERVICES | Engineering Capacity Element Materials Technology is pushing forward with its digital services, offering customers live remote access to tests and launching a digital division.

Element has accelerated the roll out of a renewed digital remote witnessing offering to improve customer experience as part of the large-scale digital transformation of the business.

Element is using market leading technologies, easily accessible by customers the world over, and which allow virtual access to its complete range of testing services from anywhere in the world.

Through the use of these easily accessible digital platforms, customers can watch live testing of their materials and products remotely, keep their testing programs on track, avoid unnecessary travel and hotel costs, and focus on more productive, value-creating activities for their own organizations.

As with standard testing protocol, all remotely witnessed testing is performed in accordance with all the relevant certification and security conformance standards. The delivery of the service is supported by rigorous operating procedures and usage guides, designed to give the customer the same high quality, efficient Element experience as they would in person.

Janet White, EVP Digital Transformation at Element, said: “I am delighted that we are accelerating the roll out of these capabilities at a time when customers across many of the end markets that we serve continue to 22

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Digital drive for testing

face challenges that have arisen out of the COVID-19 crisis.

Element has been successfully delivering remote witnessing services to many of our clients for several years, and 2020 presented us with an opportunity to optimize our capabilities to better serve them through the restrictions that the pandemic caused.

“Element’s remote witnessing offering is a shining example of our ability to drive value through internal transformation and delivering growth by leveraging data, automation, AI, and practical IoT to enhance customer experience and our competitive advantage.”

Remote Witnessing from Element can comply with many export regulations as regulated by the by the US International Traffic in Arms Regulations (ITAR), US Export Administration Regulations (EAR), US Office of Foreign Asset Controls (OFAC), Canadian

Controlled Goods Program (CGP), and the UK Strategic Export Control Lists.

Element has also formally launched its simulation arm, Element Digital Engineering, which takes it a step forward in its aim to become a leader in engineering simulation, modelling, data science and artificial intelligence to solve complex industrial challenges for its customers, as well as ensuring the safety and regulatory compliance of their products.

Element Digital Engineering’s specialists bring with them capabilities not readily available in the testing market, including digital twinning, machine learning, and mathematical optimization to MARCH 2021

Engineering Capacity | INSPECTION & TESTING SERVICES bolster Element’s comprehensive range of existing testing services.

The Digital Engineering team will primarily focus on the global medical device, energy transition, aerospace, consumer goods and mining markets.

This new business builds on Element’s existing capability in areas such as finite element analysis and engineering critical assessment, and has been accelerated by the acquisition in

early 2021 of a leading engineering and modelling simulation company based in Cambridge, UK. This acquisition and the launch of Element Digital Engineering supports Element’s ambitions and focus on innovation and digitization to develop industry leading capabilities and solutions for its customers.

Jo Wetz, CEO at Element, said: “Element Digital Engineering is an exciting and natural extension of

our commitment to develop specialist technical and digital services to solve complex problems for our customers who are working at the cutting edge of their industries. With this new expertise available to the Group, we look forward to creating new opportunities for digital technical knowledge sharing and improving partnerships with our customers.”

8 element.com

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MARCH 2021

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23

INSPECTION & TESTING SERVICES | Engineering Capacity Rochdale-based subcontractor Chelburn Precision has installed one of the tallest height gauges on the market to ensure precision on larger components.

Chelburn mostly serves the canning, rubber and plastic, paper converting, and mining industries and had problems reaching the full height of some components using its exiting height gauge. This meant it had to either turn jobs over to measure from a different plane, or make time and room on one of its precision machine tools to carry out checks. This not only required extra time, but also stopped the production of both the machine tools and their operators when quality inspectors requested and verified checks to ensure parts conformed to specification.

The new Trimos V7 height gauge, supplied by Bowers Group, is capable of tackling complex functions such as 2D, programming, and statistics, resulting in an unequalled ease of use and a substantial increase in productivity.

It features a pair of lateral insert holders that allow the use of very diverse probes up to 400 mm long with high repeatability.

Chelburn Precision also invested in the squareness electrical probe which enables the business to reach the full height of components, both for measuring positions and measuring squareness. The additional probe creates the efficiency of combining two instruments to make the 24

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Height of precision

measurement process quicker and easier, offering the team the ability to perform the precise measurements they needed.

Chelburn’s inspection department is manned full-time by two qualified inspectors who have access to a wide range of quality equipment. Thanks to the new height gauge the team know instantly if there is something that needs altering on the shop floor, allowing them to measure parts easily and quickly and get results before they reach the CMM. Since having the Trimos V7 height gauge, Chelburn has found it extremely easy to use, with

We have used Bowers Group before for a lot of different measuring devices we own, so we knew we were in good hands

‘‘

inspectors using it in preference to traditional methods of parts inspection, owing to the fact they can measure multiple sizes with the one device. Now using the Trimos V7 every day, the inspectors also use the height gauge on smaller manufactured parts, as they find it easier to use and more reliable than their previous unit.

Michael Horsfall, Production Director at Chelburn Precision said, “We have used Bowers Group before for a lot of different measuring devices we own, so we knew we were in good hands.

They even loaned us a smaller unit for us to trial as they were confident that we would be impressed by the quality, accuracy and ease of use of the Trimos height gauge.”

8 chelburn.co.uk MARCH 2021

Engineering Capacity | INSPECTION & TESTING SERVICES Contract electronics manufacturer Jaltek has invested in a second flying probe test machine that will enhance its technical capacity and throughput.

The TAKAYA APT-1400F is reported to be the fastest flying probe test system on the market, setting new standards for speed and test coverage, and will sit alongside Jaltek’s existing machine.

The system has been specially developed for the test of large quantities of complex circuit boards. The APT-1400F has 6 flying probes, of which 2 are vertical, enabling access to contact points that could not previously be reached. The design of the XY table has been completely revised and innovative test algorithms enable a significant increase in the test coverage on circuit boards.

The Takaya APT-1400F comes with a list of impressive features as standard, but Jaltek also installed a number of additional functions that it says makes its test speed, positioning accuracy and coverage unprecedented in the UK. The additional features include a laser measuring unit that allows a single-sided tester to accurately measure component heights, to check for component compliance to IPC/customer requirements, BGS co-planarity to the PCB, or for non-fitted components.

Commenting on the acquisition of this new Takaya machine Steve Pittom, Managing Director of Jaltek, said, ‘We continue our MARCH 2021

Fastest flying probe tester commitment to invest for our customers. This fully featured new flying probe will bring significant value to our customers particularly those who have AS9100 and ISO13485 requirements as well as for new product introduction. We can’t wait to start putting it to the test.’

8 jaltek.com

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INSPECTION & TESTING SERVICES | Engineering Capacity Subcontract inspection services from the Carfulan Group aim to help companies cope with the production and capacity pressures created by the fall-out from Covid.

The Group says that, during these unprecedented times, where reduced internal capacity is adding to the pressure of fulfilling orders and satisfying customer demand, the complementary manufacturing technologies it offers could be a lifeline.

Experienced engineers at Group companies OGP UK and VICIVISION UK can write programmes, recommend best measurement practices and provide comprehensive data so that businesses can reassure their customers and stakeholders, taking the stress out of inspection.

OGP’s multi-sensor metrology solutions employ optimumperformance sensors and probes to complete the work of a traditional co-ordinate measuring machine, as well as a laser scanner and profile projector, with ultimate precision.

Detailed data about even the most demanding components and features is collected quickly and reliably by trained UKASaccredited engineers, giving comprehensive feedback and reliably accurate results.

Utilising an impressive technology suite in a temperature-controlled environment, OGP UK can help with dimensional measurement, component measurement, non-destructive inspection, first article inspection and gauge R&R on parts up to 0.5m3.

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Inspection services remove stress

OGP UK’s services include first and initial sample inspection, gauge repeatability and reproducibility measurement and the measurement of complex shapes. OGP’s multi-sensor measurement systems combine optics, laser and probe to measure complicated parts in a fraction of the time it takes other systems.

Whether it’s medical, aerospace, automotive or packaging, manufacturers of precision parts can benefit from shorter production cycles and improved quality control whatever their application.

VICIVISION’s world-leading optical, non-contact measuring systems cater specifically for turned, ground and cylindrical parts, guaranteeing improved manufacturing efficiency, reduced downtime and increased productivity through superior data analysis.

Using a combination of high-resolution video camera

technology and light projection, its solutions deliver fast, detailed and consistent results, completing metrology tasks that were once reliant on the time-consuming and unreliable manual methods reserved for specialist labs.

Whether it’s diameters, angles, orthogonalities or thread pitches, coaxialities, cylindricities, axial runouts or dynamic parallelisms, even the most complex features can be inspected in seconds, down to the last detail, by a team of experienced engineers.

By more readily satisfying the modern standards required to reduce noise on production lines across the medical, automotive, aerospace and oil, gas and energy sectors, VICIVISION UK is offering metrology services that allow manufacturers to minimise part non-conformance and reliably deliver top-class products to gain a competitive advantage.

8 landing.ogpuk.com/subcontract MARCH 2021

Engineering Capacity | INSPECTION & TESTING SERVICES State-of-the-art connected metrology systems from Renishaw will be critical to the machining and inspection capabilities of the Digital Manufacturing Centre (DMC).

The DMC is further expanding its partnership with manufacturing technology leader Renishaw and says the new agreement is critical to the DMC’s on-site machining capability, which is delivered by precision engineering specialist Produmax.

The partnership will see Produmax’s machining and inspection services linked into the DMC’s intelligent, connected process chain. This will be a key element in the realisation of a true ‘digital twin’ and the real-world application of Industry 4.0 principles. Thanks to Renishaw, Produmax’s connected metrology solutions will significantly enhance the DMC’s efficiency and ability to deliver exceptional parts for the most demanding sectors.

Equipped with a new DMG Mori DMU 60 eVo linear 5-axis mill, Produmax will utilise a Renishaw OMP600 high-accuracy optical probe in conjunction with NCChecker and NC-PerfectPart software from Renishaw associate company, MSP, to ensure machine capability and enable complex part alignment prior to machining. A Siemens controller will then be used to proactively adapt machining processes to the subtle variations in net-shape components made through additive manufacturing.

During machining, a Renishaw NC4+ Blue laser tool setter will be MARCH 2021

Digital metrology connection used to achieve the high levels of precision required to deliver the tolerances and surface finishes required by DMC customers. Produmax will then comprehensively analyse the parts using a versatile Renishaw REVO 5-axis measurement system to certify quality.

The REVO’s multi-sensor capability and high-performance scanning provide Produmax with non-contact and surface finish analysis in a single Coordinate Measuring Machine (CMM). It will come equipped with Renishaw’s 5-axis tactile scanning and touch trigger probe, surface finish measurement tools (SFP2) and non-contact optical Fringe Probe (RFP). This will give the DMC and Produmax the ability to carry out a variety of measurement tasks in one single datum system and in one operation.

Jeremy Ridyard, Managing Director at Produmax, commented: “Metrology is an essential aspect of delivering industry-leading machining, finishing and inspection services.

Thanks to the support of Renishaw, we are bringing worldclass metrology capabilities to the DMC, allowing us to digitally connect the entire process chain.

“This new agreement will enable us to link all the steps, each providing data to inform subsequent operations. Through digital connectivity and our wellestablished Quality Management Systems, the DMC will confidently deliver on the requirements of a wide variety of sectors, from aerospace to industrial.”

Kieron Salter, Chief Executive Officer at the DMC, concluded: “We are thrilled to have Renishaw play such a central role in enabling critical elements of the DMC. Together, alongside Produmax, we are realising the potential of connected additive and subtractive manufacturing. The addition of connected metrology is yet another demonstration of our ambition to level up UK manufacturing and establish ourselves as a world leader in advanced manufacturing.”

8 digitalmanufacturingcentre.com produmax.co.uk www.engineeringcapacity.com

27

INSPECTION & TESTING SERVICES | Engineering Capacity

A ‘model’ for maintaining quality G&P, which provides quality management services to the manufacturing industry has developed a model and system that allows it to drive and support the quality management process, identifying problems in real-time allowing manufacturers and suppliers to respond much quicker.

The company says its Quality Excellence Model has helped manufacturing customers, including automotive and aerospace OEMs and Tier 1 suppliers, to improve efficiency and quality levels, which in turn reduced waste by more than £2.5bn in one year alone.

Further analysis of the system’s use shows that in just 12 months it prevented more than 21.4 million substandard parts from entering the supply chain or being turned

into waste, supporting the drive for improved performance, reputation and quality standards among G&P’s customers.

At the heart of G&P’s Quality Excellence Model is its proprietary

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

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QTrak system. This is a sophisticated project management software tool which allows realtime analysis and identification of quality issues.

As QTrak provides instantaneous results, it allows problematic supply sources to be investigated without delay, parts contained and corrective action to be deployed to prevent further defective components from being produced.

Specifically, the Quality Excellence Model enables highvalue manufacturing organisations to manage complex supply chains and control costs, while giving these companies on-demand access to the resources and expertise they need for both reactive and proactive management of supplier quality, together with their own in-house quality, quickly and cost-effectively.

It also facilitates sustainable long-term quality improvement, by enabling manufacturers and their suppliers the ability to rapidly identify the root-cause of quality problems and take decisive action to permanently eliminate them.

Strategically the Quality Excellence Model has enabled a fundamental shift in G&P’s relationship with its customers.

G&P is increasingly seen as a strategic partner, often with sole responsibility for the management of inbound component quality and the response to quality issues, including through the deployment of quality engineers.

8 gpqm.com MARCH 2021

Engineering Capacity | FORMING & FABRICATION

UV light for disease-free air Fabrication specialist, Blackrow Group, is working with an infection mitigation specialist on applying systems and technologies to reduce the transmission of harmful bacteria and viruses.

Health technology company PP-L has partnered with Blackrow to help manufacturing companies across the UK become COVID-secure by purifying air and surfaces using ultraviolet-C radiation.

The partnership will ensure manufacturers can go beyond government guidance to make their operations extremely COVIDsecure and ultimately continue to supply the nation.

The collaboration agreement also sees the two companies work closely together to introduce PP-L’s technologies – which are proven to reduce the transmission of harmful bacteria and viruses, including COVID-19 – into the Blackrow Group’s own bespoke machinery.

Paul Waldeck, chief executive at PP-L, said: “At this moment in time, it’s imperative that our team of engineers, scientists and medical experts are proactively working hand-in-hand with companies like the Blackrow Group to increase the visibility and use of safe UV-C and enhanced ventilation system solutions across a multitude of industry sectors.

“The manufacturing and production industry is under severe pressure and has been MARCH 2021

very badly hit by the COVID-19 pandemic, and technologies like UV-C are critical in allowing them to get back to the level it was operating at previously while protecting its staff in the most effective way practicable.

“Health authorities around the world agree that COVID-19 is primarily spread through airborne transmission, so the availability of clean, uncontaminated air is crucial in preventing the spread of the virus and protecting people from infection.

“Like other coronaviruses, COVID-19 will mutate as it spreads through the population, meaning it will still remain a problem even with the availability of vaccines. It is therefore important that steps are taken to protect people and environments if we are to live with this ongoing danger.

Indeed, the HSE’s recent CovidSecure Workplaces Guidance has recently been updated to help with this risk and specifically covers ventilation and UV intervention.”

The technologies and products used by PP-L have been in use for more than 80 years and have been proven to kill 99.99% of pathogens.

PP-L’s UV-C solutions have been proven to be highly successful in dealing with previous coronaviruses, such as the first SARS crisis in 2003, with highly infectious airborne viruses destroyed within milliseconds through exposure the light but in a way that is completely safe for building occupants.

Dave Stubbs, senior engineering manager at the Blackrow Group, said: “We are delighted to be working alongside the PP-L team to actively bring UV-C solutions to any industry sector which requires it.

“With our extensive engineering knowledge and expertise combined, with the tried and tested technology PP-L solutions provide we are confident the alliance will play a pivotal role in the control and mitigation of COVID-19 in the workplace.”

8 blackrow.co.uk www.engineeringcapacity.com

29

FORMING & FABRICATION | Engineering Capacity Pressworking and prototyping specialist AE Oscroft has joined forces with the AA to develop a game-changing innovation that will transform the breakdown service for thousands of drivers.

The company has used its engineering expertise to create a new freewheeling hub that allow patrols to safely tow vehicles that can’t normally be ‘lifted and towed’ on two wheels, including 4x4s and the increasing number of electric vehicles in the UK. Recovery professionals can fix the hub to the rear wheels of stricken vehicles so they can be towed by a standard van rather than having to wait for a flatbed recovery vehicle, increasing the speed of response and reducing the time motorists are left stranded on busy roads and motorways.

The new innovation has its own high-speed bearing, enabling the wheel to turn independently from the car and works in conjunction with the standard and heavy-duty Multi-fit wheel for larger vehicles.

AE Oscroft, which has recruited two new engineers to cope with expected volumes, is manufacturing 1850 sets for the AA as part of its first order, with significant opportunities being explored to export the technology to customers in the EU, UAE and the US. “This was a true collaboration between our business and the AA,” explained Chris Oscroft, Managing Director of AE Oscroft.

“We took the concept created by AA Chief Engineer Steve Ives and developed it into a workable, costefficient solution that will make 30

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On the road again

roadside assistance faster and safer for so many people. This success shows what we can achieve when inventors, engineers, prototyping and production all work together.”

James Hosking, AA Roadside Chief Operating Officer - Roadside, added his support: “AE Oscroft were tasked with coming up with a cleaner, safer, smarter solution to towing certain categories of vehicle. This fantastic innovation will help to futureproof our service and, importantly, rescue customers more quickly than our competitors.”

This latest innovation builds on the manufacturer’s successful partnership with the AA, dating back to the development of the original Multi-fit wheel that was launched in 2016 and fits 90% of

cars which don’t come with a spare as standard.

The new freewheeling hub and heavy-duty Multi-fit wheel roll-out is in the final stages and will be completed shortly.

EVs, 4x4s, and vehicles with certain issues can now be towed by standard patrol vans instead of having to wait for specialist recovery trucks. In addition, the new heavy-duty Multi-fit wheel allows the broken-down vehicle to be towed at a faster speed of 50 mph. Less time at the roadside means it is safer for both drivers and recovery teams and it allows the AA to reduce its reliance on higher-emission flatbed vehicles.

It is also lightweight, helping optimise the fuel efficiency of patrol vans.

8 aeoscroft.co.uk MARCH 2021

Engineering Capacity | FORMING & FABRICATION QFS Technologies, a specialist supplier of body-in-white (BIW) parts to the automotive industry has invested in a new Trumpf TruLaser Cell 5030 five-axis (3D) laser cutter.

The company has an older TRUMPF five-axis machine but realised that the higher performance and advanced features of the new machine would give it a competitive advantage – particularly in new project work for a major customer.

Founded in 1997, Birminghambased QFS provides the automotive industry with quick-turnaround metal-panel prototyping and lowto-medium volume production parts. Such has been its success that QFS has today become the first choice in its field for most UK automotive OEMs and tier-one suppliers, as well as yellow goods manufacturers. Current turnover at the 60-employee company is circa £7 million.

QFS develops and manufactures prototypes from single panels to complete assemblies for BIW, concept and show vehicles. Customers often continue to use the company’s skills right through the initial prototype and manufacturing process, into mass production.

“As we supply panels in batch quantities of 25-150 through various prototype build phases, we already have some of the tooling in place, we’re increasingly being asked to support OEM customers with production volumes – often running into thousands of parts,” explains Managing Director Neil Holloway. “Maybe the pandemic MARCH 2021

Faster laser cut car panels situation where major production suppliers of panels being shut down during lockdown has contributed to production dies being delayed, but of course the OEM’s still need to meet their build schedules to sell vehicles. We’ve found ourselves in a position to provide the necessary support.”

When Mr Holloway recently put forward a business case for a new project with a major automotive customer, he realised that a new five-axis laser cutter would be required.

“Once the investment decision had been made, it was always going to be a Trumpf machine,” he states. “I’ve worked with other laser cutters in the past, but Trumpf machines are a lot more reliable. When you think about the curvature and complex shapes of a car panel, it’s easy to imagine the essential role of a 3D laser cutter at QFS. We cannot afford to run an unreliable machine.”

The TruLaser Cell 5030 is and entry-level machine for flexible 2D and 3D laser cutting.

With its low machine-hour rate, the TruLaser Cell 5030 is well suited to small and medium batch sizes, and for applications where components are frequently changed. The Trumpf TruTops Cell Basic software enables users to make quick adjustments to programs directly at the machine.

BIW parts produced on the new TruLaser Cell 5030 are mostly made from aluminium, although some are cut from high-strength steel, typically 1-3 mm thick.

The TruLaser Cell 5030 is located within the company’s dedicated laser shop, in a total space of 34,000 sq ft.

“More speed is an obvious advantage with the new machine, while quality has also been enhanced,” states Mr Holloway.

8 qfs.uk.com/ www.engineeringcapacity.com

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HEAT & SURFACE TREATMENTS | Engineering Capacity Erodex has supplied Krohne with a carbon fibre composite graphite fixture for the UK’s largest horizontal vacuum brazing furnace.

Krohne is a leading manufacturer and supplier of industrial process instrumentation, and its UK operation in Wellingborough is the company’s global centre of excellence for Coriolis mass flowmeter technology.

This involves working with specialist materials such as Duplex 31803 and Super Duplex 32750 stainless steels where the brazing process is highly critical.

As the largest of Krohne’s products to be brazed are up to two metres in length, it had a problem that there was no suitable furnace in the UK with a hot zone large enough to process them. This meant that the brazing had to be subcontracted to a French company, which brought challenges with lead times, transport, and associated cost issues.

Krohne Ltd’s decided to bring the brazing of its larger products inhouse, thus ensuring complete control over quality and lead times, and invested in the UK’s largest horizontal vacuum furnace.

The company therefore needed assistance with the design and manufacture of a fixture that would possess the specific hot zone capability, be of appropriate size and at the same time cope with weight, cost and distortion limitations whilst processing these larger products and turned to Erodex UK. Evolution of fixture design Discussions started around six to 32

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Fixture for biggest brazing furnace

nine months prior to when the furnace was due to arrive.

The original concept design provided by the Erodex UK team was based around using graphite plates and spacers.

Following close consultation with their Krohne counterparts this was reviewed and it was determined that a flat grid method would be more suitable, due to strength requirements of the fixture and to enable the required reduction in fixture weight.

The resulting design was a 2.4m x

1.2m Carbon Fibre Composite (CFC) fixture consisting of two layers and a cover plate to ensure that there was no direct radiation heat onto the components processed on the top layer and that heat is evenly distributed within the furnace.

Production Engineering Manager Darren Hawes comments: “The Erodex team were able to understand our specific requirements and design a fixture based on a CFC grid. We then had a further meeting and added in channels and a cover plate that sits MARCH 2021

Engineering Capacity | HEAT & SURFACE TREATMENTS on top of the CFC grid structure to maintain 0.1mm flatness.

“Perforated holes were added to allow the 360-degree gas cooling to flow underneath the fixture to the parts, because cooling is one of the critical features of the process. Side rails were added to the fixture to remove the possibility of any parts falling off and we added lifting points to the fixture, so once removed from the furnace, if the loader were to break down at any point, the fixture could be removed from the loader by overhead cranes”.

The right material Krohne Ltd Manufacturing Engineer Tom Harrison explains why, guided by the Erodex UK team, it opted for a Carbon Fibre Composite (CFC) graphite fixture: “We had to find the right material for the fixture when considering weight, cost and distortion limitations and we could not find another material that was comparable to CFC for achieving this.

“The CFC fixture is lightweight yet as the temperature increases within the furnace the material gets stronger. Our main requirement of the fixture and the plate itself was to have a 0.1mm flatness tolerance, so when we manufacture and process our parts, any distortion of the fixture does not impact on the assembly that is being processed.

“The straight tube assemblies being processed within the furnace also have a 1/600mm straightness tolerance. Up to two metres we can have 3mm distortion end to end in the bow of the tube. To get that right, we required the fixture base to be as true as possible, so that we MARCH 2021

are not adding any additional distortion into the processing of the parts. The CFC fixture was therefore designed and manufactured by Erodex to deliver on that 0.1mm flatness constraint.

“In addition, the more mass within the furnace, the greater the effect on heating and cooling rates. A metallic fixture can act as a heat sink, using CFC reduces the mass greatly so our process is optimised and the energy we do use is used efficiently”.

Duplex stainless steel and Super Duplex stainless steel are mainly used for corrosion resistance, meaning that any carbon or other contamination picked up from the fixture itself could affect the metallurgy of the material, which in turn can add further complications to the products being processed.

To avoid this, the CFC graphite fixture was coated in a Yttria Zirconia coating to prevent any carbon ingress into the material.

Darren Hawes says: “The knowledge of the application and properties of CFC within the

Erodex UK team was vital in helping us to understand what could be achieved both with the material and the fixture design itself. As we moved through the process, the design became more complex, so having their expertise at hand to help develop this was very beneficial to us.

They acted like a partner on this project, and it was clear from the outset that they were willing to listen, accommodating changes and providing new ideas”.

Tom Harrison adds: “The fixture itself has been used now since October, we have completed numerous cycles and it is holding up to design requirements of flatness, the coating is performing well and ultimately, the fixture is achieving what it was required to do.

“Ultimately, this has given us full control over processing. It has given us the capability to develop our processes and increase productivity and allows continuous development and improvement of the process too.

8 erodex.com www.engineeringcapacity.com

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HEAT & SURFACE TREATMENTS | Engineering Capacity Selective electroplating can play a key role in remanufacturing and building components back to original specifications says Tony Arana, Southwest Sales Manager for SIFCO ASC. Remanufacturing is on the rise.

Already commonly used in the automobile, heavy equipment and off-highway vehicles (OHV) sectors, this manufacturing trend is expected to continue growing across even more industries and applications. This includes marine, aerospace, general industry and more, as businesses seek to reduce capital costs and extend the life of equipment and machinery.

Growth of remanufacturing can be further attributed to the constant desire to drive down the total cost of ownership of expensive equipment. Examples include landing gear in aerospace, diesel engines in OHV, pumps, valves and turbines in many industries, and much more.

There’s a greater need now, more than ever, to minimize repairs and replacements, while enhancing agility throughout engineering processes – and remanufacturing fits this need perfectly.

In all industries, all equipment, from the smallest component to the biggest (and most expensive) machines are constantly subjected to unpredictable field conditions harsh operating environments, and sometimes even abuse, all of which combine to increase the risk of wear and tear, corrosion and damage.

If not properly maintained, many of these components – or entire 34

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Building back to original specs

pieces of machinery – may need to be scrapped, increasing capital equipment costs and downtime.

This is where remanufacturing comes into play, returning OEM parts back to original specification – or better – for a longer, more reliable lifespan.

Extending operational lifespan It’s clear that remanufacturing is an increasingly prominent way to extend the operational lifespan of equipment. However, it’s just as crucial to ensure that downtime is minimized when doing so, especially as the costs of such downtime can quickly rack up. In industries like marine and shipping, power generation and mining, any way to quickly, costeffectively and sustainably

enhance components, improve wear resistance and repair damage is key. Here, selective electroplating offers a vital benefit.

Selective plating (also known as brush plating) is a method of repairing and restoring critical dimensions and surface properties of worn components back to OEM standards, using an array of triedand-trusted solutions, such as copper, nickel, nickel-tungsten and cobalt. Even more crucially, it MARCH 2021

Engineering Capacity | HEAT & SURFACE TREATMENTS can be completed on site, to reduce the downtime and cost associated with disassembly, transport and reassembly.

This is due to the ability of selective electroplating to treat specific areas of a component, with accurate, selective brush plating of materials onto localized surfaces and diameters, enabling in-situ repair and enhancement that is typically faster than alternative surface coating methods.

As opposed to tank plating – the other major method in electroplating – brush plating does not require extensive masking or special fixtures. It can also plate deposits between 30 to 60 times faster, with no risk of part distortion thanks to the process taking place at room temperature.

All of which combines to make this particular remanufacturing process a faster, more costeffective and lower-risk option.

Given the continuous use and sometimes harsh direct impact experienced when equipment and machinery is in operation, selective plating needs to bond at the atomic level.

This is something not provided by traditional surface coating methods, such as thermal spray, which only forms a mechanical bond.

To create this atomic bond, selective plating uses electrochemical principles: an electrolyte solution, containing ions of the deposit material, is introduced between the negatively charged plating surface and the positively charged tool. This is powered by a portable power pack, MARCH 2021

enabling precision control over amperage, voltage and duration.

When the tool – or anode – touches the surface, a circuit is created, with a cover material around the tool providing a reservoir to ensure even distribution. The current within the circuit causes the ions between the interfaces to bond – building up the plating layer and delivering a highly adherent and dense metal deposit.

Selective plating also allows for more accurate control of deposit thicknesses – often allowing parts to be plated to size with no post-machining. With the portable nature of brush plating, repairs are able to be undertaken either in the shop or on the job site – meaning accuracy is matched by a fundamental flexibility in the process.

Plating in practice So, selective electroplating has been discussed in theory, but what happens actually out in the field?

One example is SIFCO ASC’s work with a well-known heavy equipment and OHV manufacturer.

Due to size, cost and lead time, replacement parts or components for heavy equipment are not

typically available on short notice.

However, many components with wear and/or surface defects can be repaired, rather than replaced.

A common scenario is damage to hydraulic rods and rams, ranging from light scratches to deep impacts and corrosion damage. This can be permanently repaired by selectively plating using the SIFCO Process®.

Defects are typically repaired with one or more layers of copper, then covered with a wear resistant deposit with good release or wetting characteristics.

These types of repairs are easily completed on rods and rams made up of carbon or stainless steel that have been plated with chrome or nickel. Copper is applied to the damaged area and then dressed back to just below the surface.

Finally, a thin layer of cobalt-nickel is applied to a slightly larger area and then polished to match the surface texture.

Using less solution and chemicals, and generating very little waste, as well as reductions in the carbon costs of emissions, transport and shipping, selective electroplating is a sustainable option. The reduction in fumes and hazardous waste requiring disposal delivers a safer, healthier working environment.

Overall, remanufacturing and selective plating present a distinct way to do things better: returning vehicles, machines, and equipment to operational effectiveness for a longer life of efficient and reliable service, with minimal downtime in the process.

8 sifcoasc.com/remanufacturing www.engineeringcapacity.com

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HEAT & SURFACE TREATMENTS | Engineering Capacity

Coating capacity ring-fenced Fastline Steel Services will have exclusive use of the Telford Plant A facility of Corbetts the Galvanisers following a multimillion pound agreement guaranteeing over 15,000 tonnes of perimeter steel fencing will be galvanized there every year.

The decision, which creates up to 40 new jobs and safeguards a further 80 more across the two firms, marks a switch from dual sourcing to a more strategic partnership that will deliver increased capacity and reduced lead times, not to mention world class, repeatable quality.

“This marks the next stage of a five-year relationship and a new way for galvanizers and manufacturers to work together,” explained Sophie Williams, Finance Director and General Manager at Corbetts the Galvanizers.

“The pandemic and subsequent lockdowns had cut our volumes in certain sectors and that meant we temporarily consolidated all business into our larger Plant B. Whilst this was not ideal, it did give us the opportunity to take a longerterm view of how we wanted to work with our customers to build more strategic partnerships.”

She continued: “One of those was with Fastline Steel Services, who has been growing rapidly and was in need of guaranteed additional capacity to cope with consistent increases of work in construction, prisons, rail, utilities and with the Ministry of Defence (MoD).

36

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“We held several detailed discussions and eventually agreed to bring back Plant A to serve as a dedicated galvanizing facility. A further 10 jobs are to be created in the initial three months, with the installation of palisade lines directly on site supporting the manufacture of railings and high security steel perimeter systems.

“Over £500,000 has been invested in creating the infrastructure so that the products can be manufactured and sent straight to be dipped in baths just a few metres away.”

Corbetts, which celebrated 160 years in business in 2020, currently galvanizes over 100 tonnes of products every week for Fastline, with the second line providing the opportunity for exponential increases.

Mike Fellows, Managing Director of Fastline Steel Services, went on to add: “This is a very exciting move for the business and

will help support growth plans that will initially take turnover from £15m to £30m over the next eighteen months.

“There is significant interest in our core fabricated products, including steel palisade, rigid mesh, chain link, weldmesh and fabricated railing systems, with a host of new automated solutions also coming online.

“This means we require a strategic partner we trust to deliver the galvanizing capacity and quality going forward and Corbetts really stepped up when we gave it the challenge.”

8 wcorbett.co.uk fastlinesteel.co.uk MARCH 2021

Engineering Capacity | PLASTIC MOULDING

Diversifying automated moulding KUKA UK Gold system partner, PC Moulding & Automation has witnessed a significant decline in automotive manufacturing, with certain next generation model launch plans being shelved in favour of EV alternatives. In the third quarter of 2019, enquiry levels were consistently high with some 75% of their order intake attributed to automotive. A further 20% of enquiries came from the medical sectors and 5% ‘other’.

Roger Ewers, Sales Director, PC Moulding “Automotive project enquiries were often based not only around the need to deliver labour savings, but address complexity of assembly for which automation was a natural fit”.

Insert loading is still a huge consideration within the automotive sector, primarily for two reasons. Health & safety considerations dictate that operators should not be climbing inside of large machinery, to reduce the risks associated with trips, falls and the likelihood of injury. Solutions such as that pictured above, illustrate how bespoke applications incorporate end of arm tooling. In this instance a double-sided end effector with demould, insert load and insert gripper capability, can undertake such tasks.

This particular automated, application manages the insert loading from a sliding table exterior of the cell perimeter, picked by the end of arm tooling MARCH 2021

which is equipped with a Schunk QC (quick changeover) system - the EOAT can be changed within the cell and without operator intervention.

Roger Ewers says: “When historically 70% of your inbound enquires satisfy a specific sector and that dynamic changes suddenly and unexpectedly, you have to diversify. We had to take the experience that we have and apply it in other areas.”

Medical and pharma projects are gradually being brought back

to the UK, as manufacturers re-shore post Brexit, with a focus upon productivity gains, increased throughput and improved efficiencies.

“When COVID hit the UK, the demand for breathing devices and respirators soared. As a result, the production and manufacturing of filters intended for use in these systems increased the demand for automation, as manufacturers recognised the benefits afforded by robotic process automation, says Mr Ewers. www.engineeringcapacity.com

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PLASTIC MOULDING | Engineering Capacity PC Moulding & Automation produced an automated filter production line which comprised three KUKA KR AGILUS HM (hygiene machine) 6 axis industrial robots and ultrasonic cutting tooling for the filter medium, applying similar principles to the execution of the application of those which had been undertaken for automotive clients.

“Automation enquiry levels continued to rise throughout 2020, a large majority of which we found were intended to address reduced staff levels whilst increasing output. Unfortunately, as automotive manufacturing was severely impacted by the pandemic, medical was our primary sector focus in 2020, and into 2021. Automotive is recovering slowly, but with certain next generation model launch plans being shelved in favour of EV alternatives, new model EV launches are being planned over the next five years and onwards, supporting that recovery”.

Adam Hudson, Sector Manager – Plastics and Injection Moulding, KUKA UK, echoes the opinions of Roger, in that the COVID-19 pandemic has encouraged manufacturers, who might not have considered automation as a natural fit to their operations to view robots as a value-add, supplementary technology.

“The benefits that can be afforded through the adoption of robotic process automation are endless, but more importantly measurable.

The range of industrial robots available to choose from, 38

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can be applied to almost any task in any environment”.

Adam continues “The plastics industry is a diverse and fast moving focus sector for KUKA and as such, we work closely with PC Mouldings to ensure that we provide the correct solution to our customers exacting requirements, with a number of considerations at the heart of their design, from productivity gains to cost savings, health and safety compliance to quality output.

All are valid requirements that can be addressed through the adoption of automation”.

“Some quick examples include; the KUKA KR DELTA that can be used effectively within a conveyor application: fast moving plastic components can be detected through vision and fast picked, stacked and sorted at high speed; the KUKA KR SCARA used for fast picking in cost sensitive plastic

applications, offering high levels of accuracy and reliability; the LBR iiwa can be utilised within complex mould removal applications. Using the sensitivity of the robot products are released from the moulds, thus reducing breakages and the likelihood of injury to the operator”.

Adam concludes “The plastics sectors is one of many that is witnessing an increase in the adoption of robots. Currently the UK lag behind our European peers, with only 71 robots per 10,000 workers, compared to Europe’s 73. The gap is closing and as reshoring accelerates we anticipate that UK manufacturing will finally acknowledge the benefits associated with robotic process automation, and stamp our mark as a leader on the global manufacturing map”.

8 pcmoulding.co.uk Kuka.com MARCH 2021

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

KM Engineering sales@kmengineering.co.uk www.kmengineering.co.uk

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

Falcon Engineering Productions Ltd sales@falconengineering.co.uk

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

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

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

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

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

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

MARCH 2021

btma.org

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DIRECTORY | BTMA MANUFACTURING MEMBERS

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

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

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

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

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

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

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

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

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

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

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MARCH 2021

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

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

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

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

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

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

C Dugard Limited sales@dugard.com www.dugard.com

MARCH 2021

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

Wickman Coventry Ltd o.coyne@wickman.co.uk www.wickman-group.com

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

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

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Qualiturn are a very modern subcontract machining service. We offer CNC precision Turned and Milled components to your specifications and quantities. We work with all sizes of customers, offering the same service to all. Supplying various market sectors across the world.

7 Fountain Drive, Hertford, Herts, UK, SG13 7UB Tel. +44 (0) 1992 584499 www.qualiturn.co.uk

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

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PRECISION ENGINEERING 8

MACHINING (5 AXIS) 8

Mini Gears is a subcontract manufacturer of machined components, gears and racks.

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

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

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.

PRECISION ENGINEERING 8

Qualiturn Products Limited

Mini Gears (Stockport) Ltd

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 REPETITION TURNED PARTS 8

MACHINE TOOL MANUALS 8

CNC PRECISION COMPONENTS 8

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

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

PRECISION ENGINEERING 8

JFL Broaches and Broaching

PRECISION ENGINEERING 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

MARCH 2021

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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