Engineering Capacity November 2024 Digital Edition

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

November 2024

FORMING & FABRICATION | AEROSPACE | SUSTAINABILITY

INDUSTRY NEWS: Fast parts, faster bikes

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FOR MANUFACTURERS ABOUT SUBCONTRACTORS

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FOR BUYERS OF CONTRACT MANUFACTURING SERVICES Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Commercial Director: Arfan Qureshi sales@engineeringcapacity.com Tel: 0208 013 5752 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: 01737 270 648 Published by: Engineering Capacity Ltd 27 High Street, Horley, Surrey, RH6 7BH United Kingdom Registered in England company no. 10567217 ISSN 0306-0179 COMING UP IN OUR JANUARY 2025 ISSUE Machined Components, Laser & Waterjet Cutting, Casting & Forging, Sustainability, Additive Manufacturing, Electronics, Southern Manufacturing & Electronics Preview

Editor’s View When I sat down to write my comment column in September I was worried about the hard times that some companies seemed to be having – particularly subcontractors.

I had heard from various people that cash flow was very tight and I was getting noticeably more magazines returned marked ‘addressee gone away’. I don’t give up lightly on these and tend to look into whether it is just the person that has moved on or whether it is the company. I found that when I looked them up on Google a depressingly significantly number were listed as ‘Permanently Closed’.

I signed off by saying ‘…we need to make sure that the Government offers real support and not just more costs’.

Well that went well didn’t it? SMEs have been clobbered from nowhere by a massive rise in employers’ National Insurance contributions. The Chancellor of the Exchequer, who has no experience in industry, let alone in manufacturing, and whose career in high finance has been called into question, said that companies would just have to make ‘efficiencies’.

Most engineering companies are already working on paper thin margins. Any efficiencies can only come from finding ways to work more with fewer people. So fewer jobs and less money for the Government from income tax and National Insurance – hardly the intended outcome.

Andy Sandford, Editor

Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website

Member of the Engineering Industries Association

NOVEMBER 2024

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Contents November 2024

12 FORMING & FABRICATION

News

Features

06 Fast parts for fast bikes 06 Protolabs helps

11 Forming & Fabrication 06 Digital spring for Protaform New £10m facility at MTL

Harley-Davidson fine tune race performance

15 Machined Components 06 Clean air benefits New life for old mills

07 Selling out of space 06 Next year’s Automechanika Birmingham is 85% booked

08 PCB reshoring win 06 Cope brings work back

16 MACHINED COMPONENTS

from China

25 Sustainability

time and money

06 Flow plate investment pays off Unlocking reshoring opportunities Lighter, greener Aston Martin

10 Cleaner aluminium investment 06 Molten metal filtration at Bridgnorth Aluminium

30 Turned Parts

21 AEROSPACE & DEFENCE www.engineeringcapacity.com

doubles up Multi-billion additive market

23 Metrology

09 Outsourced stock checks 06 RGIS vision system saves

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19 Aerospace & Defence 06 Aerospace machinist

31 BTMA Directory 06

NOVEMBER 2024

Engineering Capacity | INDUSTRY NEWS

Medical moulding investment Europlaz, a contract manufacturing specialist for the healthcare sector, has invested £750k in three additional allelectric moulding machines to cope with an increase in orders.

This is part of a £3.5m investment drive that also includes robotic technology, Piovan material dryers, a new CMM machine and toolroom/ cleanroom upgrades.

Boosted by an increase in capacity at its Southminster facility, the company is focused on both UK and international medical device manufacturers and engineering design houses looking for a strategic partner who can take a project from proof of concept through to routine and large-scale commercial manufacturing.

“There has been a massive surge in demand for our services, which support the development and commercialisation of devices for use in diagnostics, drug delivery, biotech and pharma,” explained Katy O’Keeffe, Marketing & Strategy Director.

“Europlaz is known for our agility and our ability to tackle complex projects, leveraging our design for manufacture experience, our technical knowledge and capabilities that stem from tooling and small batch work to long-term, high-volume production.”

She went on to add: “This, combined with our 40-year track record, has seen us build an NOVEMBER 2024

impressive long-term client list, including the NHS, GE Healthcare, Johnson & Johnson and Medtronic.

“We know there is a massive opportunity and have responded by continuing to invest in the first eight months of 2024. This takes our total spend to £3.5m over the last three years and we’ve got more technology on order and on its way. This is the perfect time to press the ‘growth’ button.”

Europlaz, which is ISO13485certified, operates from its stateof-the-art production facility on The Maltings Industrial Estate in Southminster, near Chelmsford.

From here, the family-run business offers injection moulding, assembly, product validation and access to modern cleanrooms, all certified to ISO Class 7 for the manufacture of Class I, Class II and Class III medical devices.

Most of its work is focusing on helping medical device and

healthcare businesses commercialise new technology, with recent success stories featuring a home dialysis machine, a patient friendly and easy-to-use breath operated inhaler and a bioartificial liver.

Thanks to the vast regulatory approvals it holds, the company also manufactures its own product ranges, including neonatal flow sensors.

Rory O’Keeffe, Commercial Director at Europlaz, went on to add: “Sales have increased by 20% to £12.5m for this financial year and we’ve got contracts in place to achieve over £14m by 2025.

“Investment has flowed into the latest equipment, and we have matched this with a major recruitment drive - taking on 25 new staff, with a good proportion of these in our industry-leading technical team. There are still positions available that we are looking to fill.”

8 europlaz.co.uk www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity Quick turn parts from digital manufacturer Protolabs are helping Harley-Davidson Factory Racing team win more podium places in the King of the Bagger series of motorcycle racing.

Touring motorcycles from Harley-Davidson and Indian form the basis of this motorcycle series that sees touring bikes adapted to race at speeds exceeding 180 mph.

Says Harley-Davidson factory team racing boss Jason Kehl, “For us to be successful we need to respond rapidly to what we are learning on the racetrack, and we need a partner that can bring these ideas to life in just a few days. As a digital manufacturer, Protolabs allows us to make those weekly incremental improvements that lead to season-long success.”

The production HarleyDavidson Road Glide weighs up to 960 lbs., while King of the Baggers bikes race at 620 lbs.

The team relies on Protolabs’ digital manufacturing processes to implement new part designs.

These changes increase speed

Fast parts for fast bikes

and performance critical lean angle while maintaining race weight.

Protolabs expertise has allowed Harley-Davidson Factory Racing’s engineering team to take lessons learned from a Sunday race and translate this knowledge into new part designs. During this week the team can prototype, test, learn, iterate, and order the final part using a race-ready lightweight material before the next race.

The result has been significant improvements in race times and many podium finishes.

In one example, a 3D printed

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8 Protolabs Harley-Davidson

exhaust allowed the team to take tighter turns on the track to gain extra time. This is particularly complex on a Harley-Davidson tourer due to its size. The design freedom of using 3D printing allowed the team to create an organic design that brings the components nearer to the bike while maintaining the foot position for the rider’s comfort.

This incremental change was crucial because every ¼ degree extra lean angle saves 1/10 of a second in a corner, with some racetracks having as many as 14 turns a lap.

Through the season Protolabs has produced injection moulded, machined and sheet metal as well as 3D printed parts. They have also used the company’s global network of manufacturing partners for larger, complex parts.

The result has been significant improvements in race times and more podium finishes for the riders.

8 protolabs.com/en-gb/ NOVEMBER 2024

Engineering Capacity | INDUSTRY NEWS With 85% of stands already sold, Automechanika Birmingham 2025 is rapidly approaching full capacity, with the organisers urging potential exhibitors to act fast to secure their spot.

Taking place from 3 to 5 June 2025 at the NEC, Birmingham, the event offers an unparalleled opportunity for companies in the automotive industry to showcase their brand, products and services, and network with more than 15,000 professionals, including garages, motor factors, retailers, bodyshops, the supply chain, dealerships and detailers, at the UK’s largest automotive aftermarket trade exhibition.

The event hosts The Automotive Supply Chain Forum, which attracts engineers, purchasing teams and R&D professionals from OEMs, and Tier 1 Manufacturers to find solutions for the production of vehicles. Engineering Capacity is an official media partner.

A number of leading automotive companies are signed up to exhibit, including Alliance Automotive, Avayler by Halfords, Bosch Automotive Aftermarket UK, Brembo, Castrol, Comma, DEWALT Automotive, Draper Tools, GSF Car Parts, Hella, ISN Europe, Jack Sealey, JHM Butt & Co, LKQ Euro Car Parts, Liqui Moly, MANN-FILTER, Niterra, Ring Automotive, Snap On, Texa UK and Wix Filters, with only a limited number of stands remaining.

Joanne Knowles, Event Director, Automechanika NOVEMBER 2024

Selling out of space

Birmingham commented: “Following the outstanding success of Automechanika Birmingham 2023, which welcomed over 14,000 visitors, we have been truly overwhelmed by the demand for exhibitor stands for the upcoming event, which has intensified even further since Automechanika Frankfurt in September. Automechanika Birmingham has become a central hub where key professionals unite to drive the industry forward, and we are excited to see how this momentum will make the 2025 show our most successful to date.

“It is recognised as a permanent fixture in the calendar year, offering a strategic platform, built on networking, learning and hands-on engagement, enabling exhibitors to better connect with the market.”

Exhibitors will have the unique opportunity to engage with over 5,000 garages, who will be

provided with not only complimentary parking and breakfast to kick-start the day, but a comprehensive three-day experience.

Neil Grant, managing director of HELLA, said: “Automechanika Birmingham is a key event for HELLA, providing us with the opportunity to connect with the broader automotive community, share our latest mobility solutions and collaborate on the pressing skills challenges that the industry faces today.

“As a progressive innovator, we’re committed to driving automotive advancements, and we believe this show is key to accelerating that mission. We’re excited to join an event that embraces such valuable, face-toface engagement with partners and customers, and we’re looking forward to showcasing our latest technologies that are shaping the future of mobility.”

8 bit.ly/AutoBham25 www.engineeringcapacity.com

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INDUSTRY NEWS | Engineering Capacity PCB assembly manufacturer Cope Technology has won back a contract that had left the UK for China thanks to its quality and speed of response.

It’s a significant victory for the 40-year-old firm, which supplies low and medium volume electrical assemblies for use in CCTV monitoring, traffic management, emergency vehicles, vending machines and automotive accessories.

The Black Country-based manufacturer was recently sold by the company founders to an Employee Ownership Trust (EOT), giving staff the opportunity to gain a share and voice in its future direction.

This was supported by the Business Growth West Midlands in Dudley Programme (BGWM), which has provided the new management team with strategic planning advice and support in employee engagement.

“We have a very strong history and track record in providing world class contract electronic manufacturing, with all of our attention, capital investment and supply chain management dedicated to building assemblies for our customers,” explained Production Director Adam Holmes, who has been with the company for more than two decades.

“These core values will continue under the Employee Ownership Trust, but there is also a focus on how we modernise the business and continue to digitise our operations so we can become even more efficient and 8

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PCB reshoring win

potentially take our PCB knowledge into new markets.”

He continued: “When you are taking steps into the unknown for some of us, that’s when you need a good sounding board and Business Growth West Midlands has been a fantastic resource for us.

“Our Business Growth Adviser has been with us on the entire journey, providing strategic advice around planning, structure, forecasting and, importantly, building a strong employee engagement strategy. The transition has certainly been smoother with their involvement!”

Cope Technology tapped into the GROWTHmapper® tool, a free business diagnostic which SMEs benefit from when participating in the Business Growth West Midlands in Dudley programme.

This helped the new management team identify strengths and weaknesses within its operations and prompted honest discussions among the team. The insights gained

8 (l-r) Donna Watkins (BGWM in Dudley) with John Cope and Adam Holmes (both Cope Technology)

have been instrumental in taking the business forward, securing the recent reshoring win and accessing additional support and grants.

Donna Watkins, Business Growth Adviser for the BGWM in Dudley Programme, said: “It has been a pleasure to work with the senior management team at Cope Technology, who has built upon the honest communication they were having, taking our recommendations onboard and moving the business to the next level.

“What is really pleasing is the determination to get even better at what it does, and we’ll be helping them to achieve this through one-on-one support and identifying potential grants for new equipment and technology.”

8 cope-technology.co.uk businessgrowthwestmidlands.org NOVEMBER 2024

Engineering Capacity | INDUSTRY NEWS Manufacturing and industrial facilities can now benefit from outsourced stock checks using new technology created by RGIS. RGIS is a global specialist in inventory management, providing outsourced stocktaking services which save its clients time and money.

Established in the retail industry for over 65 years, the company now also serves a growing base of industrial and manufacturing clients using its innovative RGIS Vision technology.

RGIS Vision is an advanced industrial solution that goes beyond barcode scanning to speed up stocktaking and inventory checks by eliminating paperwork and manual data entry. The versatile technology can scan part numbers, product codes and barcodes, boosting the operational efficiency of RGIS’s auditors during industrial inventories. An RGIS team equipped with this hardware can deliver quicker and more accurate results than an in-house stock take, offering companies significant productivity savings, and often financial ones too.

Kiran Soni, Managing Director – UK and Ireland of RGIS said: “RGIS Vision enables all manufacturing and industrial facilities to realise the benefits of outsourcing their inventory checks – even those who don’t have a barcode system in their warehouses.

“Some businesses still don’t understand the high internal expenditure required for an inhouse stock take. And others NOVEMBER 2024

Outsourced stock checks

don’t think they can outsource unless they already have a barcode system in place. RGIS Vision fully addresses these issues, making outsourcing viable for many more companies.”

RGIS Vision uses pioneering camera handset technology to capture part numbers, QR codes and product codes as well as barcodes. It can even read smudged, faded or blurred part

numbers. The cloud-based system creates a data file that can be imported into any system or spreadsheet, saving hours of manual data entry.

Outsourcing an inventory check to RGIS allows manufacturing facilities to maintain smooth operations without the disruptions caused by shifting staff.

8 rgis.co.uk

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INDUSTRY NEWS | Engineering Capacity

Cleaner aluminium investment Bridgnorth Aluminium has invested £1.6m in molten metal filtration equipment which is deployed prior to the casting process to produce cleaner castings for high-end applications.

This will help the company to increase its share of new and growing markets. It’s decision to target new markets in EV technology and packaging is already proving successful.

The company, which employs more than 330 people, has seen sales increase by 33% in 2024 and is currently recruiting for another 10 roles.

The growth is good news for Bridgnorth Aluminium which was negatively impacted in 2023 by rising UK energy prices and the decision of a major customer to move production from Europe to China.

Gerhard Trilling, General Manager of Bridgnorth Aluminium, said: “We expected our Bridgnorth workforce to total around 305 at this point in the year but we’re already at 330, with more jobs being created now for additional production operatives plus support roles in engineering and other disciplines.

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8 Bridgnorth Aluminium has announced a £2m investment at its Shropshire site

“The £2m investment in casthouse technology will support our growing order book in the EV market and packaging and we are positioning ourselves to support the growing demand for aluminium products in battery technology and in electrification.”

Bridgnorth Aluminium primarily manufactures aluminium coils for use in lithographic printing plates, pharma and household foils for packaging, and battery foil stocks for electrification.

Adam Hunter, Deputy General Manager, added: “The leadingedge technology will give Bridgnorth Aluminium cleaner metal in the casting process.

This is really important for the battery foil market as well as high-end packaging.”

8 bridgnorthaluminium.co.uk/ NOVEMBER 2024

Engineering Capacity | FORMING & FABRICATION Aston University is working with Redditch-based manufacturing firm, Protaform Springs and Pressings Ltd, on a digital transformation of its production processes in a pioneering project that could provide a blueprint for similar companies across the UK. Through a Knowledge Transfer Partnership (KTP), researchers from Aston University will enable Protaform to reap the benefits of both Industry 4.0 advances – which include innovations powered by automation, big data analytics and smart systems – and Industry 5.0 approaches, a rapidly advancing area of operations management research which place the wellbeing of the workforce at the centre of the production process.

The team will use the latest smart sensors and microcontrollers to enable automated data collection from Protaform’s manufacturing processes. They will create real-time, data-driven dashboards, enabling factory data to be accessible from any location worldwide. They will also use a whole systems approach to review and analyse the human-machine interactions within the company, identifying key success factors and areas for further optimisation.

The project will enable Protaform to implement more effective production planning and control its end-to-end manufacturing, creating a transformation in their business and management processes to drive efficiency improvements and deliver sustainable growth.

NOVEMBER 2024

Digital spring for Protaform

Enhanced efficiency will prepare Protaform for rapid growth, ensuring it continues to reduce waste and energy usage and shrink its carbon footprint.

Paul Taylor, group finance director at Protaform, said: “The team at Aston University has been great to work with and very proactive.

“They’ve taken the time to understand our needs properly, rather than making assumptions about what we do and where we want to go. That’s been very reassuring and makes a strong foundation for a productive partnership.”

Professor Ben Clegg, previously head of operations and information management at Aston Business School, is leading the project. He said: “Implementing a new piece of technology or digitising a machine is doomed to fail, unless you rethink strategy, processes and address people’s attitudes towards change.

“A factory is a complex system, and it’s the interaction between different parts of the system – the people, the machines, the data, the regulatory frameworks – that provide opportunities for success.

“This is why, for a project of this kind, you have to take a whole systems approach.”

An award-winning innovator, Professor Clegg has worked extensively with organisations to increase their productivity through smarter use of people, processes and technology. He has developed a novel methodology, Process Oriented Holonic (PrOH) Modelling, which has been successfully adopted by companies through previous KTPs. PrOH Modelling is used to define systemic problems within organisations and support knowledge-based decisionmaking and implementation to tackle those problems.

8 prohmodeller.org protaform.com www.engineeringcapacity.com

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FORMING & FABRICATION | Engineering Capacity Rotherham-based MTL Advanced has expanded with a £10m investment in its new Advanced Manufacturing Centre.

The new 67,000 sq. ft. factory represents a substantial £10 million investment towards the future growth of the business, driven by the award of a long term ongoing multi-millionpound contract in partnership with a key customer. Production at the new facility is set to begin during December.

As part of this strategic investment, MTL has significantly enhanced its manufacturing capabilities with the acquisition of several pieces of innovative equipment.

These include a large format LVD press brake, which will enable the precise bending and forming of large metal components, increasing MTL’s capacity to handle complex and heavy-duty fabrication tasks. The company has also invested in two Doosan auto pallet horizontal machining centres, designed for high-speed, high-precision milling and drilling of complex parts. These machines are equipped with automatic pallet changers to minimise downtime, boosting productivity and operational efficiency.

Additionally, MTL has installed seven Yaskawa robot welding centres, which feature fully automated welding technology, ensuring outstanding repeatability, speed, and precision in welding operations. This advanced setup will allow MTL to maintain high production volumes while adhering 12

www.engineeringcapacity.com

New £10m facility at MTL to the highest quality standards. As part of this investment, MTL also installed a state-of-the-art fully automated welding line for high volume and complex high strength steel structures.

This expansion is not only a significant step towards enhancing MTL’s production capabilities but it also has a positive impact on the local community through job creation, fostering economic growth in the region. The company is actively recruiting, with 100 new staff expected to join the business over the next 12 months. This will take MTL’s headcount past the 400 staff mark in 2025, including over 10% of apprentices.

Karl Stewart, General Manager of MTL Advanced, said: "This £10 million investment is a major milestone for MTL Advanced, reinforcing our commitment to long-term growth and stability.

Our new Advanced Manufacturing Centre and stateof-the-art equipment will not only expand our production capabilities but also strengthen our ability to meet the growing

demands of our customers.

“This new business has been won on the back of excellent quality, outstanding on-time delivery performance and a collaborative approach to customer service. We are delighted that our valued customers continue to trust our ability to deliver.

“Securing contracts such as this, alongside our recent other successes within Defence, Rail, and Construction is an endorsement by our customers of MTL’s ability to add value to their supply chains.

“It’s taken years of hard work from all our team to build that trust with our customers and our main focus remains on building a strong and sustainable order book, ensuring long-term stability for MTL and the skilled workforce that supports us.”

Coinciding with the launch of the new factory, MTL has also unveiled a complete rebrand that it says reflects its forwardthinking approach and renewed focus on innovation, quality, and manufacturing excellence.

8 mtladv.com NOVEMBER 2024

Engineering Capacity | FORMING & FABRICATION

Thistle sculpture for Linlithgow A family-run fabrication and welding company has combined artistic excellence and natural beauty to create a stunning centrepiece for a West Lothian high street.

Granfab Ltd was commissioned to design and engineer a bespoke planter and sculpture to enhance the beauty of the local town. To ensure it’s able to be enjoyed for generations, it also enlisted the support of local galvanizers to protect it against rust and corrosion for up to 70 years.

Kevin Hope, Director at Granfab Ltd, said: “As part of their commitment to horticultural, environmental and community activities, a few months ago we were approached by Burgh Beautiful Linlithgow, asking if we could create a bespoke piece to take pride of place in the centre of the town, close to the Palace. It sounded like a great project, and one we were thrilled to be involved in.

“In total, the thistle planter and sculpture took around 80 hours to fabricate, and was made from steel tube, plate and spheres. The structure proudly stands three metres tall, and boasts three individual stems and flowers.”

As Scotland’s national flower, the thistle has strong roots within the town. Not only does it represent resilience, protection and longevity, but it was also the original name for the town’s Amateur Football Club.

“Like what it stands for, we NOVEMBER 2024

wanted to ensure that this piece would be protected against the elements, and able to be enjoyed for decades,” Kevin continued.

“So, we called upon our long-time partners, Scottish Galvanizers Ltd due to their high quality workmanship, knowledge, and professionalism.”

The thistle sculpture was

transported to Scottish Galvanizers Ltd where it was entirely immersed in a bath of molten zinc at temperatures around 450C, to allow for a metallurgically-bonded coating to be formed. It was then installed, using a crane, into its high street location in June.

Paul Tait, Commercial Manager at Scottish Galvanizers Ltd, added: “It was great to work with Kevin and the Granfab Ltd team again, and to support them with this project that’s set to become a piece of local history in Linlithgow.

“We’re regularly in awe of Kevin’s fantastic creations when he brings them to us to be galvanized. Because of this incredible talent, his unwavering loyalty, and the beautiful sentimental meaning behind this particular piece, we’re delighted to announce that it will feature in our prestigious Wedge Group Galvanizing Ltd calendar 2025.”

Scottish Galvanizers Ltd is part of Wedge Group Galvanizing Ltd, the largest hot-dip galvanizing organisation in the UK with a history dating back over 150 years.

8 granfab.co.uk wedge-galv.co.uk

As part of their commitment to horticultural, environmental and community activities, a few months ago we were approached by Burgh Beautiful Linlithgow, asking if we could create a bespoke piece to take pride of place in the centre of the town, close to the Palace. It sounded like a great project, and one we were thrilled to be involved in

‘‘

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FORMING & FABRICATION | Engineering Capacity The Bulgarian fabrication facility of William Hughes is celebrating its 20th anniversary.

First opened in 2004, the original 1,000m2 site has grown from one machine and thirteen employees to now include five machining bays, an office suite and 175 employees – seeing an almost sevenfold increase in useable real estate.

The success of the Bulgarian operation is built on the easy access it has provided to European customers for springs, wire forms and wire assemblies, largely within the automotive industry. Changing manufacturing patterns across Europe have seen a growing demand from the developing local markets in Romania, Serbia and Turkey as well as traditional markets in the UK, Poland, France and Germany.

Bulgaria also supplies a large number of parts to William Hughes’ Dorset factory where

Bulgarian anniversary

they can be warehoused and distributed to customers in the UK, who get the benefit of a cheaper cost base without having to deal with the transport or the logistics normally involved in buying from low-cost countries.

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“The success of our Bulgarian operations has reinforced the forward-looking decision we made two decades ago,” explained Emma Burgon, Engineering Director at William Hughes. “We saw where industry was headed and made the bold move to follow it and set up shop locally.

“To cater for the huge uptake in demand for our class-leading springs and wire forms, there has been broad expansion in both technology and capabilities, with the site now boasting 35 CNC wire-bending machines, seven vertical and two horizontal injection-moulding machines and two nylon plastic-coating lines, along with MAG, MIG and spot welding. There are also seven robotic welding cells, complemented by an Electrophoretic black paint line and Deltatone Finishing.”

8 wmhughes.co.uk NOVEMBER 2024

Engineering Capacity | MACHINED COMPONENTS Automotive subcontractor Tooling 2000 has invested in improving air quality in its workplace, improving the working environment and productivity.

The company has installed onmachine mist extraction systems from Filtermist that are protecting the workforce and allowing faster turnaround times between jobs.

Founded in 1996, Tooling 2000 offers everything from product prototyping and development to 5-axis laser cutting, CNC machining, precision tooling and presswork for customers such as Rolls-Royce, JLR, Aston Martin, Magna and Bentley. It runs a range of Hurco CNC machines, from the compact Hurco TM12i turning centre, and 3 and 5-axis VMX machines, to the large bed Hurco DCX42i, that are fitted with the Filtermist systems.

Senior Business Development Manager at Tooling 2000, Mr Iain Bubb said: “To eliminate airborne particulate in our facility we installed Filtermist systems. This enables us to take any atomised coolant out of the atmosphere inside the work enclosure immediately. This then enables us to do two things. Firstly, it protects our workforce which is of paramount importance. Secondly, it allows us to open the doors to our machine tools sooner which provides us with more machining uptime on our machines.”

With more machine shops employing high-speed machining and high-pressure coolant systems that deliver fluid to the NOVEMBER 2024

Clean air benefits

cutting edge, airborne coolant mist is a significant and growing issue for manufacturers. As Iain continued: “Before having the Filtermist systems, we would have to leave the machine tool doors closed for an extended period, giving any atomised cutting fluid time to settle within the machine. The Filtermist system completely clears the enclosure of mist - this enables us to gain seconds on the production process and this helps our bottom line.”

If the doors of the machine tools are opened immediately after a cutting cycle with no mist extraction in place, the oil mist enters the air, creating an oily film on everything from the machines and the workstation to tools, the floor and anything else in the vicinity – causing a health and safety concern.

Discussing this, Iain added: “With the Filtermist system, we are removing all airborne particulates from the machine tool atmosphere. This keeps the inside of the machine clean. It also helps to remove the swarf as it does not stick to the tacky coolant that may be left on the machine bed, so it helps to keep the machines cleaner, and it helps with maintenance.

“We take our employees' welfare very seriously, so taking any ‘nasties’ out of the environment is very important to us. Productivity is also very important to us as a business and that cascades down to the bottom line. With the Filtermist technology we get more uptime from our machines and that gives us better productivity and profitability.”

8 tooling2000.co.uk www.engineeringcapacity.com

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MACHINED COMPONENTS | Engineering Capacity Three large, travelling-column bed mills at the Swansea factory of subcontractor Afon Engineering have been retrofitted with a Heidenhain TNC 320 control and new drives to improve their reliability and performance.

It has been an object lesson in how mechanically sound machine tools built in the late 1980s can be given a new lease of life for a fraction of the cost of investing in new equipment.

CNC milling forms the mainstay of the company's business and upgrading three of the Elgamills on site was a prime objective. Engineering Director Andrew Beaujean commented, "The project has given us more confidence to take on a much broader variety of contracts and is bringing in new business as a result, such as evaporator tube plate machining.

The refurbished machines have beds measuring 12, 10 and 8 metres respectively in the X-axis and the mid-size model, when it was installed in 2009 with an earlier Heidenhain TNC 355 control, was the first CNC machine on site. The other two Elgamills, which arrived five and 11 years later, were fitted with a TNC 155 CNC system. Two smaller, as-yet unmodernised machines from the same manufacturer are also on the shop floor.

The ageing electronics and wiring on a pair of even older manual Elgamills, previously in operation in Swansea, had become unreliable. Replacement 16

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New life for old mills

parts were no longer supported, and it was necessary to go to internet marketplaces to try to source spares. Refurbished parts were becoming very difficult to obtain. Consequently breakdowns were frequent, lasting from a few days up to one month, making job planning problematic.

Afon Engineering had been firefighting in this way for many years before it started to invest in CNC machines. Even with the more modern 12-, 10- and 8metre models on the shop floor, reliability issues meant that the three machines were rarely all operating together and sometimes only one of them would be running. With a lot of mainly one-off emergency work carried out on the Swansea site for the steel and energy supply power sectors, and some parts requiring to be on the machines for up to three weeks, it caused a

lot of difficulties for Mr Beaujean and his management team.

Steve Wright from the technical sales department at Heidenhain (GB), Burgess Hill, and Simon Hopkins, Engineering Director of approved CNC retrofitting company SDH Controls and Services, Worcester, met with Mr Beaujean in 2020 to discuss the problems.

Due to the age of the CNC Elgamills, well in excess of three decades, they all had the original analogue drives. A decision was taken to retain analogue technology and perhaps even keep the original motors.

However they were no longer supported, so new, more NOVEMBER 2024

Engineering Capacity | MACHINED COMPONENTS economical analogue drives and motors were fitted, together with the TNC 320 control. Assurance was given by the Heidenhain factory in Germany that the latter would be fully supported for at least the next 15 years, while the drive manufacturer gave a similar undertaking.

Reliability is of the essence in the Swansea factory, rather than speed. Dimensional accuracy is also important, as some milled features are tied up to ± 0.1 mm.

Machining versatility is needed as well, so the 12- and 8-metre machines have 5-position spindle

heads driven by M-codes from the control, while the 10-metre machine has a one-degree rear head controlled by an analogue signal from the TNC 320 and a 2-position front head controlled

by M-codes.

Another advantage of having new controls is that off-line programming is now feasible, whereas on the older controls this was cumbersome and time consuming. Being able to prepare cutter paths away from the machines maximises spindle uptime. Reliable connectivity also allows input of data from reverse

engineering of complex components that could not realistically be programmed in any other way.

Take for example a recent job, a sugar industry evaporator tube plate measuring four metres in diameter and containing 4,500 holes. Scan data, in this case provided by the customer, was loaded into Afon Engineering's OneCNC CAD/CAM system. A program was then created, post processed and run on one of the Elgamills, the whole project lasting about one month.

8 afonengineering.com

United Bright Bar Phone +44(0)1902 791010 Email sales@unitedbrightbar.co.uk Web www.unitedbrightbar.co.uk BS EN ISO 9001 and ISO 14001 Cold drawn bright bar made in the UK using the latest technology that is ideally suited to CNC machining.

Metric and Imperial Bar • Round bar from 6mm – 76.2mm • Hexagon bar from 8mm – 70mm Fast turnaround from stock or made to order.

Bespoke lengths, end chamfering, crack detection and tolerances to meet your requirements.

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NOVEMBER 2024

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MACHINED COMPONENTS | Engineering Capacity

Challenging EDM applications A third Sodick machine at Anotronic is tackling extremely challenging wire EDM work.

The Leighton Buzzard company offers subcontract machining services and also manufactures its own range of EDM fast-hole drilling and EDM die-sinking machine tools.

Martin White, Managing Director of Anotronic Ltd, said: “My father started the business in 1982, and I joined the company in 1985. We tend to machine a lot of difficult materials such as inconel, titanium, and special stainless steel, and everything is difficult to machine. We take on the worst jobs because we can - and we have all the machines and processes inhouse to do what we need.”

The Bedfordshire manufacturer currently operates three Sodick machines, with the latest ALC600G Premium wire EDM with linear motor drive technology, supplied by Sodi-Tech UK, arriving recently.

The new machine has X, Y and Z-axis of 600 by 400 by 500mm and the U X V-axis travel of 120 X 120mm, which gives the company an edge on capacity.

“We always buy premium machines, and as the company has become more experienced, we always look to buy better machines. This always comes down to reliability and the ability to run unmanned. We have a Sodick AQ35L die sink machine that we’ve had for a very long time, and Sodi-Tech UK has 18

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looked after this machine for us for over 20 years.”

The reliability and performance of the Sodick AQ35L meant that when Anotronic was in the market for another EDM machine, it once again turned to the Sodick brand.

Martin said: “We bought a Sodick AG 600LH around seven years ago. That machine enables us to do tool work up to 500mm high, which we regularly do. We have a large bobbin on this machine, enabling us to run 70 to 80 hours unmanned.”

“We bought this latest machine because we had a project with a sister part. The project typically consists of 40 parts that would maybe take us three months to complete. We suddenly had an order placed on us last year for 300 parts. We couldn’t have done this without another machine, as

we knew we would have had to have been machining 24 hours a day to get the parts done.”

Sodi-Tech UK Sales Manager Richard Bailey added: “Martin and Anotronic don’t just take on run-of-the-mill CNC jobs. This company tackles the higher end of the industry and often the parts that companies don’t want to tackle themselves. Anotronic looks at jobs from an application perspective rather than a ‘machining time’ point of view.

With the Sodick technology and the special characteristics within the machine, Anotronic can utilise this to run all of its applications and do jobs that are unique and out of the norm. In this instance, the application that Martin has been working on requires some very steep table angles.”

8 anotronic.co.uk NOVEMBER 2024

Engineering Capacity | AEROSPACE & DEFENCE ANT Industries, which manufactures aero engine and gas turbine components, has successfully achieved the National Aerospace and Defence Contractors Accreditation Program (NADCAP) accreditation for its non-destructive testing (NDT) processes.

Unique in the achievement is that ANT Industries has been awarded a 24-month merit status, a testament to the company's high standards and performance in the aerospace and defence sector.

Shaun Rowley, Managing Director of ANT Industries, proudly announced the accreditation: “Receiving NADCAP accreditation with a 24-month merit status is a tremendous achievement for our team. It highlights our unwavering commitment to quality, precision, and compliance with the most rigorous industry standards. This accomplishment reflects our dedication to delivering worldclass components to the aerospace and defence sectors.”

The NADCAP program is globally recognised as the benchmark for quality in the aerospace and defence industries.

A 24-month merit status is reserved for companies that demonstrate exceptional performance during their audits, with only minor findings and no non-sustaining corrective actions identified in both their current and previous audits. This extended merit status means ANT Industries will now undergo re-accreditation audits every 24 NOVEMBER 2024

ANT achieves NADCAP

months, rather than the standard 12- or 18-month intervals.

Achieving this level of recognition under NADCAP is a significant validation of ANT Industries’ capability and commitment to maintaining industry-leading standards in its critical process manufacturing.

The company's Atherstone headquarters serves as a hub for its cutting-edge work in aero and gas turbine engine components, delivering high-quality products to some of the world’s most demanding industries.

8 Shaun Rowley, ANT Industries MD

Rowley added, “This accreditation is a reflection of the expertise and dedication of our team, and the trust our customers place in us to deliver consistently high-quality results - it means our customers can trust our control of this crucial process is at the highest level, such is the expectation of world class customers which include Rolls-Royce, ITP Aero and Siemens.”

8 antindustries.com

Visit our website or contact us for a quote or advice

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AEROSPACE & DEFENCE | Engineering Capacity

Aerospace machinist doubles up ASG TGM (Techni-Grind Machining) has doubling the footprint of its Preston facility acquiring an additional 11,000 square feet adjacent to its existing works.

This expansion supports the winning of a high-value Tier 1 aerospace contract, involving the machining of large aerospace components up to 2.5m in length.

Currently, ASG TGM is managing eight different part numbers as part of this project, with the value of the orders exceeding £1 million annually. The work is being executed in close collaboration with ASG Phoenix in Nottingham, reinforcing the group’s reputation for seamless coordination and supply chain excellence across its multiple manufacturing locations.

The additional space is already being filled with new CNC machinery. This includes a £500k Mazak SDR machine, an advanced 5-axis machine and can handle components up to 3.8m, providing the precision, efficiency, and versatility required to support the

highly specialised needs of the aerospace market.

“This expansion is about futureproofing our business,” said ASG TGM Managing Director, Sarah Stephens. “The additional capacity has allowed us to respond swiftly to new opportunities, including a significant contract with a major Tier 1 aerospace prime. This has given us the confidence to further invest in our capabilities, ensuring we remain a critical supplier to the aerospace sector.

“This investment allows us to better balance our capacity and

Aerospace Oil & Gas Nuclear Defence

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

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Automotive Electronics Hi Fi

Industrial & High Volume Machining

8 ASG MD Sarah Stephens with the new Mazak machine investment

meet the demanding requirements of the aerospace sector. It’s a strategic step to ensure we are prepared not just for today’s contracts, but for future growth as well.

“We’ve already brought on three new team members – a quality inspector, a CNC programmer, and an additional CNC operator – to support this growth,” said Stephens.

“With plans for a further seven Mazak machines, we’re positioned to continue scaling our operations to meet demand for existing singleaisle structural rib work for wings.”

She added: “Developing the next generation of talent is a priority for us, but it remains an uphill battle.

There’s a need for greater support from the government and a shift in attitudes towards careers in manufacturing. Young people need to see the exciting, high-tech opportunities that exist in this field.”

8 asg-group.co/tgm NOVEMBER 2024

Engineering Capacity | AEROSPACE & DEFENCE The market for additive manufacturing (AM) hardware, materials and parts in the aerospace sector is forecast to be worth $20.5bn by 2033.

The research carried out by VoxelMatters reveals that AM products in aerospace (including hardware, materials, and parts) generated a total value of $1.58bn in 2023, representing a year-on-year growth of 23%. This market is expected to expand over the next ten years, with a compound annual growth rate (CAGR) of 29%.

This new market study offers an in-depth analysis and forecast of metal, polymer, and technical ceramic AM in aerospace parts manufacturing, focusing on the hardware, materials, and services segments of the additive manufacturing market.

Additionally, the report presents VoxelMatters' first-ever analysis of data on AM part production by vertical end-user companies in aerospace manufacturing, including OEMs, tier-1/tier-2

Multi-billion additive market

suppliers, organisations, and other contract manufacturers.

In 2023, civil aviation was the largest contributor to the market, accounting for 22.9% of the share, while military aviation contributed 20.3%. Overall, the aerospace AM market was largely driven by adopters, which made up 45.5% of total revenue at $718m. Hardware and services accounted for 23.5% ($370m) and 22.5% ($355m), respectively.

Materials, the smallest subsegment, contributed 8.5% with revenues of $134m.

Metal AM products dominated the aerospace market, constituting 62% of revenues, followed by polymer AM products at 36.9%. Within the metal AM segment, adopters generated 50.3% of revenues, amounting to an estimated total of $492m (31.2% of the market). Parts for aviation (both civil and defence) generated the highest revenues, with hardware contributing $196m (12.4%) and services adding $214m (13.5%). Materials accounted for 7.8% of metal revenue, increasing by 35.9%.

Polymer AM had a significant impact in civil UAVs, contributing 56.5% of total sub-vertical AMrelated revenue, while civil aviation generated $150m, accounting for 41.5% of polymer revenues. Although technical 8 Ten-year total revenues ($m) by sub-segment and material

NOVEMBER 2024

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AEROSPACE & DEFENCE | Engineering Capacity ceramic AM remains niche, it has seen substantial growth due to applications in civil space.

Metal hardware constituted the largest portion of the hardware subsegment, contributing 53.1% of total hardware revenue, which grew by 29%. Metal AM services led the services subsegment, comprising 60.2% of total revenue and growing by 20.7% to $214 million (13.5% of the market).

Civil and military aviation are leading the growth of polymer and metal AM, particularly in civil aviation. Civil unmanned aerial

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vehicles (UAVs) have shown the strongest growth in both categories, indicating increased adoption of unmanned aircraft.

Metal AM products overall are expected to dominate the aerospace AM market, comprising 70.6% by 2033, driven by a 30.9% CAGR. This segment is anticipated to grow to $14.5bn by 2033, up from $978m in 2023, with the adopters subsegment contributing 39.5% of total revenue, growing at a 32.3% CAGR. Metal AM services will represent 15.3% of the market, while metal AM

materials will account for 5.7%.

Polymer AM is projected to reach $5.7bn by 2033, up from $582m, also driven by the adopters subsegment, which will constitute 39.8% of revenue (with a 26.2% CAGR). Hardware will see 29.6% market share (26.2% CAGR), while services and materials will represent 22.1% and 8.5% of the total, respectively.

Although the smallest category, technical ceramic AM is expected to grow to $310m by 2033, driven by hardware sales that will make up 43.9% of the revenue.

8 voxelmatters.com

NOVEMBER 2024

Engineering Capacity | METROLOGY

Faster, more accurate inspection Precision engineering company Boneham & Turner has significantly improved its inspection process by investing in the Baty Venture FV 3020 measurement system from Bowers Group.

Allowing for faster, more accurate batch inspections and maintaining tight tolerances, particularly in the measurement of micro pins, the implementation of the Baty Venture FV has boosted inspection speed whilst simultaneously increasing accuracy and repeatability.

Stacy Denton Beaumont, Group General Manager at Boneham & Turner said: "Many of our customers require parts to very intense specifications. Previously, we could only inspect a maximum batch of 5 micro pins at a time, but with the Baty Venture FV 3020 now we can check significantly larger quantities quickly and reliably, maintaining very tight tolerances. We’ve experienced higher levels of repeatability, a faster inspection process, and overall improvement in the quality of our parts. With the right equipment in place, we've reduced return rates and eliminated repeated inspection errors."

As Boneham & Turner continued to grow and meet the increasingly stringent demands of its clients, the company faced challenges in its inspection processes. A key issue was the difficulty in inspecting micro pins, which could only be measured in NOVEMBER 2024

batches of up to five. This limitation not only slowed down the workflow but also left room for potential errors during the inspection phase.

Faced with the growing need for higher precision and faster turnaround times, the company identified that inadequate inspection equipment had become a major bottleneck in its operations. This led to recurring errors and compromised both efficiency and consistency, highlighting the need for more reliable measurement solutions to maintain the high-quality standards expected by its clients.

To address these challenges, Boneham & Turner made a strategic investment in a range of high-precision measurement tools from Bowers Group. This included the new Baty Venture FV 3020, an instant, non-contact measuring system designed for precision inspection, offering fast and

accurate measurement of complex components through advanced vision technology.

Introduced to improve inprocess checks and final inspections, with a focus on critical components such as dowel pins, drill bushes, and shims, the Baty Venture FV 3020 has proven to be highly effective in streamlining Boneham & Turner’s batch inspection process.

The Baty Venture FV 3020 is a versatile, fully automated, non-contact measuring system designed for precision inspections.

With advanced vision technology and easy-to-use software, it offers accurate measurements for complex components and geometries, making batch inspections more efficient across various materials.

Its ability to quickly and accurately measure multiple complex geometries simultaneously has enabled the team to conduct batch inspections more efficiently, handling larger volumes while maintaining strict quality standards.

With high-magnification and advanced lighting, the Venture FV continues to deliver clear, reliable results, helping to significantly improve part quality. It has also improved repeatability and streamlined the inspection process, leading to faster, more consistent outcomes and eliminating potential errors.

8 bowersgroup. co.uk boneham.co.uk www.engineeringcapacity.com

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METROLOGY | Engineering Capacity At the recent Advanced Engineering show Central Scanning introduced two new handheld Artec 3D scanners.

The Artec Point is a brand-new metrology grade, highly accurate 3D scanner that’s compact in size, ensuring portability and flexibility in tight spaces for industries such as manufacturing, engineering and healthcare. For the most demanding of measurements and reverse engineering tasks, it can maintain high precision with up to 0.02mm 3D resolution.

The Artec Spider II builds on the success of its predecessor, it features faster scanning speeds, a larger field of view and blue-light technology to capture everything from fine surface details on small

New handheld scanners

objects to large and can capture colour. With a resolution of 0.05mm, fine details from coins and jewellery can easily be captured.

Central Scanning is a 3D Scanning, 3D Printing, Reverse Engineering and Inspection specialists based in Bromsgrove, Worcestershire. It is an Artec Ambassador & Gold Certified

reseller in the UK and a specialist in this field, providing scanning equipment and related software/accessories.

It is also part of the Zeiss #HandsOnMetrology partner network and can provide sales, training, and ongoing support.

In addition to its 3D scanning capabilities, the company offers a comprehensive 3D printing service utilising 3D printers from Stratasys, Mark Forged, Ultimaker and Prusa. It can print in a wide variety of materials and has the full colour multi-material Stratasys J750 printer.

8 central-scanning.co.uk

Sub contr contract act inspection from fr om your your trusted metrology metrology par partner tner irst Our inspection capabilities include F First Principles, tactile CMM, optical CMM portable table measur measurement ement with laser and por scanning, which can be utiliz utilized ed for: for: First/Last Article Inspection (F (FAIR/LAIR) AIR/LAIR) Scan to see how we can support you!

Initial Sample Reporting (ISIR) Gauge R&R & MSA 3D chr chromatic omatic rreports eports (colormap) Process Pr ocess e evaluation valuation testing Non-contact -contact VMM inspection and mo more mor e www.industrialphysics.com www .indust ustrialp alphysics.com sics. sic tms.inspection@industrialphysics.com tms.inspection@ind ndustri trialph physics.com

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NOVEMBER 2024

Engineering Capacity | SUSTAINABILITY A £1.8m investment by Precision Micro in new plant for the manufacture of flow plates for renewable energy applications has been rewarded with its first big order.

The £1 million order, scheduled for delivery by autumn 2024, follows a series of anticipated major contracts from multiple clients at the photochemical etching specialist, highlighting Precision Micro’s commitment to advancing hydrogen technology for leading OEMs around the globe.

Ben Kitson, Head of Business Development at Precision Micro, said: “With over 60 years of industry experience, Precision Micro has been a pioneer in etched flow plate technology since 1990, and this sizeable order affirms our position as one of the largest suppliers of etched flow plates across the globe.”

Metallic flow plates play a vital role in various applications, including natural gas cooling, hydrogen electrolysis and precooling in refuelling stations, fuel cells and carbon capture in renewable energy sectors. Their compact, complex and lightweight design reduces material costs, simplifies handling and maximises space efficiency – essential factors in industries where optimisation is key.

Kitson continued: “Our core photochemical etching process is crucial for machining the intricate channels which dramatically enhance heat transfer efficiency and thermal performance. With a growing NOVEMBER 2024

Flow plate investment pays off

demand for our services worldwide, the recent £1.8 million plant investment into a second etch room has provided Precision Micro with the necessary capabilities to increase our support for both new and existing customers.

As the push towards Net Zero intensifies, sectors such as fuel cell vehicles are expected to experience substantial growth. A recent forecast predicts that the global fuel cell vehicle market will expand from $1.2 billion to $46 billion by 2030. Plate heat exchangers, integral to hydrogen refuelling, will also be pivotal in meeting this growing demand and supporting the hydrogen supply for diverse vehicle types.

Kitson added, “This significant order is a testament to the

success of our strategic investments and our commitment to driving cleaner energy through chemical etching technology. We are enthusiastic about the future and remain dedicated to providing exceptional solutions to our customers.”

Precision Micro’s investment in its production facility, totalling more than £7 million since 2020, has enhanced its capacity and efficiency, ensuring the timely delivery of high-precision components tailored to customer specifications. The company’s ongoing advancements and commitment to cutting-edge technology reflect its dedication to maintaining the highest industry standards.

8 precisionmicro.com www.engineeringcapacity.com

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SUSTAINABILITY | Engineering Capacity

Unlocking reshoring opportunities A new centre in Glasgow could help reshore supply chains and unlock new opportunities for manufacturers by promoting circular economy practices.

The £5.5 million ReMake Value Retention Centre (RVRC) centre in Glasgow aims to support the transition to net zero while driving substantial UK economic impact by reducing waste and emissions.

The RVRC will be located within the National Manufacturing Institute Scotland (NMIS) and the University of Strathclyde - the operator of NMIS, in partnership with the University of Exeter and the University of Sheffield. The centre is funded through UKRI’s ‘Accelerating the Green Economy’ programme.

While much of the focus around net zero has been on the transition to renewable energy sources, nearly 45% of global CO2 emissions come from what we make and use. In sectors, such as energy and transport, around 70% of emissions are locked in during raw materials extraction and initial processing meaning that it’s essential to extend product life for as long as possible to maximise value while preserving the earth’s precious resources.

The RVRC will focus on ‘high integrity’ sectors critical to national infrastructure including aerospace, marine, wind, nuclear, industrial and power generation.

It will adopt a system-wide 26

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8 Stephen Fitzpatrick, director of Digital Factory at NMIS

approach, addressing challenges through business models, policies, standards, culture, skills, and investment along with metallic and composite based circular manufacturing technology and inspection processes.

Partnering with organisations from the private, civic, and public sectors, the new centre will explore how components such as aeroplane structures, energy systems, and industrial equipment can be reused or remade, aiming to keep products at their highest value instead of sending them to landfill.

Stephen Fitzpatrick, director of the Digital Factory at NMIS, said: “The RVRC will tackle one of the

biggest current manufacturing challenges and bring significant economic impact to the UK. We’re decoupling economic growth from negative environmental impact and expect this work will grow local businesses, reshore supply chains and launch new manufacturing companies.

“Focusing solely on the energy transition won’t achieve net-zero since a large portion of global emissions comes from extracting and processing manufacturing materials. To mitigate the projected 500 million tonnes of material demand that we will need to dig out of the Earth over the next decade, we must embrace a circular economy, reusing materials and remaking existing products.

“This challenge requires collaboration across industries and organisations. The RVRC will drive system-level change, making reuse, remaking and repurposing viable for critical sectors.”

Professor Sir Jim McDonald, Principal & Vice-Chancellor of the University of Strathclyde, added: "The establishment of the ReMake Value Retention Centre is a significant milestone for the UK’s journey to net zero. This centre will bring critical circular economy practices to the forefront of manufacturing, helping to reduce waste, cut emissions, and create sustainable, high-value jobs across Scotland and the UK." 8 nmis.scot NOVEMBER 2024

Engineering Capacity | SUSTAINABILITY Broder Metals Group uses advanced melting technology to convert metal scrap into high quality powders for additive manufacturing (AM) and hot isostatic pressing (HIP).

Based in Sheffield since its inception in 2003, Broder is a stockist and distributor of high specification stainless steel, nickel alloys and super alloys to UK, European, and Worldwide markets for oil & gas, motorsport, aerospace and nuclear. It recently launched its new powder division.

Broder Powder offers a diverse range of metal powders and alloys for Additive Manufacturing (AM) and Hot Isostatic Pressing (PMHIP), along with next-generation alloy development maximizing the

NOVEMBER 2024

Quality powders from scrap potential benefits and solutions that AM and PM-HIP can deliver.

It has also secured a strategic partnership with 6K Additive, based in the USA as its official UK and Ireland distributor. All Broders powders are produced with 6K’s revolutionary UniMelt Plasma Production System.

This technology converts metal scrap and end-of-life parts into high-quality powders such as nickel, titanium and refractory alloys, while drastically reducing energy consumption and carbon emissions compared to traditional methods. This innovation is a leap forward in performance and

a stride towards a more sustainable future.

Broder says it is committed to providing its global customers with world-beating customer service through direct support, metallurgy and its AM expertise.

It has held ISO 9001 since 2005, gained AS9120 Aerospace approval in 2019 and all the material it sells has full traceability and complete certification. Over 40% of sales are to export markets and Broder has in-house expertise in export, regulations, shipping, and declaration compliance.

8 broder-metals-group.com

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SUSTAINABILITY | Engineering Capacity

Lighter, greener Aston Martin Coventry manufacturer Sarginsons is leading on a £6m project to develop an Aston Martin car that is made out of recycled aluminium – reducing carbon levels by 95% - and is also using AI software to make the car up to 30% lighter.

The research programme will see automotive and aerospace cast components made from 100% recycled aluminium.

The research partners, including castings firm Sarginsons and Aston Martin have been awarded the £6 million matched grant by the Advanced Propulsion Centre and Innovate UK for its Performance Integrated Vehicle Optimisation Technology project (PIVOT).

It is being described as a game changer in the production of all new vehicles, making them more sustainable, lighter, cheaper and better performing.

Altair - a specialist in computational intelligence that provides software and cloud solutions in simulation, highperformance computing (HPC), data analytics, and AI - will work with Sarginsons to develop software that will use AI to produce organic designs of new chassis components for an existing Aston Martin model.

The software will provide a highly automated simulation driven design process for new components, ensuring rapid development whilst reducing time to market and development costs.

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The natural, organic designs the new software produces will actually increase component strength whilst reducing mass by simulating the varying mechanical properties of the part to put the right material in the right place.

The new software will also allow Sarginsons to better support its clients, from across the automotive, aerospace and renewable industries, by allowing them to better control casting development to de-risk production manufacture.

The research will seek to demonstrate that the mass of a vehicle’s chassis can be reduced by up to 30% whilst maintaining mechanical integrity – thus reducing the weight and increasing the driving range of new vehicles.

8 Gavin Shipley, Technical Director at Sarginsons

Another part of the research is paving the way for a sustainable future for the way aluminium is sourced as a raw material for automotive manufacturers – and other manufacturing industries – by using secondary, fullyrecycled aluminium for stronger components.

Currently, all structural vehicle components are made by using primary, high carbon un-recycled material. Through strengthening recycled aluminium with trace amounts of key alloying elements, PIVOT will reduce carbon content in a typical vehicle’s aluminium cast components by up to 95%, whilst improving ductility for crash safety, in support of the Advanced Propulsion Centre’s NOVEMBER 2024

Engineering Capacity | SUSTAINABILITY acceleration towards a net zero automotive industry.

Part of the project will see Sarginsons working with Brunel University and metal recycling experts, GESCRAP, to develop grain structure refinement techniques to overcome impurities traditionally inherent in recycled aluminium.

The research will also be developing a new UK-based recycling network for secondary aluminium to kickstart a shift away from using primary aluminium sources, of which there is a finite amount, to secondary aluminium with significantly lower embedded carbon. Currently in Europe, primary material sits at around 12 tonnes of carbon per tonne of aluminium, and is higher elsewhere in the world. 100% recycled secondary material represents a 95% reduction to less than 0.5 tonnes of carbon per tonne of aluminium.

Sarginsons is leading on the research in conjunction with key partners including Aston Martin,

Altair, Brunel University London and GESCRAP and has secured around £3 million of the PIVOT grant to assist with new equipment and workforce expansion for the research.

Gavin Shipley, Technical Director at Sarginsons, said: “This world-first research is a major step not just for the global EV market, but any market that uses aluminium, and has the potential to lay the blueprint for so many industries to increase the efficiency of their manufacturing in a sustainable and affordable way – and it’s happening right here in the Midlands.

“For now, this project’s focus is on electric vehicles. As crucial as un-recycled aluminium has been to the automotive industry due to its strength and reliability, it has high levels of associated carbon, so to have had this level of investment in identifying ways that we can use this material in a sustainable manner is a game changer for this industry.

“The UK exports over 250,000 tonnes of downgraded scrap

aluminium to be processed every year, which this proposal should dramatically reduce, while creating new jobs.

“Sarginsons has already been using software to design, develop and test castings – the technology is proven – and this latest PIVOT grant is about developing this technology and making it available to a wider audience for the benefit of the wider manufacturing industry.

“The licensed software will be able to demonstrate to manufacturers ways that aluminium components can be strengthened whilst reducing their mass.

“As a firm we are ideally placed to collaborate and make this research project a success thanks to the ongoing investment we have made in recent years to our software, skilled workforce and our high-tech Sarginsons Technology Centre, where we have helped prestigious manufacturers to develop and test products from scratch.

8 sarginsons.com

Sustainable aerospace materials Aerospace materials manufacturer ATI has joined the University of Strathclyde’s Advanced Forming Research Centre (AFRC) as a Tier One Member.

This marks the beginning of a collaboration in advanced engineering and materials science that will support

NOVEMBER 2024

sustainable air travel.

Access to the AFRC’s pioneering FutureForge facility is expected to support ATI with the development of the next generation of materials and process technologies, with the world-leading forging research facility providing an industrialscale iso-thermal testing

platform. As airlines increasingly focus on sustainability, new metallic alloys that can endure higher temperatures than ever before will be key to allowing jet engines to operate at maximum efficiency and, ultimately, burn less fuel.

8 nmis.scot

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TURNED PARTS | Engineering Capacity A new multi-tasking lathe has significantly increased capacity and capabilities at Macro Manufacturing.

The Fanuc-controlled DN Solutions sub-spindle, Y-axis Lynx 2600SY lathe is being used to machine a range of components for a growing number of customers in the oil and gas, renewables and agricultural industries and sectors.

These parts, typically machined in medium batch sizes, are made from a range of different materials including 316, 316L and 17-4 stainless steel, duplex and super duplex alloys, aluminium, exotics such as Inconel and Hastelloy as well as some engineering plastics.

Parts machined by Macro Manufacturing are also characterised by their complexity with tight tied-up geometric tolerances and exacting surface finish requirements being the norm rather than the exception.

These parts frequently exhibit intricate and delicate features that can only be machined, or can only be machined efficiently and economically, on a multi-tasking lathe.

Macro Manufacturing’s owner and director Matthew Forbes said: “The Lynx 2600SY is a highaccuracy multi-tasking lathe that has significantly increased our inhouse machining capacity and capabilities and enables us to machine complex parts quickly, in one set-up.

“Since its arrival, we have been able to secure new machining contracts from both new and 30

www.engineeringcapacity.com

Multi-tasking capabilities

existing customers, and have strengthened our position within a number of customers’ manufacturing supply chains.”

The Lynx 2600SY is the first machine tool Macro Manufacturing has acquired from DN Solutions since the company’s incorporation back in 2022. It is also the first new machine acquired by the company in its two-year history.

Like many new precision

subcontract start-ups, Macro Manufacturing had relatively humble beginnings, starting life in a shed on a local farm with initial machining contracts being undertaken on a couple of used CNC machine tools.

“The early days were a challenge”, remembers Matthew Forbes. “I was still employed fulltime at my previous employer, and was having to manage and run the new company in my spare time… during the night and through the weekends.”

This situation was always intended to be a temporary, stop-gap measure until the company was more established and, after just a few months, Mr Forbes decided to ‘bite the bullet’ and put all his time and effort into making Macro Manufacturing a success.

His vision was to supply highquality, competitively priced precision machined components to customers, and to grow the business through developing long-term partner relationships.

Part and parcel of these plans was to relocate the business to new premises, and to increase the company’s in-house machining resources.

The company plans to relocate again to larger premises, take on additional staff and, as part of its commitment to continuous improvement, invest in more advanced machine tools and ancillary technologies.

8 macro-manu.com NOVEMBER 2024

BTMA MANUFACTURING MEMBERS | DIRECTORY

The British Turned Parts and Machined Component Manufacturers Association Find out how our members can benefit your business Enquire directly with our Members, via btma.org or mail to info@btma.org

Arturn Ltd enquiries@arturnengineering.com www.arturnengineering.com

Colpa Precision Engineering Ltd steve@colpa.co.uk www.colpa.net

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

Ashtead Engineering info@ashteadeng.co.uk www.ashteadeng.co.uk

C&M Precision Ltd office@onehitcnc.com www.onehitcnc.com

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

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

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

Dobson & Beaumont sales@dobsonandbeaumont.co.uk www.dobsonandbeaumont.co.uk

Bailey & Wade Engineering Ltd www.turnedpartsrus.co.uk Louise.Fisher@nuttersfastenings.co.uk

CTPE Ltd www.ctpe.co.uk alex.taylor@ctpe.co.uk

Falcon Engineering Productions Ltd sales@falconengineering.co.uk

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

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

Global Engineering sales@globaleng.co.uk www.global-engineering.co.uk

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

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

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

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

Davturn Precision Turned Parts Ltd matt@davturn.co.uk www.davturn.co.uk

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

NOVEMBER 2024

btma.org

31

DIRECTORY | BTMA MANUFACTURING MEMBERS

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

Newport CNC Ltd steve@newport-cnc.com www.newport-cnc.com

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

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

Norjon Engineers Ltd andy.fell@norjon.co.uk www.norjon.co.uk

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

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

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

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

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

Oracle Precision Ltd shaun.palmer@oracle-precision.co.uk www.oracle-precision.co.uk

Rowes Precision Products Ltd phil.willoughby@rowesprecisionproducts.co.uk www.rowesprecisionproducts.co.uk

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

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

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

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

Scot Bennett Engineering Ltd rob@scotbennett.co.uk www.scotbennett.co.uk

MJ Engineering Ltd www.mjengineering.net enquiries@mjengineering.net

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

Sheldon Precision Engineering Ltd www.sheldonprecision.co.uk info@sheldonprecision.co.uk

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

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

Solstrand Industries Ltd james.valentine@solstrandindustries.com www.solstrandindustries.com

32

btma.org

NOVEMBER 2024

BTMA MANUFACTURING MEMBERS | DIRECTORY

Sub CNC Precision Engineering Ltd www.sub-cncprecision.co.uk george.dingley@sub-cncprecision.co.uk

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

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

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

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

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

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

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

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

Universal Fabrications (Coventry) Ltd email@universalfabrications.com https://universalfabrications.com

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

Enquire directly with our Members, via btma.org or mail to info@btma.org

BTMA TECHNICAL MEMBERS | DIRECTORY

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

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

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

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

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

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

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

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

NOVEMBER 2024

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DIRECTORY | BTMA TECHNICAL MEMBERS

Gen2 Group pmasters@gen2group.co.uk www.gen2group.co.uk

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

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

Premier Machine Tools UK Ltd david.dunn@premiermt.co.uk www.premiermt.co.uk

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

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

PSL Datatrack sales@psldatatrack.com www.psldatatrack.com

Turbex Ltd sales@turbex.co.uk www.turbex.co.uk

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

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

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

Mills CNC Ltd tdale@millscnc.co.uk www.millscnc.co.uk

SolidCAM UK Ltd info@solidcamuk.com www.solidcam.com

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

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

34

www.engineeringcapacity.com

Qualiturn Products Limited 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

METROLOGY 8

JFL Broaches and Broaching

CNC PRECISION COMPONENTS 8

BROACHING 8

The Association for UK machined component manufacturers

Bowers Group Bowers Group is a leader in the field of measurement, supplying quality metrology instruments to organisations worldwide.

Unit 3 Albany Court, Albany Park, Camberley, Surrey, GU16 7QR Tel +44 (0) 1276 469866 www.bowersgroup.co.uk

NOVEMBER 2024

TURNED COMPONENTS TO AEROSPACE

STANDARD

!

GET YOUR QUOTE TODAY

DJJ Precision Engineering Ltd Providing CNC Milling, Turning, 5 axis and Robotic automated machining, Honing, Grinding, Broaching, ID marking, surface finishing & PPAP certification for hundreds of industries.

Precision mill turned parts up to 65mm in diameter from bar and 300mm billet work

PRECISION ENGINEERING 8

We are a subcontract machine facility that manufactures precision Turn/Mill components using one-hit technology. We supply various industry sectors which has helped us develop our machining techniques over the years.

Unit 3 Mill Lane Fullbridge, Maldon, Essex CM9 4NX Tel: 01621 852569 office@onehitcnc.com

SUBCONTRACT CNC TURNING 8

C & M Precision Ltd

WE MACHINE ALL

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TUVRheinland ISO 9001:2015, JOSCAR accredited Ford Tier 1 Global supplier. Winners of BAE Systems International Chairmans Award. Cyber Essentials

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

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

dpc.co.uk

SPRING MAKING 8

PRECISION ENGINEERING 8

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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

Contact Sales for more information T. 01495 760561 mail@djjengineering.com

NOVEMBER 2024

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

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

Falcon House, 30 Ivanhoe Road, Hogwood Industrial Estate, Finchampstead, Wokingham, Berkshire, RG40 4QQ www.simpsonsprings.co.uk

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