MTD Audiobook

Over 80% of the UK's SMEs believe apprenticeships are at least partly the solution to the UK's skills gap crisis, with a further 69% of the view apprenticeships are a ‘valuable alternative to university' Four in 10 (44%) feel not enough is being done to encourage young people to consider apprenticeships. The findings are taken from the latest independent research commissioned by Close Brothers Asset Finance and are in support of National Apprenticeship Week (NAW), which highlights the positive impact that apprenticeships make on individuals, businesses and the wider economy. According to a survey by the Learning and Work Institute, around 70% of employers reported a skills shortage in their workforce. The Close Brothers Asset Finance research confirms that 50% of business owners are concerned there's a skills gap in their sector while a further 16% say the issue is regionally based. Over a third (37%) of responding firms report having an apprenticeship scheme of their own, with many (65%) stating that if financial assistance were available from either the government or the private sector to help contribute towards wages and/or training, they would put someone from their company forward to participate in an apprenticeship scheme. The National Apprenticeship Service states that 96% of employers with apprentices have experienced at least one benefit from taking on apprentices, and most can count at least eight benefits. In addition, 74% of employers say that apprentices improved products or service quality, and 78% say that they improved productivity while 73% say that staff morale is improved by having apprentices. Steve Gee, CEO of Close Brothers' Asset Finance's Industrial Equipment Division, said: “As a funder of a number of sectors that rely on apprentices, we've long seen the need and value of apprenticeship schemes, which encourage new talent into industries that really need them.”  “As part of our commitment to the SME community, we've been funding an apprenticeship scheme since 2015, in partnership with the University of Sheffield's Advanced Manufacturing Research Centre (AMRC). Under the scheme, we contribute towards the wages of the apprentices in both the first and second year, with all training costs also covered. “The reality is, it's not cheap for an SME to invest in apprentices – and its important small business owners see it as an investment and not a cost. Handled correctly, apprenticeships can help an SME flourish and, at the same time, develop the individual apprentice.” “I believe we all have a duty to look at where, as ‘UK PLC', we need to concentrate our efforts and money. I would strongly encourage firms to support apprentices – we know first-hand what a hugely positive impact they can have.” Nikki Jones, Director of the University of Sheffield AMRC Training Centre said: “At the AMRC Training Centre, we're transforming lives through apprenticeships. We combine classroom learning and shop floor industrial experience to equip new, young talent with all the skills they need to become the advanced engineers of tomorrow. 

Edging closer to its 50th anniversary, the Progressive Technology Group has enjoyed a meteoric rise over the last decade. Founded in 1977, the relocation to larger premises in 2013 was one of the many catalysts for the Newbury company's decade-long growth. Opening multiple new divisions and branching into new markets, the company now employs more than 250 staff. Among its accolades are many prestigious awards from AMG Petronas and Rolls-Royce, to name a few. However, this pedigree cannot be bought; it is embedded in the company's culture, with Progressive Technology opening its Apprentice Academy in 2015. In this bedrock for developing the talent of tomorrow, Tooling Intelligence Ltd has just donated a SmartDrawer® vending solution. The impressive Apprentice Academy at Progressive Technology enlisted 18 apprentices as part of its 2024 cohort, and this production line of talent nurturing has contributed significantly to the business's ongoing success. Aiming to mirror the high-tech manufacturing facilities, the Apprentice Academy has a complete range of technologies, from simple two and 3-axis manual machines to high-end 3 to 5-axis multi-functional machine tools. Three full-time trainers and a classroom with PCs support academic and computer-based training. Part of this progression from apprentice to a skilled engineer in an advanced manufacturing facility includes using high-end cutting tools and the associated inventory management systems. With technical partner Industrial Tooling Corporation (ITC), Tooling Intelligence installed its first vending solution at the ISO:9001 and AS:9100 subcontract outfit in 2014. The success of this first SmartDrawer® system led to a second installation in 2016 and a third in September 2024. The versatile SmartDrawer® system from Tooling Intelligence is a drawer system that is completely configurable to the end user's requirements. Using smart technology, the SmartDrawer® can dispense single or multiple items with reliable, accurate, and monitored inventory control, giving the end user complete visibility and control of its supply chain. The benefits of the SmartDrawer® were evident at Progressive Technology, and this is why the company rapidly adopted additional systems when shop floor inventory management required them. The SmartDrawer®, which comprises individually locked compartments controlled by a user-friendly touchscreen interface, provides ‘self-serve' access to consumables, equipment, and cutting tools. This has enabled Progressive Technology to manage, monitor, and control its cutting tool consumption with greater visibility while automatically re-ordering stock to ensure the right tool is always available. With a complete audit trail, the SmartDrawer® provides visibility regarding which employee uses which specific item and where and when it is used. With apprentices destined to enter the advanced production facilities in the future, understanding the inventory management process at the West Berkshire company is essential. This is why Tooling Intelligence has made such a generous contribution. The December 2024 arrival of the SmartDrawer® in the Apprentice Academy was installation number four, with the fifth SmartDrawer® being installed simultaneously on the shop floor of the 24/7 manufacturing site. As part of Tooling Intelligence's donation, ITC has supported the installation with a selection of regularly used cutting tools for the Apprentice Academy. Included are a complete selection of solid carbide and indexable milling and turning tools. The apprentices now have access to the consumables they require as and when they need them from a single source system. Commenting upon the installation, Tooling Intelligence's Managing Director, Richard Swaffield, says: “We are delighted to support such a valuable customer in their growth journey over the last 10 years. An industry-leading subcontract manufacturer's repeat business for over a decade is a testament to how our SmartDrawer® system delivers an inventory management system that is bespoke to the demands of each customer. Since investing in its first SmartDrawer®, Progressive Technology has witnessed cost savings, improved inventory management and control, and complete visibility over what products are used and when. This level of insight is essential for the future of any modern manufacturing business. This is why we have donated a SmartDrawer® to the Apprentice Academy at Progressive – the talent of tomorrow needs a complete understanding of the benefits of effective inventory management as well as the implications of not managing your supply chain.”

The Brough Superior, a classic British motorcycle designed by George Brough in 1919 and manufactured in Nottingham, was of such high quality that it was dubbed the Rolls-Royce of motorcycles. One famous customer, T.E. Lawrence (Lawrence of Arabia), owned eight and died in 1935 from injuries sustained when he crashed number seven. The design was beautiful and practical, and a sidecar was often added. Although the factory closed after the Second World War, enthusiasts have ensured the name survives. In 2004, around 1,000 original Brough Superior motorcycles still existed. The brand is regularly seen in period movies and television series, as well as in classic bike shows, hill climbs, and motor races. In 2014 the Brough Superior brand was purchased by a Jersey-registered corporation, which engaged Thierry Henriette to create a Brough Superior factory in St Jean, Southern France, near the aerospace capital of Toulouse. The factory produces luxury motorcycles at the pinnacle of exclusivity and distinction. Although production is in France, the British design spirit has been maintained through a joint venture with Aston Martin to create the AMB 001 Pro, a limited-edition, high-performance motorcycle. To support the R&D process, bringing in-house the manufacture of some complex prismatic components was necessary. A Hurco VMX42SRTi 5-axis VMC was chosen due to its ability to achieve the accuracy and surface finish required. It can also accept 3D models directly into the proprietary WinMax control, renowned for its suitability for high-mix, low-volume production. Additionally, and most importantly, it enabled the manufacturer to go even further in customising motorcycles for its discerning clientele, offering different machining finishes and engraving possibilities and assuring the impeccable quality of parts. The VMC also supports CNC machining of a new, dual-cylinder, 997cc engine for the AMB 001 Pro, a high-performance, turbocharged, track-only motorcycle born from a collaboration between Aston Martin and Brough Superior. It draws inspiration from Aston Martin's Valkyrie AMR Pro hypercar, which has a power-to-weight ratio comparable to a Formula One car. Manufactured from solid aluminium billet, the engine is lighter, stiffer and more powerful than in previous Brough Superior bikes. In addition to powering the AMB 001 Pro, it has been engineered to fit perfectly into contemporary versions of the classic Lawrence and Dagger motorcycles. Most metal removal and finishing are completed in a single set-up on the Hurco VMX42SRTi.

Difficult-to-cut materials are defined as engineering materials with significantly lower machinability than typical. These materials are often referred to in shoptalk as ‘hard-to-machine,' ‘tough-to-cut,' or even ‘nasty.' It is important to note that high hardness is not the only characteristic that makes these materials challenging to machine; several other factors contribute to their machining difficulties. Every industrial branch, in one way or another, must deal with such materials. However, the leading consumer of these materials is the aerospace industry. It is in this sector—whether in the production of turbine engines, landing gear components, or primary airframe elements—that difficult-to-cut materials have found their most significant application. In the aerospace industry, the key characteristics of required materials are strength-to-weight ratio, robustness, fatigue life, and resistance to corrosion and hot temperatures. It turns out that materials meeting these characteristics are difficult to machine, posing a serious challenge for production. When speaking about such materials, the following information should be considered: l High-alloy high-strength steel, l Titanium alloys, l Hot temperature superalloys, l Composites. High-strength steels are used in elements subjected to extreme mechanical load, such as landing gear. They are also the primary material for various fasteners. Titanium alloys, with their excellent strength-to-density ratio, high corrosion-proof, and creep resistance, have become the preferred material for producing the main parts of a jet engine's cold section. These alloys also provide a suitable alternative to steel and stainless steel for weight savings. Hot-temperature superalloys (HTSA), which can maintain their strength in high-temperature environments, are common in the components of a jet engine's hot section. Composites offer impressive specific strength, helping to decrease an aircraft's weight and opening new prospects for aerodynamic fairing. In military aviation, composites contribute to improved aircraft's stealth characteristics. However, machining these materials presents numerous challenges for several reasons. The main challenges are as follows: l High material strength results in significant cutting forces that increase the mechanical load on the cutting tool. l Intensive heat generation and low thermal conductivity of the material (for example, when machining titanium alloys) cause poor heat transfer. This leads to a growing thermal load on the tool and increases the risk of build-up on a cutting edge. l Work hardening of materials (specifically HTSA) increases the strength and hardness of the workpiece surface during cutting, making machining difficult. l The high abrasion factor (when machining composites) intensifies the galling of the tool's active area. Additionally, other specific material features affect machinability. For example, the ‘springiness' of titanium alloys contributes to vibration, worsening machining accuracy and surface finish. The inner structure of composites is associated with material delamination during machining. All the mentioned aspects accelerate tool wear and diminish tool life. The trends in the aerospace industry distinctly point to the increased usage of difficult-to-cut materials. This is manifested by introducing new alloys with higher strength and heat-resistance characteristics, the broad application of composites, and the utilisation of hybrid-structure (metal-composite) materials. To meet these challenges, the metalworking industry introduces new cutting strategies based on the impressive capabilities of modern CNC machines and CAM systems. However, the cutting tool is the final link in the entire machining chain, which directly contacts the material and removes its layer during operation. This link is the most ‘conservative' part of the chain, and its development is slow, often hindering the full utilisation of advanced machines' capabilities. To overcome the existing difficulties, it is necessary to reduce machining data, which leads to low productivity and increased machining costs. Understandably, every step forward, even a small one, in the tool field can significantly improve machining ‘nasty' materials. Therefore, the metalworking industry welcomes the latest advances in cutting tools, hoping they will radically change the situation. What are the main requirements for tools intended for efficient machining of tough-to-cut aerospace materials? In brief, they need to be hard, durable, and precise to enable productive machining while ensuring predictable and stable prolonged tool life and the required accuracy level. However, meeting these understandable and reasonable demands requires significant efforts, and even small progress in this direction faces challenges. Every new advance involves serious R&D work and extensive testing. Hence, tool development focuses on the following areas: Cutting material grades. Tool design. A tool's digital component. The emphasis in cutting materials is on improving hardness, wear resistance, and high-temperature strength. This is achieved by introducing new coatings, particularly those based on nanotechnology, and expanding the use of extra-hard cutting materials like cubic boron nitride (CBN) and ceramics. In tool design, enhancements optimise macro and micro-geometries, such as the cutting edge design and cutting edge preparation, to improve cutting capabilities. Computer modelling, combined with computational dynamics and the impressive possibilities of additive manufacturing (AM), provides new opportunities for shaping flutes, chip gullets, and internal coolant channels. This contributes to better chip evacuation and coolant supply, improving tool performance. A key area is increasing the vibration resistance of the tool through advanced cutting geometry, enhancing the rigidity of the tool structure, and using vibration-damping toolholders. The tool's digital component includes the digital twin and various software products, which allow for virtual assembly, machining simulation, cutting data selection, tool life estimation, and necessary calculations such as machining power and cutting forces. ISCAR expects that this component will be compatible with data exchange standards to meet the requirements of Smart manufacturing. The noted trends are evident in the new developments from ISCAR, one of the leaders in tool manufacturing, presented within the framework of the latest LOGIQUICK campaign. The company has introduced two new carbide grades with PVD coating: IC1017, which ISCAR created for turning Ni-based HTSA, and IC716, which is intended for high-performance indexable milling titanium alloys. The range of chatter-dampening solid carbide endmills has been expanded with contemporary designs made from the bronze-coloured IC608 carbide grade, which is the first choice for the ISO S group of applications (cutting superalloys and titanium). Another carbide grade, IC5600, has been developed by ISCAR's prolific R&D Materials Sciences engineers for milling steel (ISO P group). The combination of the grade's submicron substrate, CVD coating, and post-coating treatment aims to enhance resistance to abrasive wear and thermal loading, increasing cutting speed, particularly when machining high-strength steel. CERAMILL, a new family of endmills with indexable single-sided round inserts (Fig. 1), is interesting from two points of view. First, the family utilises an ingenious mechanism for high-rigidity insert clamping. This mechanism allows for an increased number of teeth compared to a typical design of similar tools in the same diameter. Additionally, it enables simple indexing and insert replacement without removing the endmill from the toolholder. Second, the inserts are produced from ceramic grades specially engineered for machining HTSA. ISCAR has expanded its range of anti-vibration products based on the innovative built-in damping mechanism, which features a heavy mass supported by a rubber spring element containing oil for enhanced dampening. The turning line now includes vibration-absorbing boring bars for machining depths of 12 and 14 times the shank diameter (Fig. 2). Additionally, the milling line has incorporated anti-vibration shanks with MULTI-MASTER adaptation. The QUICK-X-FLUTE is a family of extended flute shell mills developed to achieve high metal removal rates (MRR) in rough milling of challenging materials such as HTSA and titanium (ISO S), austenitic and duplex stainless steel (ISO M), and steel (ISO P). These ‘porcupines' utilise cost-effective, double-sided square inserts with 8 indexable cutting edges. A key aspect of the mill design is the optimised flute geometry (Fig. 3), which balances mill rigidity and the necessity for adequate chip flow when cutting at high MRR. The QUICK-X-FLUTE mills also feature an inner coolant supply option. Using high-pressure pinpointed coolant with replaceable nozzles and face frontal outlets ensures a direct supply of coolant to the cutting zone. This enhances the cooling and lubrication action, contributing to optimal chip control. Effective coolant supply has become a primary emphasis in contemporary tool designs. In the PICCO line of miniature turning tools, ISCAR has introduced new inserts with internal coolant channels (Fig. 4). In hole making; the company has unveiled new 3-flute solid carbide drills for machining flat-bottom holes featuring three coolant outlets. The latest additions to tool holding include holders with coolant channels along the shank bore. Additionally, in ISCAR's classical HELIMILL indexable milling family, the company's R&D engineers have upgraded the design to maximise flow rate with minimal pressure drop using computerised fluid dynamic (CFD) software. Improvements have also been made to NEOITA, an integral part of the company's digital tool component. NEOITA, an expert system that recommends optimal tooling solutions and forecasts tool life for a specific application, now includes new features. One of these is the AI-powered information search, specifically designed to retrieve detailed data on workpiece materials, including their metallurgical composition and typical uses. Enhanced performance in machining difficult-to-cut aerospace materials is a complex challenge. Tool manufacturers continually strive to provide more advanced and productive solutions to address this. While no radical breakthroughs have been observed, recent developments indicate steady evolutionary progress in this area.

Building on the success of their award-winning 3D-printed stator bore tool for electric vehicle machining, Kennametal has developed an innovative 3D-printed transmission housing tool for Voith that cuts weight by approximately 45% and reduces machining time by approximately 50%. As transportation components become increasingly more sophisticated and the requirements more stringent, manufacturers need complex tooling solutions to machine those components. That poses a challenge as the weight of such tooling can become too heavy for efficient operation on machining centres, tool changers and tool magazines. Machine operators may also have difficulty managing the tool. A recent collaboration by Kennametal, an industrial technology leader, and Voith, a leading supplier of drive technologies, shows how 3D printing offers a pathway to novel, lighter-weight tooling solutions that overcome these challenges while improving productivity and efficiency. The Challenge: Machine multiple, tight tolerance, large diameter bores with existing machining centres Voith wanted an innovative solution to optimise its machining processes for transmission housings further. To achieve the required tolerances, the company needed a multi-stage tool capable of machining multiple bores in one operation. The tool also needed to have two effective cutting edges on the main diameters to achieve the specified cycle time. Finally, the tool had to weigh less than 12kg to meet the requirements for tool changing and tilting moment on the toolchain. “Finish machining a large aluminium housing with multiple bores up to 350mm and IT7 tolerance grade is a demanding application,” said Werner Penkert, Manager of Product Engineering. “To machine these large bores with such tight tolerances, we need very rigid tools, which typically means they are heavy weight. When manufactured using conventional methods, a typical tooling solution for this type of application could weigh as much as 25kg, which is too heavy for the existing machines or for an operator working with the tool.” Intrigued by how Kennametal leveraged 3D printing to produce a lighter-weight stator bore tool for electric vehicle machining, the Voith team turned to the industrial technology leader to collaborate on a solution. “Kennametal's innovative approach with 3D printing excited and inspired us to take this path together,” says Friedrich Oberländer, Director of Production Technology at Voith. The solution As with the stator bore tool, Kennametal leveraged its expertise in metal additive manufacturing—plus the concept of generative design to meet the demanding requirements of Voith's transmission tool. With conventional subtractive manufacturing, weight is reduced by removing excess material. However, with 3D printing, manufacturers can start with nothing and put material only where it is needed, resulting in lighter-weight, more complex geometries not possible via conventional manufacturing processes. To fully leverage additive manufacturing's design freedom, Kennametal used generative design, an iterative process that optimises the design of 3D-printed parts to meet an application-specific set of constraints. The generative design process often results in complex, organic shapes reminiscent of natural structures. In the case of the Voith tool, generative design directly addressed machining forces on the tool, enabling Kennametal to design a solution optimised for stability, stiffness, balancing and coolant supply—with a weight of just 11.5kg. Kennametal applied its expertise in additive manufacturing and machining to produce the tool. The tool pockets are precision machined and designed to be used in combination with Kennametal's proven RIQ inserts technology. “Additive is one tool in our toolbox, but we also applied our deep expertise in precision machining to develop a novel solution that efficiently addresses the challenges of boring deep holes in conjunction with multiple large diameters,” Penkert.  The design of Kennametal's 3D-printed transmission housing tool mimics the organic shapes found in nature, delivering reduced weight and a 50% reduction in machining time for the customer, Voith. The Results: 50% reduction in machining time Working in close collaboration with Voith, Kennametal manufactured a prototype tool and put it to the test in its demonstration centre in Fürth, Germany—part of a global network of test and demonstration centres where the company works with customers to design, iterate and validate machining solutions. This solution was particularly challenging in achieving both manufacturing and part quality requirements. Design simulation, additive manufacturing, and practical tests in the demonstration centre allowed the team to validate the machining results. Voith then conducted the first tests on-site, followed by longer-term tests for series production. Further customer requirements were implemented, and the tool was jointly perfected and finalised. “The Kennametal tool delivered outstanding quality and performance from the first use, achieving a 50% reduction in machining time while still meeting accuracy and surface finish requirements. Additionally, the reduced weight limits the load on the magazine, tool changer and spindle—effectively reducing maintenance costs,” said Oberländer. “Our collaboration with Kennametal clearly shows the enormous innovation potential of additive manufacturing when applied in such a cooperative partnership.”  Kennametal Additive Manufacturing (AM) offers a game-changing solution by utilising high-performance materials and parts that are produced faster and with the design flexibility of 3D printing. Kennametal brings nearly a century of materials and manufacturing expertise to every layer of the AM process—from raw material to finished part. This helps customers unlock the full value of 3D pr

The electrification transition and inflexible EV production quotas are taking a heavy toll on the automotive industry, but buses and commercial vehicles posted their best years since 2008. Will Stirling reports. MTD magazine is unwaveringly positive in its coverage of manufacturing news, but facts are facts: automotive manufacturing is on a downward slide. Combining cars and commercial vehicles (CVs), the UK produced 905,233 units in 2024, -11.8% from 2023, and slipping below the psychologically important one million units mark. Electric vehicles now comprise over one-fifth of all new car registrations, but the EV market contracted by 2.5% to 139,345 units. The bright spots are in the commercial vehicle (CV) and bus markets. Production in the UK rose 4% to 125,649 units, and both buses and CVs have had their best years since 2008. Carmakers face a multitude of challenges to produce both ICE (combustion engine) and EV cars in high volume. Higher energy and material costs, shortage of skilled people and potential tariffs on exports to the US, but the two most significant factors affecting the production of cars are the costly transition to electric and globally softer demand. The government has set onerous targets for the proportion of EVs that car companies make in Britain, from 22% last year to 28% this year – a tall order that experts believe won't happen – and 80% by 2030, after which the ICE car ban kicks in. The problem is that these targets are running ahead of demand. “The targets were set when demand forecasts were much higher; we know there'll be a significant shortfall,” says Professor David Bailey, an automotive business expert at the University of Birmingham. “Car firms are going to struggle to shift that volume of cars without very significant discounting, and therefore losses.” He adds: “Our two biggest producers, Nissan and Jaguar Land Rover, will struggle to meet that kind of stretched targets as they get bigger, so they will potentially be fined, and they may well have to buy credits from Chinese all-EV makers who can hit the target. So what a perverse policy that is – that you're subsidising the Chinese and fining domestic manufacturers.” Electric vehicle production and net zero targets have not been intelligently assessed. The government intends to phase out new petrol and diesel cars by 2030, and although the car industry was invited to consult on this in December 2024, many think the target is too early to hit. “The 2030 ban on ICE policy was plucked out of thin air to try to differentiate the UK from the European Union while signalling to investors that the UK is serious about decarbonisation to encourage investment in the UK. But it hasn't worked – because Brexit has made the UK less competitive and attractive, because of high energy costs, and it hasn't worked because we don't have a proper industrial strategy to support that transition,” David says. The government is now consulting on the industrial strategy, but it should have been firmly embedded in 2025 to help hit the 2030 ICE ban effectively. Stimulate demand; cost of electrification bites Demand for electric vehicles needs to be higher. The government has proposed cheap loans for EVs, but it sounds too complicated for the average car buyer, who wants to know the price, not a complex subsidy and loan. And a VAT break on EVs has been proposed, although this is a pro-tax government. “The government's problem is that it has boxed itself in agreeing to continue the fiscal rules that the Conservatives put in place, which I think was a bad mistake all along, and that has limited their room for manoeuvre. The industry wants a fiscal incentive for EVs, which could either be an upfront discount if you buy one or a VAT reduction on purchases and charging, to stimulate demand,” Bailey says. Demand for vehicles aside, car production volumes are also lower because factories spend millions of pounds and months retooling their lines for EV manufacture, affecting their ability to produce. Internalisation of component manufacturing Some tier one and smaller suppliers to UK automotive have gone, due partly to the complications and costs of Brexit. GKN Automotive moved its Birmingham factory capacity to Poland in 2021/2022. A lot of smaller companies have been cut out of European supply chains post-Brexit, and several auto suppliers have struggled or gone out of business, unable to cope with the export and reimport bureaucracy when some components may cross the English Channel several times before being assembled here. In addition, several big carmakers are internalising the manufacture of key components as these companies aim to be more vertically integrated. “Partly, this is in reaction to the semiconductor crisis where firms were caught out,” says David Bailey. “For example, Jaguar Land Rover will be making its new electric drive train in-house, probably at the i54 plant. Previously, for internal combustion engine cars, JLR would have bought the drives from GKN Driveline, but it is internalising it. We are seeing that shift broadly as well.” A good example is Nissan's partnership with battery company AESC, which supplies directly to Sunderland. This year, Nissan is expected to open a new 360m long, 23x football pitch-sized battery gigafactory in Sunderland. When operational, it will employ over 1,000 people and deliver a sixfold increase in UK electric vehicle battery production. The plant is basically an extension of Nissan's car factory, a tier-one supplier part-owned by Nissan right next door. Pay attention, subbies: Bus bonanza Deliveries of new buses, coaches and minibuses reached a 16-year high in 2024, with 8,390 new units hitting the UK's roads (total buses produced were higher due to healthy exports). Demand rose across the three main segments: minibuses, single-deckers and double-deckers, with minibuses posting 102.5% year-on-year growth. Zero emission is the main story in buses, and the UK is still Europe's biggest zero-emission bus market, with deliveries up by more than a third in 2024. As of 2023, Ballymena-based bus manufacturer Wrightbus reported a turnover of £283.4m, a significant 71% increase from £163.3m in 2022. Despite this, profits in 2023 were negative, probably reflecting the big investment in transitioning to net zero powertrains and new tooling. Wrightbus exemplifies the switch to zero emissions. “Alongside our market-leading EV bus, 95% of all buses produced by Wrightbus in Ballymena are now zero emissions – a marked change on 2019, when 95% of all orders were for diesels,” said Jean-Marc Gales, CEO of Wrightbus, when unveiling the new Streetdeck Hydroliner Gen 2.0 hydrogen-powered bus on 20 February. Wrightbus says production will increase to 1,200 this year and then again to 1,400 in 2026 – a record in the company's proud history of bus manufacture. Dozens of suppliers from across the UK and Europe visited the Wrightbus factory in February to hear how the firm's continued growth will act as a shot in the arm for the manufacturing sector, with the expected creation of up to 1,000 new supply chain jobs in the next two years. When will car making recover? Industry body The Society of Motor Manufacturers and Traders forecasts vehicle production to fall further in 2025 (cars and light vans to 839,000 units in 2025). Still, it adds that while the EV transition is affecting production, this will be temporary. While the volumes of all electrified technology cars were down 20.4% in 2023, with more than £20 billion worth of investment announced in 2023 and a further £3.5 billion in 2024 to support the UK's transition, the decline will be temporary; the SMMT stated in February. Car and light van output will increase to circa 930,000 units by 2027, it says. However, potential tariffs from the US are a real threat (second biggest UK car export market), and the lingering cost of living crisis affects EV sales. “Charging at home overnight is cheap but can be 10 times the cost at some public charging points. Plus there is 20 percent VAT at a charging point, but just five percent at home – so the one third of people who have no ability to charge at home will struggle with the transition,” says David Bailey. And while the Dept for Transport has said it is on track to install the target 300,000 charging points by 2030, many people have range and charging speed anxiety, so much more PR is needed to persuade a cash-strapped, conservative public to go electric.

Opening its doors with just four toolmakers 50 years ago, Smithstown Light Engineering Ltd is now a business with three manufacturing sites and over 165 employees. Working with the world's leading medical device and orthopaedic companies, Smithstown extensively uses OPEN MIND Technologies‘ hyperMILL CAD/CAM suite to streamline its throughput and maximise efficiency. Initially a toolmaking business supplying plastic injection moulds to the electronics industry, the Shannon-based business transitioned to medical manufacturing in 1990—and it hasn't looked back since. With two sites in Shannon spanning 80,000sq/ft and a third 15,000sq/ft facility in Poland, 75% of the company's technology is less than 5 years old. Certified to ISO: 9001, ISO:13485 and ISO:14001, Smithstown has a bank of Citizen sliding head turning centres, in-house heat treatment, Rollomatic, Jung and Jones & Shipman grinding centres, DMG MORI and Mikron machining centres, Trumpf 3D additive manufacturing and Makino EDM technology. Working with renowned clients such as Stryker, Boston Scientific, Zimmer Biomet, and Cook Medical, to name a few, the company provides a turnkey service from concept and design through prototyping, machining, and validation of medical components and orthopaedic implants. With over 14 million components manufactured annually, the Irish manufacturer adopts stringent quality measures that are a necessity for ultra-precision medical device parts used in life-saving surgery. Alluding to his role within the company and a background in Smithstown Engineering, Gerard Henn from Smithstown Light Engineering says: “I've been here now nearly three years in the role of CEO, and I support the principal director of the business in the running of the operation. Smithtown started in 1974, so we are now 50 years in existence. Our principal area of expertise is precision machining to impeccable quality levels with customer service. We really pride ourselves in supporting the customer in all their difficulties and all their successes.” Manufacturing high precision parts to stringent standards, Gerard alludes to why the County Clare company opted for hyperMILL from OPEN MIND Technologies: “There are so many different options in the marketplace, but OPEN MIND made it much easier for us to work forward with hyperMILL. The explanation of the facets, the features, and how we could optimise our machining strategies and cutting paths – it has everything. That worked in our favour. The relationship with OPEN MIND and its hyperMILL system came together and created a partnership with us.” When Gerard joined the company, one of his aims was to upskill the staff, which was a critical necessity considering the shortage of skilled engineers. Alluding to this, Gerard adds: “OPEN MIND were very enthusiastic and got behind us. They understood what we were trying to achieve, and it's been a positive relationship all the way through. We'd recommend OPEN MIND to any companies out there who are interested in upskilling their internal workforce – the partnership has been extremely positive.“ Looking closer at the types of work the company is involved in, Gerard continues: “We operate in the medical space, and we support the orthopaedic and medical device companies in Ireland and also globally. We also do instrumentation for procedures, so it's very much a medical-focused enterprise.” Occupying a large floor area and two facilities, the company is continually evolving. Gerard adds: “So, we have over 200 employees and two sites here in Shannon. The second site is just literally 1 kilometre down the road, so you find us trekking up and down quite a bit, but you see the same technologies and approach in both buildings. We have a third facility in Rzeszów, Poland, a business that's been operating for 3 to 4 years. We also recently announced a major expansion there.“ “What we find in any process development is you're going through an iterative process. You're optimising the machining and cutting process, checking dimensions back to the machine to the virtual CAD station, and bringing all that together. So, I think the fact that OPEN MIND has supported us so much means we have a great understanding of hyperMILL. The upskilling is well in parallel and enables us to bring all the strands together to succeed. By success, I mean that we can deliver parts to specification earlier. That is because that's what everyone wants. Customers want parts in their hands, and having that collaboration of everyone allows us to achieve that.”

Michael Phillips, joint owner with partner Wayne Robins of contract machining firm Atomic Precision, describes their recently purchased, Japanese-built Brother Speedio U500Xd1 as ‘a Swiss army knife of 5-axis machining centres.' His comment is due to the 30-taper machine's high quality, versatile functionality, compactness, and ability to complete an extensive range of jobs quickly and efficiently. Brother machines are sold and serviced in the UK and Ireland by Whitehouse Machine Tools, Kenilworth. Founded in East Hendred, Oxfordshire, in 2020 by the two time-served mechanical engineering apprentices, who both previously worked in the machine shop at nearby Rutherford Appleton Laboratory's space development facility, Atomic Precision specialises unsurprisingly in manufacturing components and assemblies for the space and scientific research sectors. Over the next four years, a succession of 40-taper VMCs from another supplier arrived on the shop floor: three 3-axis models and two 5-axis machines. During that time, the subcontractor enjoyed an impressive growth rate of 50% yearly. It was clear to the two partners, who work alone that the ongoing rate of growth was unsustainable without progression on the shop floor to more efficient machine tools and perhaps also automation to gain substantial periods of unattended production. They operate a single-day shift, and working longer hours is not part of their game plan. As a first step to raising productivity, Whitehouse Machine Tools installed and commissioned the high-speed Brother U500Xd1 in September 2024. The partners learned of the machine at the Southern Manufacturing exhibition in Farnborough in early 2023. The order was placed after early hesitation regarding the smaller spindle interface, which later proved to be a non-issue and benchmarking a couple of other 30-taper machines on the market. Mr Phillips commented: “The area taken up on our shop floor by the U500Xd1 is half of the space that one of our 40-taper 5-axis machines occupies, yet the 30-taper VMC produces larger parts. Not only that, but the Speedio finishes an identical component in two-thirds of the time, as the non-cutting elements of cycles are incredibly short, so tools are in-cut for typically 90% of the time during a cycle.” “The linear axes accelerate at 2.2 g up to 56m/min, and chip-to-chip time is 1.3 seconds. Rotary positioning by the trunnion and table is similarly fast, and parts come off complete, resulting in rapid floor-to-floor times.” The machine installed in East Hendred is a well-specified version of the Speedio model, with a 16,000rpm 15kW spindle, 28-position tool turret, high-pressure coolant, and Blum tool and part probing. Axis strokes are 500 by 400 by 300mm, but multi-face machining of components up to 500mm in diameter by 270mm high and weighing up to 100kg is possible owing to the layout of the machining area. As well as producing parts up to the maximum working envelope, the Speedio also machines tiny components requiring complex features cut with a 0.2 mm diameter end mill, hence the decision to opt for the highest speed spindle Brother offers. Towers are extensively used for fixturing multiple smaller parts to extend the walk-away time from the machine if individual cycle times are short. Batch size is usually up to 10-off, although often single prototypes are machined. However, in November 2024, Atomic Precision received a huge order from a new customer for 400-off aluminium brackets requiring a 3+2 machining strategy, using the rotary axes to position the part. The subcontractor could not have accepted the contract if it had been unable to use the elevated speed of the Brother machine. A 5-axis, 40-taper VMC would have been too slow to meet the three-week lead time, so the subcontractor would have had to turn down the work. If more jobs involving quantities of several hundred starts coming in, automating the Brother and other VMCs on-site will go ahead imminently. The factory processes various materials, including aluminium, stainless steel, brass, copper, tungsten, and tantalum. Mr Phillips advises that it is possible to hold ± 10 micron dimensional tolerance ‘comfortably' on the Speedio, even without climate control in the factory.

Engines were already being built at the site in Zafra in 1875, where DEUTZ today has its main factory for processing engine components. Around 500 employees in modern manufacturing facilities produce engine blocks, cylinder blocks, connecting rods, and gears for the Group's assembly lines in Cologne and Ulm. DEUTZ's new 3.9-litre diesel engine is mostly used in agricultural and construction machines. It is designed for long service life as an industrial engine and will be built until at least 2035. Series production will start in the coming year after the current prototype phase. Available in a power range from 55 to 160kW, this engine represents an important future project for Deutz with 50,000 units to be produced per year. It is the same size as its 3.6-litre predecessor, so it can be installed in the same vehicles, providing very efficient performance. “Our engines are typically deployed in off-highway applications like agricultural and construction machines, which are in constant use and move heavy loads. We'll continue to need an internal combustion engine to move those machines. For now, it will be in the form we use today: the diesel engine. Synthetic fuels or hydrogen can considerably prolong their deployment,” explains Alejandro Castilla De La Hoya, Zafra Plant Manager. He points out that the income from this area finances DEUTZ's investments in the green segment, which is dedicated to the transformation of mobility. The 3.9-litre diesel engine is already set to run on gas or hydrogen in the future. “Based on today's design, this diesel engine can become a green engine in the long run,” says Manuel Rodríguez López, Industrialisation Manager. This is possible thanks to small modifications, particularly to the cylinder head. However, the engine remains mostly the same. MAPAL is already collaborating on DEUTZ's first hydrogen engine – a huge 7.8 litres. Two weeks from design freeze to offer “Our clients' development periods for new parts are becoming shorter and shorter,” explains Thomas Spang, Global Head of Tool Management at MAPAL. This represents a growing challenge for tool manufacturers or complete suppliers like MAPAL. This is true if plans change at the last minute while the deadline for the tool design remains the same. For the engine block of the new 3.9-litre diesel engine, MAPAL only had two weeks after the design freeze to complete a final offer. An ardent team of experts in Aalen completed this ambitious task on time. Well-tuned workflows and many years of experience with the client's production methods proved advantageous for the team. MAPAL has been conducting tool management for DEUTZ in Spain for 18 years and several projects have been completed together over the years. MAPAL already engineered the machining of the engine blocks for the predecessor 3.6-litre diesel engine, which meant they could draw on practical experience and didn't have to start from scratch. For example, the tool experts already knew which machines the engine manufacturer had from previous projects. DEUTZ has equipped its assembly line in Zafra with new 5-axis machines over recent years so that they can easily switch to new products. When DEUTZ sent their request, the Tool Management department, in collaboration with the Technology Expert Team (TET) in Aalen, first gave some thought to the production process. “To be quick here, we don't concern ourselves with detail at this early stage, but instead pull together reference tools and concepts from previously completed projects,” explains Harald Traub from TET. As a project engineer, he is responsible for planning the entire process. “In this way, we can specify an approximate budget and the rough scope of the tool package for the client.” One hundred different tools for an engine block After this rough planning, the concrete tool design followed in the second week. In the end, MAPAL's offer for the series production of the motor block included almost 100 different tools. Many custom tools achieve short machining times and, thus, high economic efficiency. Aside from these, standard tools are used mainly for milling. A few close-to-standard tools were also used to produce prototypes quickly. Series production can then begin with the optimal set of tools. As part of their original delivery, MAPAL supplied consumable tools as well as the required tool holders and adapters to DEUTZ. All other consumables will be handled by the tool management on-site. From now on, the client no longer pays per tool but per completed part—i.e., the cost per part is billed. The unit costs at first correspond to the price determined during engineering. Certain ratios have been agreed upon for the following years. The client receives an increasing rebate percentage and pays a bit less per unit every year. For this business model to work out, MAPAL has to implement continual improvements to save costs. This is done with new tool technologies and corresponding optimisation. The costs per part are fixed over the contract term, after which a reassessment occurs. Such contracts run over four to five years and offer the client planning security. “With our engineering expertise, we support DEUTZ beyond the tool-setting area and cultivate a close partnership,” Spang highlights. After helping to build the prototype, it is the tool management's turn to shine on-site during series production. DEUTZ uses approximately 1,300 different tools in total. Thousands of tools are available from stock and must be managed in Zafra. To keep inventory optimal, MAPAL uses its warehouse management systems and digital solutions with the cloud-based software c-Com for tool management. The Digital Tool Management 4.0 doesn't only handle procurement processes, which are initiated semi-automatically; it also acts as a reporting tool to analyse cost drivers and stocks. Industrialisation Manager Manuel Rodríguez López praises the good collaboration with MAPAL regarding tool management: “Over the course of our cooperation, we have developed extensive technological concepts, which go far beyond mere logistics. Besides achieving cost reductions, tool setting is particularly important for us. The MAPAL employees working on-site have much know-how and ensure that production has exactly the tool they need at the right time.” MAPAL's tool manager on site is David Castaño. MAPAL also employs tool setters permanently in Zafra. They make sure that a dozen different parts are produced without a hitch. “It is very beneficial to have David here on-site with us,” emphasises Manuel Padilla Fernández, Manufacturing Engineering Manager at DEUTZ. “We can talk about any opportunities for optimisation directly at the machine. We don't consider David Castaño an external service provider but a part of our team. It's a very strong cooperation.” Developing together to solve problems If required, new tool solutions can be developed in Aalen via the local MAPAL team. That was the case in Zafra when it became necessary to optimise the tools for machining the bore in the crankshaft and camshaft. A new machining concept from MAPAL with the HPR400 reamer was implemented in cooperation with DEUTZ. David Castaño is convinced of its advantages: “The tool life of the previous tool was 350 units, and resetting was required every 100 units. With the HPR400, we achieve a tool life of 1,000 parts without resetting. The resulting machining quality is exceptionally go

Mills CNC has recently supplied Ayrshire Precision, a subcontract specialist based in Ayrshire, with two new SYNERGi systems. The systems, both derivations and highly customised versions of Mills' standard SYNERGi ‘SPRINT' solutions, were installed at Ayrshire Precision's 14,000sq/ft site. In 2023, the first system was retrofitted to a Puma 2600SY lathe, and six months later, the second was retrofitted to a Puma 2100SY. SYNERGi Sprint automation systems are compact, flexible, and cost-effective. Mills' dedicated automation experts can integrate them with DN Solutions' lathes, machining centres, and mill-turn machines to create high-productivity automated manufacturing cells. The essential elements of a SYNERGi Sprint system comprise an industrial FANUC robot with varying payloads and reaches, a two- or three-jaw pneumatic gripper, a 900 by 900mm part loading/unloading grid plate, and industrial safety guarding positioned around the system. Mills can also supply customers with multi-socket inserts to optimise each system's capacity. These are sheet metal fabrications that customers can also choose to manufacture for themselves. Ayrshire Precision serves customers in the oil and gas, subsea, renewables, power generation, and aerospace sectors. It has a well-resourced machine shop and regularly invests in its people, plant and equipment, processes, and systems as part of its ongoing continuous improvement programme. Since 2012, Ayrshire Precision has invested in various Doosan machines, from two-axis and multi-tasking lathes to large-capacity, heavy-duty vertical machining centres and horizontal borers. “We rely on machine tools from Mills. They are powerful, fast and accurate and enable us to meet the highly-regulated, tight-tied up tolerances and exacting surface finishes that characterise a majority of the components we machine,” says Chris Hepburn, Ayrshire Precision's Managing Director. Ayrshire Precision's decision to invest in automation was made for several reasons. The volatility of the markets served by the company and, as a consequence, fluctuating customer demand for the company's machining services, combined with difficulty recruiting and retaining skilled labour, all contributed to Ayrshire Precision's decision to ‘think outside the box' and begin its automation journey. “It's either feast or famine in the markets where we operate. We can either be swamped or, due largely to external macro-economic factors that impact our customers' business, can experience order cancellations and/or postponements that make it difficult to match our production capabilities and resources with changing customer requirements,” explains Chris Hepburn. Rather than be at the mercy of market forces and to protect the company's long-term viability and profitability, Ayrshire Precision decided in 2020 to explore new ways to improve its flexibility, performance, and competitiveness. The company's focus was initially on its small part-turning operation, which, at that time, comprised two Puma lathes, running over two shifts and operated by four staff members. To increase the productivity of its Puma lathes, the company had previously considered integrating a bar feeder into each machine. However, the diameters of the machined drop forged parts, the batch sizes required, and the limited diameter capacity of the bar feeders prevented this approach. Ayrshire Precision discussed its requirements with several automation system suppliers, focusing on the proposed system's configuration, availability, and cost. As part of its decision-making process, Ayrshire Precision visited Mills CNC, which had previously supplied it with eight Doosan machines. After discussing its plans further with Mills' automation application specialists and seeing a couple of different SYNERGi systems in action at Mills' Technology Campus facility in Leamington, it was confirmed that two separate SYNERGi Sprint systems would better meet Ayrshire Precision's manufacturing requirements. “We liked the design and build of the SYNERGi Sprint system,” remembers Chris Hepburn. “It was simple.” “We asked Mills to put forward their plans and proposals for two SYNERGi Sprint cells – one incorporating our existing Puma 2600SY for larger parts, and the second incorporating our Puma 2100SY for smaller components.” Says Chris Hepburn: “Mills' approach was responsive and helpful. They worked with us to tailor-make the SYNERGI Sprint systems and offered useful advice. We placed the business with Mills, not just because of their technical and automation expertise, but also because they had originally supplied the two Puma lathes and knew the machines inside out. We also thought that dealing with one supplier for our machine tool and automation system requirements would be easier and would simplify communications, servicing, training, etc.” Ayrshire Precision's first manufacturing cell was installed in March 2023. The cell comprises a Puma 2600SY multi-tasking lathe and a FANUC 35kg industrial robot with dual Schunk 3-jaw grippers. Other elements include Renishaw probing systems, safety caging, and the system's HMI control driven by Mills' proprietary SYNERGi software. With individual part cycle times of approximately 10 minutes, Ayrshire Precision is now benefiting from up to an additional 16 hours of unmanned operation of its Puma 2600SY lathe. Since installation, the company has manufactured different sheet metal pocket inserts to accommodate larger parts and different batch volumes. Ayrshire Precision's second SYNERGi cell was installed in September 2023. This cell incorporates the Puma 2100SY lathe, a 20kg payload industrial robot and a 900 by 900mm table for processing smaller components. The automation process for both cells involves the robot picking up a workpiece from the grid plate in a programmed sequence and, using the lathes' auto door opening facility, loading the part into the machine's main spindle. The door closes to enable the machining of the part's front end. After all machining operations are finished, the robot picks up the next sequenced workpiece from the table and, in one continuous movement, loads it into the main spindle. Then, it removes the finished part from the sub-spindle and returns it to its designated position on the table. Says Chris Hepburn: “Every time the auto door opens, a completed part is removed from the sub-spindle and a new part is loaded into the main spindle. The process is fast, seamless and continuous. Furthermore, one staff member can operate both cells simultaneously.” With less labour intervention required, Ayrshire Precision's small part turning operation is now more efficient and profitable. Creating its two cells has also helped free up a couple of its operators, enabling them to be deployed to other machine shop areas. Chris Hepburn concludes: “The investment in our two SYNERGi cells is paying dividends. We have two inherently flexible automated cells that have not only helped us future-proof our small-turned-part operations but have also increased our overall capacity. Although there was initially some anxiety concerning our move towards automated production, the results exceeded our expectations.”

In the aerospace industry, compliance is not just a requirement, but a culture. Senior Aerospace Weston places significant importance on workplace standards—which is why it has installed more than 50 Filtermist oil mist filters. Working primarily with OEMs like Rolls-Royce, Airbus, MTU Engines, Spirit Aerosystems, and many other prestigious clients, Senior Aerospace Weston manufactures a variety of aerofoil and aerostructure components for various platforms in the commercial aviation market. Founded in 1937 and acquired by Senior plc in 2011, the Earby-based manufacturer is now part of an FTSE 250-listed group with over 6,800 employees in 12 countries. As part of a global group in the top echelons of aerospace manufacturing with 3 to 5-axis machining and grinding, CAD/CAM, assembly, NDT, surface treatment, robotic polishing, and much more – achieving standards is critical. Gary Bell from Senior Aerospace Weston says: “Here at Senior Airspace Weston, we believe in maintaining good, orderly, clean standards, housekeeping, and a good working environment. A clean working environment is essential to ensure that we produce our high-specification components.” Providing more detail on the machine shop, Gary adds, “We make a variety of aerospace components for different aircraft programmes and work with a range of materials. This is predominantly aluminium, but we also work with titanium, bronze, nimonic, inconel and steel. We have lots of different types of CNC machining centres with 3, 4, and 5-axis machines. Each machine is specified to manufacture certain types of components, and this is why we have such a wide variety.” With Filtermist extraction units, including the FX6002 and FX7002 on 58 of the company's machine tools, it is imperative that oil mist is extracted from the machines. As Gary adds: “The type of high-speed machining that we undertake produces oil mist that needs removing from the working environment. Our first thought was to look at the industry-leading standards, and Filtermist was the name that first came up. We engaged with them straight away, and they were extremely helpful in giving us some advice and support. They were able to come on-site and carry out a free survey so that they were able to specify exactly what equipment would be available to support our needs.” With machine tools from leading manufacturers such as Matsuura, DN Solutions via Mills CNC, Grob and Hermle among others on-site, Gary continues: “In total, we have 58 Filtermist extraction units. Some machines require multiple Filtermist units to be installed to ensure the volume is extracted quickly and efficiently. We have a huge variety of machines, and the Filtermist units are flexible enough to accommodate the different types, sizes and requirements of those machines. We have machines that are large in scale, so we needed something that was able to extract from all those different types of scenarios effectively.” Discussing the maintenance requirements and the ongoing relationship with Filtermist, Gary says: “The beauty of the Filtermist system is it's easily serviceable, so we can specify whether the Filtermist units are standalone or mounted to the equipment. They are easily accessible for the service engineers to come in and replace any components effectively and quickly. The Filtermist units are fitted with F monitors, which are a really easy-to-use system. The operators can see at a glance using the traffic light system whether there are any issues with the effectiveness of the extraction.” Using the globally recognised ‘traffic light' system of coloured warning lights to alert machine operators when the unit needs servicing, the F Monitor measures velocity pressure to check the airflow through the Filtermist oil mist collector is correct. The Bluetooth-enabled F Monitor 2 measures airflow and time, and the F Monitor 2+ also monitors vibration and motor temperature - making it even easier to identify when the Filtermist unit needs servicing. For existing customers, the F Monitors

Manufacturers could only drill on inclined or curved surfaces with pre-chamfering using a milling cutter in the past. Those days are now behind us and you only need one tool - the newly developed WTX Micropilot from CERATIZIT. It can even pull off 90° countersinks at the bore entry in a single operation —saving tool changes, cycle time and costs. Micro machining has rules and practices that are different to everyday machining. Simply put, what works well with standard tool dimensions does not necessarily hold true with small diameters. “To this end, we have revised our micro drilling program and developed a genuine time saver. The WTX - Micropilot is small in stature, but big in performance. Perfectly matched to our WTX - Micro micro drill from 8xD to 30xD, the pilot drill is used at drilling depths of up to 2.5xD,” says Manuel Keller, Product Manager at CERATIZIT. When faults occur in complex, micro-sized components, they quickly end up dumped in the recycling can. The truth is that a number of things can go wrong. Drills can run off, drill holes get crooked or tools break—including damage to the workpiece itself. “Efficient machining of small components presents its own set of challenges,” says Manuel Keller. “Our customers want process reliability, the shortest possible machining times and demand extremely high-quality standards. Fortunately, our WTX - Micro series is up to the task.” Thanks to its ingenious face geometry with a 160°-point angle, the tool ensures the follow-up drill can plunge in cleanly and without running. And with the special Dragonskin coating, clean chip removal and a longer tool life are guaranteed. The WTX - Micropilot is developed from the latest technologies from the substrate to the geometry to the coating. It is also perfectly designed to work together with its ‘best buddy' WTX – Micro. This drill duo can handle the most common as well as the most demanding tasks. “One special feature of the WTX – Micropilot is that it circumvents the usual mirroring required if drilling inclined and curved surfaces with an inclination of up to 50. This eliminates one processing step, saving time and tool changes. When piloting on straight surfaces, a 90° countersink at the bore entry is also possible,” reveals Manuel Keller. What all WTX micro drills have in common is their special pointing. This maximises positioning accuracy and excellent centring properties. Their lapped surfaces and the patented chip space grinding also guarantee safe and fast chip removal. Additionally, the spiral internal cooling channels of the WTX Micro drill have been optimised to ensure maximum flow of cooling lubricant, which, in turn, secures improved surface quality of the holes. Among other things, this is thanks to a power chamber, which is fitted to the micro drills from 5xD over the entire shank length, which increases the amount of coolant at the tip while maintaining uniform pressure—thus improving tool life. Made for maximum precision With its micro-tool portfolio, CERATIZIT covers most micro-machining applications with high-quality solutions. “This also applies to the WTX - Micro product range, including the new WTX - Micropilot, which makes the impossible possible. On both inclined or curved surfaces with an inclination of up to 50°, there is no need for prior mirroring. And if 90° countersinks are required at the bore entry point on straight surfaces, WTX - Micropilot can easily handle the task in a single operation, saving tool changes, time and costs—without sacrificing quality,” says Manuel Keller.

Milling is a fundamental process that shapes everything from complex aerospace components to critical automotive parts. But despite its ubiquity, successful milling hinges on some careful considerations. How can manufacturers consistently achieve high accuracy, impeccable surface finishes, and cost-effective results? Barry Cahoon, Product Solution Specialist Rotating Indexable—Europe at Sandvik Coromant, offers his advice. Achieving optimal milling results necessitates selecting cutting tools specifically engineered to meet precise machining requirements. This must consider factors such as cutting geometry, material hardness, and machining strategies. Whether the task involves high-precision shoulder milling, high-speed face milling, or complex multi-axis contouring, the tool's performance directly influences the efficiency and accuracy of the entire process. What defines successful milling? Precision is paramount for any milling operation to be considered successful. Achieving tight dimensional tolerances and geometric accuracy is essential. Surface finish is another critical factor. A smooth, clean finish is not just an aesthetic requirement but often a functional one. In industries such as aerospace, where components such as turbine blades or compressor casings must meet stringent performance standards, even slight deviations in surface quality can lead to major problems. Efficiency also comes into play. Milling processes need to maximise material removal rates while keeping machining time to a minimum, all without compromising quality. Then there's the question of tool life. Manufacturers constantly seek ways to extend tool life, reduce tool changes, minimise downtime, and ultimately cut costs. However, tool life is closely linked to chip control and cutting forces. Poor chip evacuation or excessive force can cause rapid tool wear, reducing efficiency and producing suboptimal results. Tool selection With so many variables, selecting the right tool is often the biggest challenge. Different operations — such as shoulder, face, or high-feed milling — demand tools with specific geometries and cutting capabilities. Accuracy and precision are the foundation of every milling process. From creating flat surfaces to machining 90-degree shoulders or complex contours, precision is non-negotiable. Proper tool path control, optimised cutting parameters, and stable machine dynamics are all essential to ensure that dimensional tolerances are met. Thanks to their true 90-degree shoulder capability, tools like CoroMill® MS60 deliver reliable performance, particularly for shoulder milling. Efficiency and cost-effectiveness are key considerations in any manufacturing environment. Time saved on machining processes translates directly to reduced costs, making it essential to minimise cycle times without sacrificing quality. In this regard, CoroMill® MH20, specifically designed for lightweight milling, offers excellent performance in operations where high-speed material removal is required. Its insert design reduces cutting forces, allowing for faster feed rates while maintaining tool stability, particularly in deep cavity and pocketing applications. This increases machining speed and extends tool life, reducing the need for frequent tool changes and lowering overall production costs. Chip control and cutting forces are often underestimated but profoundly impact the milling process. Efficient chip evacuation prevents heat buildup and ensures a clean cut, especially in applications involving deep cavities or pockets. Insufficient chip control can cause chips to re-cut, leading to poor surface finish and faster tool wear. Modern tool geometries are designed to optimise chip flow, reducing the risk of clogging and improving overall tool longevity. CoroMill® MF80 offers smooth chip flow and minimal cutting forces, making it highly reliable for roughing and finishing operations. Its ability to handle various materials and machining conditions enhances versatility and productivity across multiple applications. Finally, precision and reliability are non-negotiable when selecting tools for demanding materials such as ISO M and ISO S. CoroMill® MS20, Sandvik Coromant's new 90-degree shoulder milling solution, delivers exceptional edge-line security and dimensional accuracy. This ensures high productivity and consistent results, even in challenging aerospace and oil and gas applications. Successful milling hinges on a deep understanding of the interplay between tool design, material properties and machining parameters. By carefully selecting tools that are purpose-built for the task at hand — whether that's shoulder milling with high precision or high-speed face milling for rapid material removal —manufacturers can achieve their goals of improved productivity, lower costs and exceptional part quality. The balance between accuracy, efficiency, tool life and chip control ultimately defines a successful milling operation.

On the 27th and 28th of November, Hexagon Manufacturing Intelligence invited MTD magazine to the official opening of its new Experience Centre in Holland. Located at the Brainport Industries Campus in the Northwest of Eindhoven, the two-day event was an opportunity to tour the new campus and participate in insightful presentations that demonstrated how Hexagon is driving innovation and, as a result, developing successful industrial partnerships. Eindhoven is responsible for the Philishave, the automatic gearbox, the cassette tape and the compact disc. To foster this culture of innovation for future generations, the Dutch government funded the Brainport Industries Campus, which broke ground in 2017. At around 100,000sq/m, the innovation centre is virtually fully subscribed, and that is why construction of a 225,000sq/m phase two on the 17-hectare site will commence this year. With dozens of high-tech businesses collaborating at the campus, Hexagon is alongside cutting-edge companies with brands like Siemens and Meta (Facebook), just a few located at the facility. MTD magazine attended and the itinerary for the innovation extravaganza promised an exciting lineup. The event started with a welcome from Jan Klingen, Vice President EMEA North, and Eric Veurink, Brainport Industries Campus Director, and a facility tour. As expected with a Hexagon LIVE event, the breadth and depth of technology and insights were so expansive that delegates could choose the most relevant content for their business. Exemplifying this was one of the first panel discussions on the ‘Future of Mobility in Aerospace and Automotive', hosted by Hexagon Senior Director for Industry Solutions, Johannes Mann, who was joined by speakers Rob van Loon, Additive Manufacturing Manager at KMWE and Thom Grobben, the Vice President of the Technology Hub at KLM Royal Dutch Airlines. The discussion flowed through the challenges of accelerating innovation and agility in the automotive sector to deliver the next generation of smart, connected vehicles. This conversation then moved on to the aerospace industry's challenges in redefining aircraft architecture and propulsion systems to become more sustainable. Other prominent seminars discussed ‘The challenges in production and collaboration', ‘Extending asset lifecycles and improving productivity with HxGN EAM', ‘Surfing the future now' and ‘Innovation beyond silos: Transforming Manufacturing through connectivity, collaboration, and Cloud/AI'. There was a lot more on show, with panel discussions, presentations, workshops and roundtable debates encompassing every industry sector. Nowhere was this more prominent than in Morgan Maia's presentation, the Partnership Manager at Oracle Red Bull Racing. Hexagon has partnered with the F1 team since its inception. Flying in from the F1 Teams' weekend win in Las Vegas, Morgan discussed how Hexagon supports the team in streamlining performance by ensuring compliance with FIA regulations, precision manufacturing, and ensuring the team ‘gets it right first time'. More than just a soundbite, Mike Hughes, Head of Quality Assurance and Manufacturing Engineering at Oracle Red Bull Racing, qualified the support of Hexagon with a statement: “With Hexagon's help, we've managed to reduce our faults by 50% over the last two years.” Morgan's presentation alluded to how Hexagon is involved throughout the process chain, from 3D CAD modelling and CFD simulations in the virtual wind tunnel to simulation and physical wind tunnel testing. With over one million components handled throughout the season, Oracle Red Bull Racing combines exceptional hardware with efficient software and digital twins to deliver rapid inspection rates. The team has four QA departments encompassing mechanical, external, composites, and race support. They all utilise Hexagon tools, from CAM software to 3D scanners, laser trackers, portable measuring arms and CMMs. The Leica AT960 scanner is a core element of the trackside equipment that improves accuracy and holistic measurement. Its custom orientation enables measurement from different perspectives. For legality checks, Oracle Red Bull Racing uses the AS1 scanner to scan the floor, front, and rear wings to extract key points of the car for performance set-up. With the arrival of Red Bull's first road car, the RB17, and the opening of its 5,000sq/ft powertrain manufacturing site in Milton Keynes, Red Bull's number of components produced is set to expand significantly, as will its relationship with Hexagon. The F1 car continually undergoes design cycles that follow the same structured path. With up to 100 projects in-cycle at any time, around 1,000 design cycles are completed yearly. It starts with developing a 3D CAD model and the subsequent digital twin, which is the foundation block for everything that comes after. With CFD, prototypes and a whole raft of processes before the team gets to a finished car, Morgan said: “When you work on a car in the factory and then take it to the track, if there is an issue in manufacturing – it's too late to do anything about it. We must be sure the car is 100% correct before shipping it. That is why we need Hexagon: to ensure that everything leaving the factory is perfect for when it arrives at the track. We have thousands of parts that need to fit together perfectly. We work to the micron. It's precision you would see in a high-end watch – but not typically in a 5m long vehicle.” A presentation on Hexagon's Nexus suite by Stephen Graham, Executive Vice President and GM of Nexus at Hexagon, followed this. Stephen explained: “Nexus is our cloud-based manufacturing platform. We initially conceived it to solve an internal problem. We have acquired over 150 companies in more than 25 years, which has helped us build this portfolio of technologies throughout the product life-cycle. Our challenge is a large portfolio of technology solutions that were never really intended to work together. We wanted to offer our customers a solution to join the dots and bring the next level of value with the technologies all being under one roof. Nexus was conceived to solve this problem of connectivity. As soon as we took the proposition to our customers, we found they had the same problem. Over decades, they had purchased different technologies to solve different problems.” “Nexus directly solves that problem, and what we have found in the last few months is an ability to connect to different technologies from different vendors - it doesn't just have to be Hexagon products. Since starting development, we have found that businesses are structured very hierarchically, with different disciplines arranged in different silos. The whole thing is very process-driven, and as we try to push the boundaries of manufacturing, this becomes a barrier to succeeding. The need to drive collaboration horizontally across an organisation is coming to the fore as a challenge that needs to be faced.” To demonstrate this, Stephen provided a slide show showing a reverse-engineered workflow using 10 products from Hexagon that facilitate different elements of a product's lifecycle. The demonstration alluded to new cloud-native apps, technologies and solutions connected to products in the portfolio for decades, such as PC-DMIS. Nexus creates an end-to-end solution that connects the dots. Stephen added: “Once these collaborative workflows have been strung together, engineers can work collaboratively. This provides the opportunity to bring automated and AI technologies into the workflow as automated collaborators in the workflow. A great example of this is ProPlanAI, which we just launched. This large NAPA language model provides precise engineering answers for CAM engineers who may be programming CNC machines. It automatically collates data and generates a G-Code to drive machines on the shop floor. This gives engineers superpowers to drive productivity to the next level.” Hexagon claims that ProPlan AI cuts the time to program machine tools by 75%. The new AI technology enables machine shops to achieve operational excellence at scale, powered by Microsoft Azure services built into Hexagon's cloud-based Nexus connectivity platform. Available in Q1 2025, ProPlanAI will ‘learn' from the data created by a company's CAM programmers. This will enable manufacturers to automatically explore existing programming information to predict ideal outcomes tailored to a company's preferences, production capabilities, and needs. ProPlanAI will continuously learn and adapt, ensuring programs are as efficient and productive as possible. ProPlanAI can be trained with a company's institutional knowledge to ensure machines can be quickly and efficiently programmed to their quality standards. Additionally, a Hexagon Copilot provides suggested pathways to advise on best practices without leaving their CAM software. The innovation has been developed in collaboration with Microsoft, and Ygal Levy, the EMEA Manufacturing Managing Director at Microsoft, discussed the company's strategic partnership with Hexagon in greater detail during an afternoon presentation on the ‘Transformation of manufacturing through Connectivity, Collaboration and Cloud/AI'. Clare Barclay, President of Enterprise and Industry at Microsoft EMEA, said: “Microsoft's collaboration with Hexagon is driven by a shared belief that we can transform manufacturing productivity. It's rewarding for us to see how the AI capabilities provided by Azure are empowering CNC programmers with productivity-boosting automation while helping new users upskill faster. This is exactly the sort of transformation AI can bring to the industry, and we are excited to see Hexagon apply its manufacturing expertise to transform workplace productivity.” Verifying the Solution Just over a year ago, MTD magazine visited RODIN Machining. A few miles north of Amsterdam, the start-up company set out to develop an autonomous factory. Incorporating FASTEMS automation, robot-loaded Mazak machines, and integrated innovations that made the mind boggle, RODIN has been a beta-test customer, putting ProPlanAI through its paces before market introduction. Paul Mooij, Director of Digital at RODIN Machining, said: “Machine tool programming is complicated to automate and requires experience. ProPlanAI is exciting because we can leverage our human capital for greater machine utilisation. Our team can program machines in a fraction of the time by applying their valued skills in supervising ProPlanAI suggestions and finalising the programme specifics.”  Paul added: “We have built an autonomous factory but are limited by the engineering input we can put into it. This boils down to a race for talent, and we all know it isn't easy to get good people. We have been working with Hexagon on the development of ProPlanAI, looking at how can we fill it with our data and train it with our models, our machines, tools and our way of working - providing a suggestion of how the model thinks our way of working should be. We can then position our engineer to supervise and undertake ‘prompt engineering'. ProPlanAI is very powerful and provides the right context for the features, model, machines, and tooling available. Using the given context, it then decides, ‘I think you should use these processes for this machining operation''.” “This has become powerful, and we are progressing rapidly to make big savings. We are leveraging our human capital to achieve more by using AI to provide suggestions. Then, our engineers decide whether to accept the suggestion and proceed or refine the process. For example, we may have a 2D PDF drawing that needs to meet specific tolerances, and ProPlanAI may not know this – and this is the experience we can add to the system. It's been a fantastic collaboration, and the system continually evolves.” Discussing the current situation, Paul told MTD magazine: “Our engineers will consider how they approach a job and create the CAM file in Esprit. We then feed our models to our developers. Over the last 18 months, we have been feeding the data to ProPlan AI, which uses our approach, machining strategies, cutting tools, machines, characteristics and experience. ProPlan AI creates suggestions for the next job and pre-populates our program, so our engineers are validating and refining the suggestions to meet our specifications. It amplifies the output of our staff.” “For example, if we have an aluminium job that needs a threaded hole with a chamfer, we would have a unique way of doing that with our machines and tools in our CAM files. Based on those patterns, the model learns our strategies and recognises the parameters for a threaded hole in aluminium, the feeds, speeds and so on.” Looking at benefits during testing, Paul adds: “It is amplifying our output and boosting our efficiency. At present, the savings are impressive. We continuously add data to our ProPlanAI suite, so the savings will cascade into ever greater efficiencies as we progress.”

Archway Engineering has invested in a drill sharpener from 1st Machine Tool Accessories, and the savings have been incredible. Danielle Toner, Production Manager at Archway, a site drilling equipment manufacturer, is overjoyed with the benefits the company has enjoyed from the new Darex XT-3000. A US-made Darex XT-3000 for repeatedly regrinding carbide and HSS drill bits to ‘as-new' condition was delivered by sole UK sales agent 1st MTA to Archway Engineering's Elland factory in July 2023. By November 2023, it had already paid for itself, as Mrs Toner had not purchased a single new carbide drill in all that time to replace broken or damaged bits. According to the work going through the factory, the saving was between £700 and £1,500 per month. Mrs Toner said: “We did not previously send drills out for resharpening, so worn bits were discarded. The cost was significant, especially for solid carbide drills. One component we regularly machine involves using a 160mm long, single-flute carbide drill, and we previously needed four of them to complete the part. If we ran out of bits, we couldn't finish the job until the next drill delivery, which delayed assembly of our products.” “Now we simply resharpen a bit four times, and we are certain that the component will be finished on time. New carbide drills cost around £165 each, so the saving is considerable and contributes to lowering the cost of production.” This example is by no means exceptional. Another job requires three new carbide drills to make two parts. In a different process, an HSS taper-shank twist drill is put through 30mm thick EN19 high-tensile steel. A TC shoe made from an S355 hot-finish stainless steel tube is drilled in up to 16 places using a split-point, single-flute carbide drill that has to be repeatedly resharpened before the component comes off completely machined. Mrs Toner explained that some bits could be resharpened a dozen times or more, depending on their length, while maintaining top quality. It takes about one minute to sharpen the point, or a little longer if necessary to grind past a chip on a cutting edge. It happens quite often due to the toughness of the materials being machined and also because of a frequent need to drill cross holes at various angles into the wall of tubular components. This tends to damage the cutting edges of a drill as it breaks through. HSS jobber drills from the assembly department are also regularly sharpened, which Mrs Toner describes as ‘a massive saving'. It requires the 220-grit diamond wheel used for sharpening carbide drills to be exchanged for a 180-grit CBN grinding wheel. The process takes about five minutes, so batches of around 20 HSS bits are set aside and resharpened simultaneously. 1st MTA demonstrated the XT-3000 in the Elland factory before Archway Engineering purchased it with an attachment to process bits up to 30mm in diameter. Left and right-hand drills can be processed, and attachments are available for sharpening step drills, countersink and spot drills, and others with a 90-degree point. Standard sizes of carbide drills used regularly by the site drilling manufacturer are 8, 10, 12 and 14mm in diameter and up to 6XD in length. However, bits from 3 to 21mm in diameter can be accommodated in normal use. It resharpens bits in a three-step process. A drill is placed in a finger chuck, and the protrusion length is set at an alignment station. Carbide fingers enter the flute to fix the rotational orientation, and the drill is tightened in that position by rotating the chuck clockwise. The grinding motor is then started, and at a second station, the drill is sharpened on both sides while clamped in the same chuck. In an optional last operation, the chuck holding the sharpened drill is presented to a third station for point splitting to shorten the chisel line and lessen the force required for drilling components. In conclusion, Mrs Toner observed: “The savings that the Darex XT-3000 brings make it an obvious investment once you realise the benefits. We wish we had done it much earlier. The sharpener paid for itself in less than six months, after which the ongoing monthly savings continue to add to the profit margin on all jobs that require drilling operations, which is most of them.” “The sales arguments that 1st MTA make are difficult to ignore. We also purchase Chick workholding products from them, which have doubled productivity on one of our machining centres, and the supplier has also provided us with a new chuck for one of our lathes.”

In the realm of cutting-edge aerospace applications, precision and performance are essential for transforming the toughest materials into high-flying components. Whether titanium alloys, nickel-based superalloys or advanced ceramics, these materials and the tools that machine them are the backbone of aerospace innovation. Kennametal's tooling solutions are designed to tackle manufacturers' challenges, helping them achieve higher precision, better surface finishes and increased productivity. Reliance on high-temperature resistant materials presents challenges. Traditional tooling doesn't stand a chance when used in this environment due to friction, deformation and other component failure. For example, engine parts made from titanium and superalloys must endure temperatures over 1,000°F. That's why high-temperature machining solutions become critical. It also means that the materials being used demand more than just tough tools; they must thrive under extreme conditions. High-Temperature Machining Goes the Distance Components powering everything from jet engines to exhaust systems are built to withstand extreme environments. Machining these components requires tools that can perform without compromising an aircraft's structural integrity. This is exactly where Kennametal excels, delivering tooling solutions that meet aerospace's toughest demands head-on. Innovative Tooling Solutions Kennametal's high-temperature machining tools are specifically engineered to tackle challenges such as high cutting forces, heat buildup, and work hardening. They use advanced coatings, precision geometries, and heat-resistant materials for efficient machining under extreme conditions. Kennametal's family of HARVI solid carbide end mills is a game-changer for machining tough aerospace materials like titanium and Inconel. HARVI™ Ultra 8X excels in airframe structural machining, while HARVI™ III is optimised for titanium applications. The HARVI I TE, with its twisted cutting edge, boosts corner stability and excels in ramping and helical interpolation. It features advanced anti-vibration and anti-friction technology. The innovative flute design with chip gashes reduces cutting forces, making chip evacuation super-efficient. Building on the success of the HARVI series, the newly launched HARVI II TE end mills feature a 5-flute design for aggressive cutting in ramping and plunging, as well as a proprietary W-flute shape for better chip evacuation and a stronger core. Overall, the HARVI tools deliver significant time and cost savings in aerospace operations, with impressive Metal Removal Rates (MMR) and tool life. Drilling composites like CFRP can effectively create fuselage, wing skins, and spoilers. Still, Kennametal's KenTIP™ FS series of drills featuring a double-angle geometry is specifically designed for composites. Additionally, Kennametal offers KenShape™ MaPACS & MaxPACS and HiPACS countersink and drill solutions. These tools are engineered to handle the challenges of drilling composites, ensuring clean cuts and minimising issues like delamination and fibre breakout. By using these advanced tools, manufacturers can achieve high-quality results while maintaining the structural integrity of their components. When it comes to precision turning, especially with tough materials, Kennametal's Beyond Evolution™ line of carbide and ceramic inserts will be effective. These inserts are built to handle the high temperatures associated with turning operations, which are common when working with hardened steels in landing gear and other components. Dealing with the hassle of frequent tool changes, especially when working on large components like wing sections, Kennametal's KM™ and KM4X™ modular quick-change tooling systems come into play. They make tool changes super quickly without losing accuracy. For tasks that need high repeatability, like wing skin assembly, it's crucial to calibrate tool holders to keep everything aligned perfectly regularly. “Aerospace manufacturers can achieve exceptional precision and productivity with our tooling solutions, ensuring every component meets our aerospace customers rigorous demands,” said Eva-Maria Weber, Manager Aerospace Business Unit CE. Overcoming Challenges in High Temp Machining In high-temp machining, precision, reliability, and speed are key and always at the forefront. Sometimes, problems arise, such as in thin-wall applications, surface finishes, and milling applications. Walking the Thin Line Thin-wall applications are often used to reduce weight without sacrificing structural integrity. Parts like fuselage skins, wing sections and other structural components rely on this technique. However, machining thin walls can be challenging due to vibration, deformation, and heat. To address these challenges, adjusting the feed rate and depth of cut can help reduce vibration before resorting to complex setups. Dampening tools at lower spindle speeds can improve stability without compromising finish quality. Kennametal's high-feed mills and coated carbide inserts can successfully machine titanium for fuselage sections, maintaining wall stability and accuracy. In relation to spar fittings, machining composite components and aluminium, which consist of thin walls, requires careful part movement and precise and rigid fixturing while managing machining around multiple pockets. Milling Applications Machining materials like titanium, Inconel, and CFRP can present obstacles due to their strength, lightweight, and resistance to high temperatures. Superalloys and hardened metals generate significant cutting forces, leading to vibration, deflection, and tool wear, especially when tight tolerances are required. Aerospace components are often complex and have 3D shapes, requiring multi-axis milling and customised tooling strategies to ensure accuracy in hard-to-reach areas. “Our advanced milling solutions are specifically designed to address unique challenges, providing efficiency and accuracy when machining high-performance materials like titanium and Inconel,” said Patrick Mesnil, District Business Manager and aerospace business leader France & Benelux. Advanced tooling coated with Diamond-Like Carbon (DLC) or PCD can improve cutting efficiency. Optimised cutting conditions, including adjusting speeds, feeds, and depths of cut, help manage heat and forces during machining. Effective cooling solutions, like high-pressure coolant, dissipate heat and prevent workpiece deformation. Multi-axis CNC machines allow for precise machining of complex 3D shapes, ensuring accuracy in hard-to-reach areas. Surface Finish When it comes to high-temp machining, achieving quality surface finishes is essential. It can be affected by factors such as tool wear, cutting speed, feed rate and the material being machined. Advanced multilayer coating technologies like TiAlN and AlTiN on their carbide tools help control the heat at the cutting edge. These coatings act as a barrier, reducing friction and heat transfer. As new aircraft standards emerge, emphasising lighter, more heat-resistant, and sustainable components, continuous innovation in tool geometries and coatings plays a critical role in advancing component development. For example, larger components, such as engine cases, require challenging process controls and careful application with tool pressure in mind. Internal and external milling operations must also consider thin walls and fine surface finish requirements when working with tough materials. Additionally, turbine disks require managing low thermal conductivity and vibration to avoid part deformation. This requires application-specific tooling to provide the required cooling capabilities and productivity. As the industry continues to explore new materials and complex geometries, advanced tooling solutions must meet emerging challenges. In high-temperature machining, where precision, reliability and speed are crucial, Kennametal's tools provide aerospace manufacturers with solutions to support the next generation of high-flying components. Designing and engineering tools that solve today's challenges and anticipate tomorrow is essential.

Milling originated in the late 18th century and quickly became one of the primary machining technologies. Nowadays, it is easier to imagine any machine shop with milling operations on the shop floor; it's an essential process in manufacturing. The increasing demands of manufacturing drive this integral part of machining technology. However, there are specific aspects that uniquely impact the advancement of milling. We are witnessing significant changes in manufacturing that will have profound consequences on the development of milling directions. These changes are driven by various factors, such as the increasing accuracy of metal forming through precision investment cutting and precision forging, the widespread adoption of 3D printing, and the growing usage of new composite and sintered materials. Furthermore, there is a need to enhance productivity in machining hard-to-cut superalloys and titanium grades, and the strong focus on electric and hybrid cars in the automotive industry contributes to these changes. In addition, advancements in multi-axis machine tools have opened new possibilities for the precise machining of complex parts and enabled the implementation of new cutting strategies to improve productivity. In modern technological processes, there is a tendency to significantly reduce the machining stock intended for milling operations while simultaneously increasing the requirements for surface finish. Therefore, the advancement in milling is driven by the need for higher productivity, precision and sustainability in milling operations. Consequently, the main developments can be characterised as follows: Fast metal removal focuses on boosting the metal removal rate (MRR) to achieve higher productivity by significantly increasing cutting speed or feed per tooth. This is achieved through techniques such as high-speed milling (HSM) and, in rough operations, high-feed milling (HFM).   Precision milling provides higher accuracy in milling operations.   The utilisation of multi-axis machining centres characterises multi-axis milling to enable complex milling operations.   Adaptive milling aims to develop intelligent systems that can adapt to changing conditions during machining.   Sustainable milling strives to reduce the environmental impact of milling operations. It involves developing eco-friendly cutting fluids, recycling and reusing materials, and using energy-efficient machine tools and milling cutters. Success in these areas relies on the synergy of several key components: machine tools, cutting tools, and CAM systems. High-speed milling necessitates machine tool technologies capable of handling exceptionally high rotational velocities and advanced cutting materials and coatings for milling tools. Simultaneously, enhancing the precision of milling operations requires milling cutters with tighter tolerances and improved control systems and linear motor drives. In the case of multi-axis milling, the breakthrough lies in effectively controlled axes movement, along with the application of appropriate cutting geometries for milling tools. On the other hand, adaptive milling incorporates innovations such as using state-of-the-art monitoring systems, high-sensitive sensors, and efficient algorithms to optimise cutting data and tool paths in real-time. Moreover, sustainability advancements require energy-efficient milling strategies that employ suitable machine tools, cutting tools, and eco-friendly coolant techniques. Indexable milling reflects the advancements that feature exchangeable cutting inserts in machining operations. a) Advanced insert materials are an ongoing process to improve the cutting materials for indexable milling inserts, including the development of advanced carbide grades, ceramics, and ultra-hard cutting materials. b) Coating technologies with continuous R&D focus on new coatings to improve wear and heat resistance while enhancing lubricity. c) Progressive cutting geometry optimises cutting geometry and chip forming topology of inserts to improve cutting action and diminish cutting forces and chip flow in milling operations. d) Effective cutting material uses an intelligent insert design to provide maximum indexable cutting edges without reducing cutting capabilities. In addition, the distinct course on smart manufacturing requires the integration of digitisation into milling operations and tools. Regarding tools, digital twins and software applications have already become a ‘must' feature of a comprehensive tool range. How can cutting tool producers rise to the challenge? Which milling tool solutions will provide the right answer to the emerging trends? Is the field of cutting tool manufacturing, often considered conservative in metalworking, capable of delivering a timely response to current demands? The recent advancements from ISCAR provide greater insights into these subjects. High-speed trochoidal milling involves following a curvilinear tool path to maintain a constant load on the cutting edge to eliminate spikes in load during material entry. This strategy is efficient for milling deep slots, pockets, and cavities. Additionally, trochoidal milling has shown excellent results when working with challenging materials such as high-temperature superalloys. The CHATTERFREE EC-E7/H7-CF is a new family of multi-flute endmills for trochoidal milling techniques. The family's geometric design includes different helix angles and variable angular pitches to improve dynamic behaviour. These endmills are available in a range of length-to-diameter ratios (Fig. 1). Machine tools allow highly productive milling of aluminium alloys at extreme spindle speeds, reaching up to 33,000rpm. To meet this challenge, ISCAR has developed 90° indexable milling cutters that accommodate large inserts for a depths of cut up to 22mm (Fig. 2). The cutters have been designed to eliminate insert radial displacement, which may occur due to the high centrifugal forces generated during very high rotational speeds. High-feed milling (HFM) has become a widely adopted method for efficiently rough machining complex and flat surfaces. ISCAR offers a comprehensive range of HFM products to meet the demands of various industrial applications. Recently, the range has been expanded with new additions. The LOGIQ-4-FEED family of HFM tools, featuring specific bone-shaped inserts (Fig. 3), now includes tools with larger inserts. These new products significantly broaden the application range, particularly in the mould and die industry's high-feed milling of large-sized cavities. Another addition is NEOFEED, a family of HFM tools with double-sided inserts, providing eight cutting edges for improved cost-effectiveness. Advancements in multi-axis machine tools and CAD/CAM systems have given rise to precise milling of complex shapes with minimal machining stock, using segment or barrel-shaped endmills. ISCAR's program for these endmills encompasses three design concepts: a solid carbide design, an exchangeable MULTI-MASTER head, and a one-insert approach (Fig. 4). When milling high-temperature superalloys, cutting ceramics can substantially increase cutting speeds, reaching 1000m/min. ISCAR's latest ceramic tools include ceramic solid endmills and indexable milling cutters with double-sided round ceramic inserts. The double-sided design aims to maximise the utilisation of ceramic material grades, such as ‘black' ceramic, whisker-reinforced ceramic, and SiAlON (a silicon-nitride-based ceramic). These selected examples serve as good illustrations of the main directions of advancement in milling tools. As new demands arise, new solutions are required, and these new challenges will fuel the search for innovative tool designs.

ARNO believes that machining is now something like Formula 1 racing: every little screw is tuned to increase performance. Thinking outside the box is essential, especially when considering cutting tools and turning. It would be helpful if users could always use the right combination of tools, inserts, and coolant supply. In Formula 1, everything is constantly scrutinised to glean maximum performance. Yet only the driver and the manufacturer who have mastered the overall package can reap the world championship crown. Despite all the optimisations and specifications, cutting tools for turning have yet to reach the end of their potential. Responsible tool manufacturers think about selling as many cutting tools as possible and include the tool holders and cooling supply into the equation. On the other hand, users should be open to tips, let consulting manufacturers approach them, and allow them to enter the production process. The potential that can be achieved in this way can provide a decisive leading edge. Be open to third-party expert tips For example, ARNO Werkzeuge has long been involved in the continued development of tool holders and coolant supply. Thanks to its customer proximity, the family-run company has a wealth of expertise from numerous applications and a wide range of holders with and without coolant supply. Users can rely on the best overall packages for small and large batches, as well as Swiss and fixed headstock lathes. “Here, too, we are not interested in maximising sales figures for high-margin products. We aim to find the best solution for our customers,” assures Sales Manager Dieter Wollensack from ARNO Werkzeuge. As an experienced technical advisor, he focuses on long-term and intensive customer relationships. He detests the promise of ‘double the service at half the price' and pie in the sky. “I sometimes say to my customers: ‘No, that's not possible' or ‘We won't do that' and risk being turned down. I've always been successful with this approach - and ultimately, so have my customers.” Advice or not, process optimisation products must be convincing in practice. For this reason, the overall package consisting of a cutting insert or indexable insert with a matching tool holder and high-performance cooling must always deliver the best customer performance. This is exactly what users should attach importance to their tool partners to understand the processes and have the right overall package for every production situation. For example, universal packages for small batches, high-tech solutions for large batches, and special products for difficult-to-machine materials. Exorbitant promises never help. Innovative when it comes to ‘cost per part' When tool manufacturers adopt this mindset, new products and solutions result. One example is the clamping holders with through-tool cooling for inserts that ARNO Werkzeuge developed in 2022. They are produced using a hybrid manufacturing process that combines additive technology with conventional CNC milling, achieving better surface quality. But why? Coolant flows directly where it's needed. Three precisely aligned channels guide the coolant to the cutting edge from above and underneath without obstructing chip evacuation. The special geometry of the cooling channel creates a nozzle effect that greatly improves cooling compared to conventional channels. The outlet openings are always perfect—they need no adjustment. And since they are much closer to the cutting zone, the coolant significantly reduces the temperature. Experienced users will recognise the benefits immediately: greater process reliability, less vibration, better surface quality and a much longer tool life. Users have sent reports about tool life that is three times longer. Of course, this is not at all suitable for small batches - but when it comes to large batch orders, it's just the right ace in the calculation where everything has to do with the cost per part. Hybrid holder: productive from additive The secret isn't rocket science, but you must figure it out first. The shanks of the hybrid holders from ARNO Werkzeuge are produced using conventional CNC milling. On the other hand, the complex head part of the holder is attached directly to the shank using a 3D printing process. “This gives us new design freedom and outstanding stability,” says Werner Meditz, Head of Technology at ARNO Werkzeuge. The geometric design of the cooling ducts can be precisely optimised so that coolant is guided through the holder to the cutting tool at maximum efficiency and reaches the cutting edge directly from above and underneath. This cools the tool flanks in a way that was previously unthinkable. At the same time, the number of attachments required at the top of the head is reduced to the absolute minimum. The chip breaks as needed and is optimally evacuated - regardless of the cutting depth. “We get a lot more coolant to where it needs to go,” Meditz assures us. The innovative hybrid holder is exactly what clever users want - and this all comes from a tool partner thinking out of the box. Not only high-tech but also ‘basic work.' But even when it's not high-end, machine shops welcome innovative turning tool manufacturers with well-thought-out products. Meeting someone who can also offer the right holders and complete systems for small batches with frequent workpiece changes is refreshing. At ARNO Werkzeuge, you will find a wide range of turning holders for external machining, where the length is easily adjustable using a scale. “The ARNO special design is extremely simple and practical when it comes to adjusting the length and coolant access,” confirms Meditz. The holder and through-tool cooling are easy to install and ensure repeatable process reliability. Their nickel-plated, high-tensile, and precisely finished nature promises top quality and long tool life. The efficient cooling system, which feeds coolant directly to the cutting edge through three channels, not only ensures long tool life but also allows higher cutting speeds with optimised chip control. The machining time savings make the cost calculation look good. Variety of boring bars for internal machining Finally, we come to internal machining. Turning tool manufacturers have already given this much thought. First and foremost, the designers at ARNO Werkzeuge have also considered the customer's situation and developed suitable boring bars for a wide range of applications. The range includes boring bars of steel and solid carbide, each with two possible coolant hole exits. Depending on the turning process, users can choose between a coolant channel from above (IKO) for through holes and a coolant channel from underneath (IKU) for blind holes. Accordingly, chips are guided forward away from the cutting edge (IKO) or behind the cutting edge and flushed out (IKU). This reduces wear. Boring bars come in right or left-hand versions with different shank diameters, a wide variety of clamping holders, and many approach angles. This variety alone shows that the manufacturer thinks from a user's point of view. Combined with suitable mini indexable inserts from ARNO Werkzeuge, components from Dmin 4.8mm can be machined effortlessly, regardless of diameter and material. This is only the standard range, not customised products. This already promises long tool life because all ARNO boring bars are nickel-plated, high tensile and precisely machined, which certainly boosts confidence. Users looking for suitable, long-life productivity-enhancing tools for all their turning operations and processes should be glad that some manufacturers have adapted their thinking to include their customers applications.

Intercable Tools GmbH has been firmly rooted in Bruneck in the Italian province of South Tyrol since it was founded in 1972. Since then, the family-owned company has been one of the leading manufacturers of connection technology and tools for professionals and the industry. Since May 2024, Intercable Tools has been using ultrasonic deburring technology from Swabian company ultraTEC Innovation GmbH to remove burrs from hydraulic units in a contact-free manner automatically. With Intercable Tec, a developer and manufacturer of automotive components, Intercable Tools forms a management-led family business with branches and over 600 employees worldwide. For some time, Intercable Tools had been looking for an automated solution to replace manually deburring hydraulic units of battery-powered hydraulic cutting tools made of aluminium and steel. Such hydraulic units are used in battery-powered perforators, which the company manufactures and distributes. These sheet metal punches are suitable for punching round, square and rectangular holes up to 3mm thick. The complex task for the ultraTEC was to remove all detachable burrs from the inside and outside of the components.   “We were looking for an innovative alternative to manual deburring. It's also important for us to produce our variants without set-up time,” said Heinz Pramstaller, Team Leader of Metal Production at Intercable Tools. “The deburring process should also be optimally integrated into the process, and the components should be cleaned using the same product carrier as the parts cleaning system.” The new ultraTEC A25 S system automates the manual process. The companies first contacted each other at the DeburringEXPO trade fair in Karlsruhe, Germany, in October 2023. Heinz Pramstaller brought the component to be deburred, so an initial deburring test was carried out on the trade show machine. The component was manually guided to the sonotrode, with a positive result. The advantages of this method over the previous manual deburring process quickly became apparent to Intercable Tools. Ultrasonic deburring means that the results remain the same, there is no damage to the drill holes, and uncontrolled material removal is generally avoided. It also guarantees that no holes are forgotten, which can happen with manual deburring. The ultrasonic deburring process has the advantage of cross bores being deburred and rinsed out simultaneously. The initial tests for Intercable Tools were, therefore, very promising. Non-contact ultrasonic deburring with the patented sonotrode forms the foundation of technology. Components to be deburred are guided in a water basin along the tip of an ultrasonic sonotrode, whose generated vibrations cause the burrs and chamfers to break off in an automated and energy-efficient manner. Stimulated by a generator, the sonotrode oscillates back and forth 20,000 times per second over 0.1mm. These generated vibrations move burrs and chamfers back and forth until they are broken off with sharp edges in a process-safe manner. Similarly, ultrasonic deburring does not apply temperature to sensitive components, which can lead to deformation and discolouration. In addition to deburring common metals, ultraTEC systems can be used with components made from various titanium and nickel alloys and fibre-reinforced plastics. From the deburring tests in Laupheim to commissioning in South Tyrol, numerous automated deburring tests were carried out with components from Intercable Tools at ultraTEC's premises in Laupheim. Detailed documentation was provided for each test so that the specialists from Intercable Tools could assess each one accordingly. Regular coordination meetings and a visit from South Tyroleans in Laupheim led to them placing an order for the A25 S ultrasonic deburring system in late March 2024. Two months later, the A25 S was showcased for the first time as an innovation at the GrindingHub trade fair in Stuttgart, Germany, before preliminary acceptance was already carried out at ultraTEC in mid-June 2024. Four weeks later, the A25 S was operated at Intercable Tools in Bruneck in South Tyrol. “We're delighted that we could implement the project quickly and that Intercable Tools chose ultraTEC to automate the deburring process,” says Thomas Benzing, Sales Manager at ultraTEC Innovation GmbH. “Maintaining a sense of partnership and trust when working with our customers is very important.”

As a roll tooling and equipment design and manufacturing specialist, Bowers & Jones Ltd is increasing its in-house machining capacity and capabilities by investing in a new DN Solutions large-capacity, ram-type vertical turning lathe. The VTR 1216F machine from Mills CNC was acquired to fulfil a new steel mill order from a customer in the US that requires batches of high-precision straightening rings. Additionally, owing to the machine's size, power, precision and versatility, the new investment will also help generate new business opportunities and growth in the US and other markets, consolidate its supply chain position with existing steel mill customers, and improve its UK precision subcontract machining operations. The new VTR 1216F machine is a large-capacity wide-column ram-type vertical turning lathe. It has been installed at the company's 15,000sq/ft manufacturing facility in Bilston, near Wolverhampton, joining three previously acquired Mills machines supplied over the last four years. The existing machines are a Doosan Puma 5100B lathe installed in 2020, a Doosan DNM 750 II VMC with a 4th-axis unit installed in 2021, and a DN Solutions' GT 3100L box guideway lathe delivered in 2023. Commenting on the relationship, Jane Sommerville, Bowers & Jones' Managing Director, says: “We have built strong relationships with Mills CNC, and the breadth of the machine tool ranges they supply combined with the company's first-class after-sales service and support means that Mills is invariably our first port of call.” Under new ownership since 2020, Bowers & Jones is committed to continuous improvement. It regularly monitors and benchmarks the performance of its manufacturing operations to identify and address current and future production inefficiencies and bottlenecks. The rollout of the company's improvement programme, initiated four years ago when the change of ownership occurred, has been instrumental in streamlining and strengthening its in-house machining capacity and capabilities to deliver sustainable growth. Bowers & Jones supplies its roll tooling and equipment to steel and copper mills in the UK and worldwide. The company has recently made inroads into the US steel market. Through direct sales approaches aided by a third-party agent, it is expanding its presence in North America. Indeed, the company's new VTR 1216F investment was primarily made to meet the needs of a new US customer whose rail ‘I' beam sections, medium bar sections and angled bar sections are used extensively in the US rail and construction sectors. Jane Sommerville continues: “We needed a new large-capacity vertical lathe to machine large-diameter straightening rings for the customer. We won the business in Autumn 2023 and ordered the new VTR 1216F from Mills last October, expecting the machine to be delivered and installed in Spring 2024—just a few weeks before production of the rings was due to start.” However, in early 2024, the safety and security of transporting freight through the Suez Canal were unexpectedly delayed due to geopolitical issues. “We had to revert to Plan B quickly”, remembers Jane Sommerville. “The customer's deadlines didn't slip, so we had to use our existing machines to manufacture the first batch of rings – basically ‘holding the fort' until the VTR 1216F eventually arrived.” The machine was delivered in early May 2024. To save time and minimise further disruption, it was delivered directly to Bowers & Jones' facility from Felixstowe. Mills CNC performed its PDI, machine build, and installation on-site. Operator training followed soon after the machine was commissioned, and the VTR 1216F was cutting metal at the beginning of June. Commenting on the machine, Jane adds: “We had been looking at investing in a vertical turning lathe for some time – partly to take pressure off an older, large-capacity Berry & Binns horizontal lathe that we had acquired some years earlier, and partly to help spearhead new business growth in the US market. We approached Mills and two other suppliers to discuss our requirements and, looking at the proposed investment package as a whole, decided to place the order with Mills.” The FANUC controlled 50” chuck VTR 1216F machine boasts a maximum turning diameter of 1.6m and a maximum turning height of 950mm. It is equipped with a powerful 45kW 400rpm high-torque spindle, a servo-driven 12 tool ATC and an innovative quad tool holder with fast indexing that enables the use of four tools directly via the ram. The VTR 1216F delivers impressive processing speeds, improved machining flexibility, high accuracies and repeatability. Like all roll tool types, straightening rings are performance-critical components used in metal forming processes to enable the steel to pass through one or more pairs of rolls located on stands to reduce the material's thickness, making it uniform and consistent. Where required, straightening rings give the ‘rolled' material additional mechanical and application-specific properties needed for the ultimate end-user.   The rings process the material into bar stock, rails and structural steel beams, angle and channel stock. These are used across many industries and sectors, such as construction, rail, energy, oil and gas and automotive. The harsh and demanding environments subject rolls to high wear, thermal stress and mechanical fatigue. Consequently, they need to be monitored regularly to maintain their dimensional and profile quality and consistency, with a need for replacements over time. The straightening rings machined on the VTR 1216F are made from D2, an alloy tool steel that is difficult to machine. They are machined from solid round bars in relatively small batches, with part cycle times being long and turning operations performed at low speeds. Roughing operations were undertaken on the company's Berry & Binns lathe before the rings were sent for heat treatment. When the rings return, they are finish machined on the VTR 1216F to tight geometrical and dimensional tolerances with super-fine surface finishes. The heat treatment process gives the D2 rings their compressive strength, high wear resistance, toughness, and shock resistance properties—all crucially important for delivering high performance and long life in a demanding steel mill environment. Established in 1954, the company's knowledge of metal-forming processes is second to none. The bottom line is that Bowers & Jones' roll tooling solutions last longer and perform better than those of its competitors. Explains Jane Sommerville: “Our high-quality designed and machined rolls may cost a little more, but they are an investment and help customers save time and money by reducing re-profiling and replacement costs, limiting potential downtime and ensuring that customers' mills keep rolling.” Bowers & Jones' current five-year plan is ending, and the new five-year plan will be rolled out imminently. The company plans to upgrade its machine shop and further capitalise on new business opportunities in the US. The imminent change of administration in the United States, with its ‘Make America Great Again' mantra, may well see the US steel market become stronger and more buoyant.

In 2023, R&A Engineering won a contract to produce several hundred aluminium parts per month across six variants for assembly into sensors that optimise wind turbine orientation to maximise power output. The job involved tying up a pair of BT 40-taper VMCs, which impacted the Aylesbury-based subcontractor's ability to do other work. So, the decision was taken to order and transfer production to a 30-taper, high-speed Brother M200X3 VMC with a 16,000rpm spindle. Delivered in August 2023 by Whitehouse Machine Tools, the Speedio M200X3 5-axis VMC has, on average, halved the time it takes to complete post-anodising milling, drilling and tapping operations on the six components. Therefore, the machine can perform the same work as the two VMCs used previously, which are now free to carry out other work. Ed Piotrowski, Operations Manager at R&A, said: “We approached a couple of 30-taper VMC suppliers, but Whitehouse was the obvious choice, even though we have never bought a machine from them before. It is a family-run firm like ours and has a similar ethos regarding service, which was obvious when we visited their showroom in Kenilworth for demonstrations.” “The Brother performs very well. Cycle times are now between one-and-a-half and four minutes, half of what they were before, and the ±0.05mm tolerance is held all day long without any problem. It is an accurate machine.” Established in 1985 by Ed's parents, Richard and Alison, and currently employing 18 staff, R&A has grown by 50% since 2021. It has invested £800,000 in machine tools over the past couple of years and is looking to automate production in the turning and milling sections. The rationale is twofold: to take on extra work without compromising existing, long-running contracts; and to be more cost-competitive on the world stage to accelerate the flow of work already being reshored from Asia and elsewhere in increasing quantities. Ed has some interesting insights into why a subcontractor should invest in a 30-taper VMC. An adage in contract manufacturing is that one never knows what work will come through the door next. Therefore, the wider applicability of a 40-taper machine due to its size and power makes more sense. The first advantage of a nimble milling machine with a smaller diameter tool interface is high-speed production, which translates into greater profitability. Not only does the elevated spindle speed combined with up to 30m/min cutting feed rate provide generous metal removal rates, but idle times are lower due to 50m/min rapids in the X, Y, and Z axes. A less well-known benefit is the vastly lower power consumption of 30-taper machines. Ed advised that the M200X3 draws less than 10kVA, versus typically 50kVA for a 40-taper VMC or perhaps even more if it is an old machine. Energy bills are therefore lower and, as is the case at the Aylesbury facility, if a factory is close to its power supply limit, the lower kVA rating is a godsend. Reviewing the characteristics of the respective BT spindle machines, Ed observes that while power and rigidity are higher in a 40-taper VMC, modern, smaller-taper counterparts such as the Brother have a reasonably well-specified spindle motor with good torque, even in the medium to high-speed range. The drive motors are also consistent with robust machining, and face-and-taper-contact tool retention assists further, as in R&A's case. “Although machining of light alloys is the province of this type of machine, using modern CAM software to create intelligent cycles involving light depths of cut and high-speed contouring means that tough and difficult-to-machine metals can also be tackled.” The M200X3 has a further advantage for OEMs and subcontractors alike. It is equipped with a torque motor to drive the rotary table, allowing a component to be indexed and rotated at up to 2,000rpm so it can be machined with a static turning tool in the spindle. Completing this second operation in-cycle without the need to re-fixture the part in a lathe raises accuracy and productivity. The mill-turn capacity in a small footprint holds much potential on the shop floor at R&A. Take, for example, the wind turbine sensor job for which the machine was purchased. All six parts undergo turn-milling on a lathe before being sent out for anodising. The Brother must only remove the insulative anodic layer in certain areas to provide electrical conductivity. With the latter machine's turning capability, all parts could be completely machined. Richard and Ed are actively considering this possibility, which would require automated component handling to be retrofitted. In addition to seizing opportunities in the renewable energy sector, R&A is also taking advantage of growth in vehicle electrification. Two aluminium parts have already been produced on the Brother VMC for the latter sector. One is an EV engine terminal block, which is milled, drilled and tapped in a 20-minute cycle. Another engine part has been transferred to the M200X3 from a 40-taper machine, with the part now machined in eight minutes rather than 12, again leading to more competitiveness, shorter lead times and more overall capacity on the shop floor. Ed is already planning the next job for the Brother. Water purification work accounts for about one-third of the subcontractor's turnover. One of the parts machined from Ertacetal, an electrically conductive plastic, is currently turned and milled in four set-ups on three other machine tools. On the Brother it will come off complete after two set-ups.

The aerospace industry is experiencing unprecedented growth, driven by record demand for commercial jets, defence programmes and space exploration. To seize this opportunity, suppliers must find ways to ramp up output without compromising quality, innovation, or cost. By Will Stirling The biggest hurdle facing the aerospace industry is how to scale up production. Airlines are investing heavily in new fleets, governments are increasing spending on advanced defence systems, and private companies are pushing the frontiers of space exploration and satellite technology. While this growth is a welcome rebound after years of turbulence, it has exposed bottlenecks in the supply chain, exacerbated by rising operational costs, material shortages and evolving regulatory requirements. Nowhere is this challenge clearer than in the commercial aircraft backlog, which has ballooned to nearly 16,000 planes – valued at more than £250bn for the UK alone. At current production rates, clearing this backlog could take over a decade. Meanwhile, demand continues to climb as airlines place hundreds of new orders yearly. Yet, this pressure brings opportunity. “The fact I can't name another industry with a 10-year-plus backlog worth over US$1.5 trillion globally shows just how massive the growth trend is,” says Balaji Srimoolanathan, Director for Aerospace, Space and the Aerospace Growth Partnership at ADS. “The primes and top tiers are diversifying their suppliers, sustainability is becoming ever-more critical, and new technologies are accessible and affordable. There is more business to be won by a greater number of suppliers than ever before, adding up to more opportunities, particularly for those with the right tools and technologies in place.” Srimoolanathan explains that the key to unlocking these opportunities lies in integrating advanced capabilities, such as intelligent manufacturing systems, into today's production processes. This move has been proven to drive greater efficiency and agility without comprising stringent quality standards. Digital Innovation in Action As production ramps up, shortages of critical components like semiconductors, electronics and raw materials like aluminium and titanium continue to cause delays. The pandemic's ripple effects are still being felt, slowing assembly lines and affecting deliveries. Even seemingly minor components, such as fasteners, are in short supply. Recognising this, LISI Aerospace partnered with the University of Sheffield Advanced Manufacturing Research Centre (AMRC) to explore how digital tools can drive process improvements. Together, they developed a cutting-edge smart production line at LISI's Rugby facility. The pilot line integrates five connected factory machines, each handling a distinct process. Key innovations include sensor data and data analytics to predict component quality, alongside an expanded apprenticeship programme to support new roles like software developers and data analysts. The result is a more than 100% performance improvement, enabling the Rugby site to hit record turnover and win additional contracts worth over £2m. The project also spurred a dedicated process development department, created a dozen new jobs and paved the way for a further £6.5m investment to implement two more connected production lines by 2027. An AMRC spokesperson said the project demonstrates how industrial digital technologies can transform operations. The success has ‘set a new benchmark for fastener production processes' and clearly shows the potential of technology-driven innovation in aerospace. Process Improvements Within Constraints While LISI's collaboration showcases the benefits of innovation, industry-wide progress is often hampered by a reliance on established processes and materials. “The industry is built on aircraft and parts certified to specific production techniques, many of which were designed decades ago,” explains Andrew Mair, Chief Executive of the Midlands Aerospace Alliance (MAA). While this reliance on legacy methods may limit flexibility in core manufacturing processes, there's significant scope for improvements in areas that run parallel to assembly. Upgrading to integrated software platforms for production planning, resource management and inventory tracking, for example, is an area where many smaller manufacturers lag, yet can unlock substantial efficiency gains. Similarly, using robotics and automation to move materials or load machines can streamline operations and reduce manual labour and downtime. Design innovations also hold promise. Advances in simulation and digital twin technologies allow suppliers to optimise components and assemblies before physical production, compressing design cycles and identifying potential issues earlier. Generative design, where AI-driven software explores thousands of potential configurations, is helping create lighter, stronger, more cost-efficient components. Combined with additive manufacturing, suppliers can prototype and produce highly complex parts faster and, importantly, with significantly less waste than traditional ‘subtractive' machining. For instance, Airbus and Autodesk have used generative design and additive manufacturing to produce the world's largest 3D-printed cabin component. Inspired by cellular structures and bone growth, the latticed partition to separate the passenger cabin from the galley is structurally as strong as conventional designs but 45% (30kg) lighter. When scaled to the entire cabin, Airbus estimates that the new design approach could save up to 465,000 metric tonnes of CO2 emissions a year. Government Backing Fuels Further Investment Recognising the transformative potential of advanced technologies, recent government announcements are geared towards accelerating adoption. One such initiative is the expansion of Made Smarter, an industry-government programme aimed at helping SME manufacturers adopt technology and build digital skills. Since its 2019 launch in the North West, Made Smarter has engaged with 2,500 manufacturers, funded over 330 technology projects, created more than 1,500 jobs and upskilled nearly 2,800 workers. Its upcoming national rollout to all nine English regions by 2025/26, followed by Scotland, Wales, and Northern Ireland in 2026/27, will extend those benefits to thousands of manufacturers across the UK. “The programme has proven the value technology and digital skills can bring,” says Donna Edwards, Director of Made Smarter NW, who described the national roll-out as “a huge vote of confidence in the contribution SMEs make to UK manufacturing.” Additionally, the government's announcement of £975m to extend the Aerospace Technology Institute (ATI) programme to 2030 was welcomed – although many favoured a longer-term commitment. With matching industry contributions, the funding will exceed £2bn, providing critical support for ultra-efficient and zero-carbon technologies. “This support for R&D is crucial at a time the sector is ramping up rates to meet today's demand while delivering ambitious technology programmes to bring next-generation aircraft technologies to reality,” says Gary Elliott, CEO of ATI. Plotting a Sustainable Flight Path The UK is making significant strides in sustainable aviation. The latest development saw a new Sustainable Aviation Fuel (SAF) mandate come into force on New Year's Day. The mandate requires that 2% of UK jet fuel demand be met by SAF, rising to 10% by 2030 and 22% by 2040—delivering up to 6.3 megatons of carbon savings annually. The mandate will be bolstered by the introduction of a revenue certainty mechanism to de-risk investments in new SAF plants and provide the confidence needed to scale domestic production. The potential of hydrogen-powered aviation is also gaining momentum, with Russ Dunn, GKN Aerospace CTO, recently named as the new chair of the Hydrogen in Aviation Alliance. The HIA's first major report, published in 2024, outlined a clear roadmap for industry and government to drive adoption. Yet, realising this vision requires more robust support for R&D, particularly within the manufacturing supply chain. Andrew Mair explains that nearly all the R&D support currently goes to large corporations or start-ups, leaving the existing supply chain underserved. “We need more regionalised support, particularly for clusters like the Midlands Aerospace Alliance, to ensure small companies get the backing they need.” Srimoolanathan of ADS underscores that aerospace is uniquely positioned to deliver immediate and long-term benefits for the UK economy. “The backlog presents an opportunity for short-term growth, job creation and technological advancement,” he says. “But this hinges on balancing the immediate demands of today with strategic investments in areas like zero-emission technologies. With sustained support, the UK can maintain its position as a global aerospace leader while delivering tangible economic and environmental benefits.”

2024 was a mixed year, with some stellar announcements like Tata Group's gigafactory investment offset by the cancellation of Phase 2 of HS2 and a budget black hole to pay for, but an Industrial Strategy may give the industry the long-term stability it needs. This article is by Will Stirling The Chancellor Rachel Reeves received a boost a week before her Autumn Budget when the IMF revised its forecast for UK growth this year to 1.1% (up from 0.7% in July) and 1.5% in 2025 – the biggest upward revision for any advanced country. It's a sign of better things to come, and 2024 was not a banner year in manufacturing, more one defined by steady stability, yet it still notched up a few memorable headlines for British industry. Spiralling costs meant the previous Tory government cancelled Phase 2 of HS2 from Birmingham to Manchester, affecting hundreds of supply chain companies, which the new Labour government partly blamed for the cost overruns. The Secretary of State for Transport Louise Haigh launched an independent review to ensure lessons will be learned and the costs for HS2 are controlled. The cost of Phase 1, London to Birmingham, is expected to reach £66bn. Covid and the semiconductor-shortage-affected UK automotive sector got a fillip in February when Agratas, the battery division of Tata Group, confirmed a new £4bn battery gigafactory in Somerset. It was a relief for the car sector to see the UK stall on the global league table for gigafactory capacity, a key metric for car plant investment. While carmaking recovered strongly in 2023 after semiconductor supply returned, it is slowing down. By August, the UK had manufactured 522,833 cars, down 8.5% on production at the same point in 2023 when ythe figure was 571,671. Interestingly, year-to-date vehicles for the domestic UK market had increased by 12%, but exports, representing over 84% of all car production, were down 13.6%. The production of electric cars, including hybrids (EVs), fell by 26%. Automotive business group SMMT said this decline is expected to be reversed in the longer term as new models come on stream. Massive manufacturer discounting saved car sales in Europe in September, pushing BEV sales to 56,387 registrations. Siemens opened its new train factory in Goole, Humberside, in October and announced a further £40m in addition to the £200 investment in the Goole Rail Village, which will now bring up to 1,000 new jobs to the region, as well as around 1,700 supply chain job opportunities. In addition to maintaining the bogies from Siemens' 572 trains running in the UK, it will also include new production lines for assembling bogies for new trains, which will be the first for Siemens in the UK. Aerospace is battling delivery rate challenges: after Covid, orders poured in, and the industry is pulling on all levers to find ways to go above ‘Rate 60' into the consistent 80s or even 90 aircraft per month to reduce long delivery times. Ninety commercial aircraft were delivered in August, the highest in that month of the year since 2018. But that's not the whole story. While the global backlog of aircraft on order is 15,651 planes according to the industry group ADS - an extraordinary number - aircraft orders in the year-to-date are two-thirds behind 2023 levels. Perhaps it was a sign that Brexit was the past. The FA appointed Thomas Tuchel as the senior men's coach, causing gossip as the first German coach of the England football team. A week later, Britain and Germany signed a government-described “landmark' defence agreement to boost security, investment, and jobs. German defence giant Rheinmetall will build a new factory in the UK to make barrels for artillery guns, and German marine surveillance aircraft will supply patrols from RAF Lossiemouth. The factory will need British steel and will create 400 jobs. It's the first defence pact with Germany of this scale, although both countries already collaborate on making armoured vehicles, for example. In October, BAE Systems Maritime launched the sixth Astute class submarine, Agamemnon. Attention will soon switch to the multi-billion AUKUS submarine (SSN-A) programme, where the boats will be built in the UK and Australia. Fhaheen Khan, senior economist at Make UK says “Manufacturers this year experienced the most stable period of business conditions in almost a decade, despite still facing higher costs, tight interest rates and skills shortages.” While it could be seen as a year of two halves – the first six months boasting strong production, order books and investment intentions, and the second looking far more mixed due to an inevitable domestic market slowdown –manufacturers remain buoyant in their expectations.” h Accountants and business advisors are expecting more investment in the economy in 2025, following several years where major events and inflation have made business conditions that could be generally described as ‘sh*t'. Fhaheen Khan thinks the new 10-year industrial strategy is an important milestone in achieving economic growth, although some seasoned business leaders will say they have heard it all before. It's hard to remember, but the UK has had at least four official industrial strategies since the 2008/9 recession: in 2009 (Mandelson), 2012 (Vince Cable), 2017 (Greg Clark) and now in 2024. Khan says “It's highly encouraging that advanced manufacturing will be a key sector driving that growth, and the Industrial Strategy Council will help lay the pipework needed to modernise UK industry through the wide adoption of AI, computing, and techniques like 3D printing.” Of particular relevance to MTD readers, the numbers show that industries specialising in producing capital equipment like machinery, electronics and metal fabricators have experienced a positive year. This is due to strong exports to the US and the EU as many Western countries are investing in the kit to modernise their manufacturing – for example, the US's Inflation Reduction Act and, one could say, on the wave of ‘Make America Great Again'. Khan says “These subsectors have much to look forward to in 2025 as economic conditions stabilise further, inflation cools, and interest rates are loosened." The manufacturing technology expo MACH 2024 organisers said visitors were up 6% on the previous show and reported a good vibe. Greg Capp, sales director at EDM machinery firm Sodi-Tech, said: “Footfall has been the best in a long time. On Day One, we had enough enquiries for the next six months.” Overall, investment in manufacturing in 2023 (last full year) is up by 4% on 2022, from £40.24bn to £41.8m, and economists expect this to rise in 2024. Despite the numbers and late positivity, on the ground, some manufacturing machinery vendors and subcontractors report a frustrating year where the anticipated rush of orders failed to materialise. That flat confidence from 2022-2023 seemed to be overspilled into the year's first half. Andrea Wilson at deep hole drilling and boring engineering company Hone-All Precision says “2024 has been a challenging and varied year for most businesses. “Uncertainty and political instability have created conditions that have not been beneficial to business and have created barriers to growth. “The creation of the 10-year Industrial Strategy will hopefully give business and investors the confidence they have been lacking the last few years.” The new industrial strategy focuses on eight sectors: advanced manufacturing, clean energy industries, creative industries, defence, digital and technologies, financial services, life sciences, and professional and business services. High-tech, hard-tech, high-potential companies can benefit hugely from close government support. The top two sectors in the strategy are advanced manufacturing and clean energy industries. “Tokamak Energy does both!” says David Kingham, the executive vice chairman and a co-founder. He says that the company that designs, manufactures and operates a plant for nuclear fusion to generate power aims to accelerate the development of fusion energy, the most valuable technology of the 21st Century. “We were delighted to see the new consultation on the Industrial Strategy. A company like Tokamak Energy, with over 250 employees and global ambitions, can grow rapidly if we have consistent strong backing from the government.” The company has had spectacular success in recent years with the record-breaking ST40 high field compact spherical tokamak – which reached 100 million degrees Celsius plasma ion temperature, the threshold needed for commercial fusion energy. Its high-temperature superconducting (HTS) magnet development has also set records for magnetic field strength at a temperature of 20,000C. David says: “Our industrial strategy is to pursue fusion energy by assembling consortia around our core technologies to provide the complimentary capabilities necessary for the development and deployment of fusion. This will require major investment by governments and consortium partners, but the prize is the elusive goal of commercial fusion energy. The fastest achievable timeline for fusion is 10 years to a 50MW pilot plant, a goal set by the US Department of Energy milestone-driven fusion development program. “So a bold, consistent industrial strategy from the Government could enable the UK to have its fusion “cake” in the long term and “eat” the economic benefits of the magnet spin-off technology in the short to medium term.” In the supply chain, companies like Hone-All Precision want long-term stability, vision, and potential targeted support through programmes unafraid of ‘picking winners' that have previously blighted attempts to assist the industry within state aid rules. Managing Director Andrea Wilson says “The new Labour government must commit to long term strategic thinking and investment decisions, and the newly formed Industrial Council will hopefully achieve this.” “The council's success will be increased dramatically if it's informed by business leaders, owners, and most importantly, if it includes SME representation. The outcome of these two positive moves will hopefully result in us seeing the confidence and stability we all need to thrive.” Machine tool and machinery suppliers need orders, and for that, their customers need confidence to buy. Adrian Haller, managing director of Bruderer UK, a leading manufacturer of precision high-speed presses says “The UK has a fantastic opportunity in advanced engineering, and we have so many brilliant companies – at all levels of the supply chain – that are prospering despite the lack of a coherent Government strategy to support the sector.” “This isn't tubthumping; this is what we see every day when our sales engineers and installers commission precision high-speed Bruderer presses on shop floors across the country. Imagine what we could do if we had a long-term Industrial Strategy that focuses on our strengths and invests in them? And I don't mean the odd grant here and there. It needs to be substantial and flow down to SMEs – that is the critical bit. For industry to become more efficient, an area to improve is the education of manufacturing engineers about new, ‘smart' technology. Mark Weymouth, MD of PLUS Automation and UK representative for Contrinex and Satron, who runs a popular LinkedIn newsletter says “There's a pervading tendency for engineers to buy and commission what they know and not look at new, better plant and equipment that can raise productivity.” While PLUS Automation is in its fourth year of growth, many food and liquid process manufacturers are not explaining this technology to their site engineers. He says “The UK is about seven years behind mainland Europe in adopting many process technologies.” Although the increase in employers' national insurance payments may dampen this optimism, the indicators are that this new strategy for industry will help businesses, especially those in advanced manufacturing areas.

Anotronic Ltd is a well-recognised subcontract machining business and manufacturer of high-quality EDM fast-hole drilling and EDM die-sinking machine tools. Founded in 1982, the Leighton Buzzard business started in ECM, ECD and EDM tooling and machining, evolving to the production and growth of its own ECM and ECD technology brand. Along this journey, the company has worked with Sodi-Tech UK and the Sodick brand of machines. Martin White, Managing Director of Anotronic Ltd, says: “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, special stainless steel, and everything that is difficult to machine. We take on the worst jobs because we can - and we have all the machines and processes in-house to do what we need.” Over the years, Anotronic has continually expanded its factory footprint, services and range of machines. This has resulted from an aggressive growth strategy, staff development, and investment in the latest machine tool technology. The Bedfordshire manufacturer currently operates three Sodick machines, with the latest ALC600G Premium wire EDM with linear motor drive technology arriving recently. The high-end plant list gives Anotronic the edge over its rivals. The Sodick ALC600G Premium from Sodi-Tech UK, with its spacious X, Y and Z-axis of 600 by 400 by 500mm and the U and V-axis travel of 120 by 120mm, clearly gives the company an edge. Martin recalls how Anotronic arrived at the ALC600G: “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 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 says: “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.” The remarkably high level of lights-out machining with the Sodick AG600LH and its incredible reliability persuaded Anotronic to invest in its latest EDM machine, the Sodick ALC600G Premium with linear motor drive technology. “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 says: “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 angles. The ALC600G Premium has very large U and V-axis travel, allowing the processing of tapered angles up to 45°. So, when it comes to machining this part, it can be done in situ with the integration of a fourth and fifth axis.” “Manufacturers can also use the on-board technology and IQ software system that brings Anotronic's model into the machine and draws the profile on-board utilising the U and V-axis cutting technology. The programme is generated, the parts machined, and the job is complete!” “We're using a very complex 4-axis programme to cut a rotary part with 45° slots in it. The only way we could do that was to use the software we currently use and without it, we couldn't manage to do the part. So, we used the on-board software within the CNC control of the Sodick machine to create a 3D model and a tool path to cut the part. This is machining at extreme angles. We're cutting at 45° and machining up to 40 to 50mm in the U and V-axis to create this particular part. We also had to specify wide nozzles and wider guides to machine this part, and the ALC600G did a brilliant job.” “I have been a Sodick user for 35 to 40 years, and the beauty of the Sodick machines is that you can jump straight into a point anywhere in the programme without editing the entire programme. It makes things very easy as it is a powerful and user-friendly software system. It has many benefits, such as the negative offsets - normally, you have to cut a comp on a machine, but with the Sodick, we can drive the comp the other way and cut the other side of the part using a negative value. Most control systems would just throw that out, whereas the Sodick accepts it and gets the job done.” “I was working 15 to 20 hours daily, which was too much. I wasn't seeing my kids growing up, and something had to change, so we went down the automation route. We have a great team that works very hard and helps us reach our common goal - we run a lot of machines with very few people through our application of automation. Sodick is a very established brand, and they have a great customer base and exceptional knowledge with engineers who are really, really good. I've known Peter at Sodi-Tech for over 35 years, and this relationship is based on our excellent support - it's been a fantastic marriage between the two companies.”

With 75% of its turning centres bought from Dugard Machine Tools, it's safe to say that C&K Precision Engineers Ltd is reaping the rewards of working with the South Coast machine tool specialist. The Stoke-on-Trent manufacturer is a subcontract machining, assembly and fabrication business serving the medical, aerospace, surveillance and general manufacturing sectors. Working in these high-end segments, C&K Precision demands machine tools capable of delivering high-quality, tight-tolerance workpieces from the most challenging material grades. Matthew Kelsall from C&K Precision Engineers says: “We moved to a new large facility in 2017, and since then, we have continually grown. We've invested in new machines with a better working environment and aim always to increase productivity. There is a skills shortage, and we are lucky to have a good team around us, but we have to maximise that with the most productive machines.” This is why six of the company's eight turning centres have been purchased from Dugard Machine Tools. The second-generation business was founded in 1969 kand eeps returning to Dugard, Matthew says: “One of the main things is reliability. The first Dugard machine we bought has been with us for six years and has been remarkably reliable. It's a very robust and rigid machine with box guideways, and we need that as we machine many exotic materials - we have a lot of faith in the machine.” The turning centres supplied by Dugard are all fitted with a Siemens CNC system. “With a lot of machine tool manufacturers, if you want a machine built to order, it typically takes twelve months to wait, and we simply couldn't wait for that. Dugard had a machine in stock with many additional bells and whistles, such as a sub-spindle, that we never had before. The success of that machine led us to buy two more machines. That's because if something serves you well, you stick with what you know.” “Since we purchased the first machine, we found that we could get more and more work through it, which eventually created a bottleneck. We had to do something about the bottleneck, so we bought a second machine with a Y-axis last year. We have now just had the third machine installed”. As a turner operating four machines at C&K Precision Engineers, Matthew Gerrard says: “The machines are built extremely well, and they perform brilliantly on materials like inconel 625 and titanium – they fly through the material. You can make massive cuts on the Dugard SMEC machines, whereas others can stall. This is due to the really high quality and high specification motors and the box way construction. We also love Siemens control as it is very user-friendly and has a lot of technical add-ons. If we're doing jobs out of titanium that may have just a 0.9mm wall thickness, the Dugard SMEC machines ensure that you don't get any vibration. Additionally, the machines have BMT65 toolholders that are very large and robust for heavy-duty cutting.” “Looking at the first machine we bought with the Y-axis, it's just so much more versatile and capable than our other machines. We have other machines with live tooling, but the Dugard Y-axis is perfect for opening slots and counter-boring holes. We were so impressed by the sub-spindle on the SMEC SL2500SY that we purchased a SMEC SL2500Y, which is an almost identical machine except for the sub-spindle. We purchased this as we only needed one machine with the sub-spindle, but we still needed a machine with a Y-axis for doing one-off jobs.” “We've just added a SMEC SL2000, and my son, who is just starting his apprenticeship, is on that machine. It doesn't have the live tooling facility, but it has a Siemens 828 CNC control and is perfect for learning.” Matthew Kelsall says: “When you buy a machine, nobody wants to be stuck at the end of a phone talking to someone you've never spoken to before, but when you speak to Dugard, you have a great relationship that work well.”

Recent research commissioned by Close Brothers Asset Finance has revealed the significant impact of rising costs on businesses across the UK, with a majority of respondents reporting adverse effects on their operations and financial health. According to the research, 71% of businesses have been affected by the rising cost of doing business, while 25% reported no impact, and 5% were unsure. Among those experiencing increased costs, 56% indicated that it has negatively impacted their cash flow. Conversely, 27% reported no negative impact on cash flow, and 15% did not notice an increase in costs. The survey also identified the top five primary inflationary cost pressures affecting businesses – in order of most impactful: l Energy (gas, electricity) l Supplier costs l Fuel (petrol, diesel) l Interest rates l Rent Additionally, 67% of businesses have seen their business insurance costs rise in the past 12 months, while 26% haven't, and 7% are unsure. In response to these increased costs, 24% of businesses have passed them on to customers completely, 61% partially, and 15% have not passed on any costs. Regarding employee wages, 54% of businesses reported wage increases in the past six months, 34% did not, and 6% were unsure. Anton Nebbe, Head of PR and Communications, and responsible for commissioning research at the firm says “These findings underscore the challenges faced by UK businesses in the current economic climate. They highlight the need for strategic planning and support to navigate these pressures, and it's clear the rising costs of doing business are presenting significant issues for many enterprises across the UK.” “Our research highlights the critical areas where businesses are feeling the pinch, from energy and supplier costs to increased insurance premiums. “At Close Brothers Asset Finance, we're committed to providing the support and resources businesses need to navigate these pressures and continue to thrive. By understanding these challenges, we can better assist our customers in developing strategies to mitigate these impacts and ensure long-term success.” For more information please visit: closeassetfinance.co.uk

The design concept of assembled drills with exchangeable solid carbide cutting heads, adopted by ISCAR at the turn of the century, significantly altered the company's holemaking product program. As part of this concept, a precise carbide head is mounted in a steel holder using the ‘self-clamping' principle, which relies on the holder's elastic deformation without any mechanical clamping means. This approach is characteristic of various successful ISCAR products, such as the SELF-GRIP and MULTI-MASTER tool lines. These have substantially improved machining performance and revolutionised traditional perspectives on cutting tool design. This is complemented with stoppers and locking sections for reliable security. In the assembled drills with carbide heads, the cutting head has a specially shaped rake surface to optimise chip formation and a centring area to ensure high accuracy. The drill body is produced from a high-strength steel grade and features the innovative design of the head pocket, helical flutes, and internal channels for coolant supply. Advancements in technology, particularly in powder metallurgy processes and CNC machining, have made this design feasible. The concept of assembled drills with carbide heads guarantees several key advantages: 1. With a rigid structure, reliable clamping principle, unique cutting geometry and advanced carbide grade of the heads, the drills guarantee productive results. This significantly reduces cycle times and enables high-quality holes. These drills can be used for machining a wide range of materials, including steel, stainless steel, cast iron, titanium and high-temperature alloys. 2. High repeatability and ISCAR's ‘no-setup-time' principle promise that a worn head can be replaced without removing the drill from a machine, eliminating additional setup operations and considerably decreasing downtime. The simple change of the heads makes the drills user-friendly and easy to handle. 3. The drills are available in a wide range of diameters and overall lengths to suit various applications. 4. The use of interchangeable heads diminishes the need for a large drill inventory. ISCAR's drills with exchangeable carbide heads provide customers with a valuable tool solution to enhance the profitability of holemaking operations. Over the past 20 years, these drills have undergone significant changes. Beginning with the CHAMDRILL family, each new phase in the concept's enhancement has led to new products that outperform their predecessors. Today, SUMOCHAM is ISCAR's most popular family of assembled drills with exchangeable carbide heads and is highly regarded by customers. The continuous search to increase drilling productivity, mainly when machining materials that produce fine chips, has created the LOGIQ-3-CHAM – a family of three-flute drills that utilise the same self-clamping approach. ISCAR's development of carbide-headed drills continues to aspire. Unsurprisingly, ISCAR's latest product campaign, LOGIQUICK, has unveiled innovative designs that enrich the existing product families, broaden their scope, and pave the way for new application areas. The new holder with three flute heads allows a 10:1 drilling depth-to-diameter ratio. The holder's main feature is a specific flute design that minimally affects the tool's structural strength. Another innovation is the expansion of the LOGIQ-3-CHAM family application to include counterboring. The specially designed three-flute heads are mounted on existing tools and transformed into highly efficient counterbores. The unique design features of the heads include a corner chamfer for rapid chipping, specialised deflectors for improved chip formation and a unique margin for enhanced support and guidance. This significantly boosts performance when machining materials like sticky steel, stainless steel and high-temperature superalloys. This design facilitates a broad spectrum of counterboring operations, ensuring high-quality holes, even when machining cross-holes with inclined surfaces. The CHAM-SPADE-IQ is a new family of holemaking tools with exchangeable heads. Introduced as part of the LOGIQUICK, the family provides a solution for drilling steel profile construction beams. Machining beams often occurs under non-rigid conditions, presenting a significant challenge for manufacturers. To address this issue, drilling tools must have an adaptive cutting geometry to compensate for the lack of rigidity. The newly introduced family, dedicated explicitly to profile construction, includes two flute carbide drilling heads and reinforced steel holders. The heads feature a specific self-centring cutting edge for secure hole penetration and sharp corners to prevent deformation. The holders' durable structure maximises the tools' dynamic stability when drilling at a depth-to-diameter ratio of up to 5. New drills with MULTI-MASTER adaptations that carry exchangeable carbide heads essentially serve as a ‘bridge', connecting the successful SUMOCHAM and MULTI-MASTER families. The drills are a component of a versatile modular tool assembly that allows the mounting of drilling heads on a wide range of MULTI-MASTER tools. This facilitates an easy and quick change of the heads and the drill bodies. Moreover, the modular concept provides straightforward customisation and flexibility regarding overall length and diameter and finding the optimal tool configuration. It's worth noting that the holemaking innovations in the LOGIQUICK campaign aren't solely represented by assembled tools with exchangeable heads. Several products of another design concept can also be highlighted. The three-flute flat-bottom solid carbide drill with internal coolant channels is one such product. The drill features a small isle for improved penetration, wavy cutting edges for assured chip control, an optimised core diameter to increase tool rigidity, and narrow wiper sections to reduce friction. This improves surface finish and combines with an internal coolant supply that extends tool life and improves chip evacuation. These incredible attributes contribute to the promising prospects of this product line. In the boring line, a new series of boring heads with extra fine digital adjustment has replaced the existing heads with an MB connection. In the milling line, the portfolio has been enhanced with the addition of the The QUICK-D-MILL is a family of multi-functional indexable cutters. These versatile ‘all-in-one' cutters are suitable for various machining applications, embracing the milling of shoulders, slots, and pockets and drilling flat-bottom holes. The overview of the mentioned products highlights that ISCAR's focus on holemaking continues to drive its development efforts. With the metalworking industry seeking solutions to enhance holemaking performance, ISCAR is confident that its latest LOGIQUICK drilling developments will effectively meet the industry's demands.

Prima Additive and Comau, two Italian companies and global leaders in their respective sectors have joined forces to showcase the advantages of dual-layer laser cladding. This results from developing a high-speed, fully automated brake disc coating system for Stellantis. The first in a series of robotic-driven Rapid Coating Process cells was presented during the Stellantis Factory Booster Day, held in Turin on September 18th. By hard coating the raw brake discs with resilient steel and composite materials, the solution will enable Stellantis to significantly increase brake disc durability, reduce emissions pollution by up to 80%, and keep cycle times at a minimum. This will allow the automotive manufacturer to fully comply with the Euro 7 standard, which requires a 27% reduction in particle emissions from brake discs by the end of 2026. With a combined commitment to innovation that spans over 50 years, Comau and Prima Additive developed the robotic cell using a combination of advanced laser systems, high-speed robotic arms, additive manufacturing processes and safe powder management. Furthermore, the full integration of Comau's robotic arms with Siemens SINUMERIK Run MyRobot allows the industry-standard software platform to directly control the robotic arm without needing external or embedded robot controllers. The modular system also allows maximum flexibility and productivity. Indeed, the cells are equipped with adjustable grippers that can handle different sizes of discs, from cars to trucks, to address evolving production mix scenarios. Finally, besides being highly versatile and energy efficient, the solution is characterised by a reduced overall footprint. Paolo Calefati, CEO of Prima Additive says “We believe that collaboration and innovation are the driving forces shaping the future of manufacturing.” “Our collaboration with Comau joins two companies with deep expertise in their respective fields to develop a truly cutting-edge industrial solution in automation and advanced laser systems for material processing. More importantly, the laser system developed for the brake disc coating application is one of the most profitable and sustainable cases of laser additive manufacturing/laser cladding technology applied in mass production for automotive. This solution not only contributes to improving the performance of automotive brake discs but also plays a crucial role in promoting sustainability by reducing the overall environmental impact of motor vehicles.” Pietro Gorlier, CEO of Comau says “This robotised solution represents a great example of innovation, led by two Italian companies who have developed advanced technologies to meet important sustainability targets.” “In working together to automate high-speed laser cladding safely, Comau and Prima Additive are helping meet a growing demand in Europe and beyond for flexible, turn-key solutions that will help reduce particle emission pollution in response to recent regulations. We're confident there is significant market potential for this type of solution.” The jointly developed Rapid Coating system is scheduled to be deployed at the Septfonds plant in France by the end of 2024, making Stellantis one of the first automakers to launch a fully automated line for the hard coating of brake discs in compliance with Euro 7 policy standards.

Architectural ironmongery manufacturer Instinct Hardware has recently invested in a host of equipment that includes an Italian-built Biglia bar-fed, twin-spindle lathe with a ± 45 mm Y-axis turret having and 15 driven tools. Installed in the Stirchley factory where premium quality door knobs and handles, door stops, and accessories are manufactured, the latest turning centre was sourced in May 2024 from the Whitehouse Machine Tools. The company supplied the machine as a turnkey package with a bar feeding unit and a gantry-type system for unloading components onto a conveyor. This handling method was chosen to prevent damage to the components' surface and preserve their aesthetic appearance. Whitehouse also supplied programs and tooling for producing two key components and their prove-out in Kenilworth, plus comprehensive training. Instinct Hardware products are either standard catalogue items or manufactured to bespoke designs and have been used in prestigious projects. These include the ongoing refurbishment of Citibank UK's London headquarters, Google's new headquarters in King's Cross, various London Underground stations, the recent renovation of Wembley Stadium and Liverpool FC's modern training centre. Until now, stainless steel has accounted for 80% of production, with the remainder mainly brass and bronze. However, an increasing amount of aluminium is being processed due to its easy recyclability. Director Nil Chohan says: “Since we moved to our current premises, we have been increasing our machining capacity to reduce our reliance on subcontractors. All of our lever handles require a square hole to be broached. This has always been done separately on a hydraulic press, as before the Biglia B 620 YS was installed, we did not have a rigid enough lathe.” “We bought the Italian turning centre specifically because it can broach our stainless steel handles, which Whitehouse demonstrated before we committed to the machine. So, we can now perform all operations in one hit rather than in five or six operations. It significantly reduces scrap rate by avoiding repeated manual setups and greatly speeds manufacturing time, enabling us to fulfil our promise of a 10 to 14-day order turnaround.” A case in point is machining a component assembled into a stainless steel, oval-profile, mitred lever handle. It previously required six machining operations from turning on a 3-axis lathe, milling and drilling on a VMC, broaching on a hydraulic press, further prismatic machining on a different VMC, slotting on yet another VMC and mitring on a bandsaw before welding. This consumed 15 minutes of machining time plus 10 minutes of handling and setup for each of the five additional operations. On the Biglia, the part comes off complete in 8.5 minutes, representing an eight-fold time saving, with the added benefit of eliminating work-in-progress and the potential damage to components. Nil Chohan needed a robust and powerful machine capable of broaching stainless steel, he was impressed by the specification of the B 620 YS, particularly the 30kW direct-drive, liquid-cooled main spindle motor offering 700Nm of torque. The lathe has boxways in the X and Y axes to promote rigidity and accurate machining, with a linear guide rail in the Z-axis for traverse speed. He says: “Reputation is hard to establish but even more challenging. Through hard work and endeavour, we have become a leading European manufacturer of bespoke architectural ironmongery. Today, our team is committed to continued investment and further developing our range and brand with an increased focus on sustainability of materials and logistics. We are constantly looking at new machinery like the Biglia to develop and enhance our offering whilst maintaining our passion to continue driving the company and our industry forward.”

Hexagon, a world leader in digital reality solutions that combine sensors, software and autonomous technologies, has expanded its collaboration with the automotive manufacturer SEAT S.A. The deal builds upon a 25-year partnership working with Hexagon's Manufacturing Intelligence division. The companies have signed a strategic agreement that aims to deepen the digital transformation of SEAT S.A, focusing on the digitalisation of vehicle components, the management of digitised information and advanced process simulation. This agreement will enable SEAT S.A. to optimise production and make decisions on process adjustments in real-time. Hexagon has successfully implemented SEAT S.A.'s measurement and quality control systems. Through the extended collaboration, the team will integrate a digital twin that applies metrology data with process simulations to predict outcomes and improve efficiency. The solution will use systems to digitise the car body and its components, manage their data and provide reports and analytics to drive efficiency and reduce costs. The collaboration is based on three fundamental pillars: the digitalisation of the vehicle's manufactured parts, the management of digitised information and the simulation of processes. Under the new agreement, Hexagon's PRESTO system will fully automate the high-precision 3D laser scanning of the entire body with high-speed robotic inspection. The second pillar is managing digitised information, which uses Hexagon's eMMA data management, quality planning and analytics platform. This automatically captures metrology data and manages it in a standardised way. The centralisation of all 3D measurement data captured during the digitalisation process facilitates informed and efficient decision-making, allowing SEAT S.A.'s production and quality managers to monitor the condition of the parts and optimise quality in all assembly phases. The third key aspect is process simulation, which allows SEAT S.A.'s quality analysts to accurately predict problems and optimise critical vehicle manufacturing processes such as part alignment, assembly and subsequent welding operations. Thanks to Hexagon's simulation solutions, SEAT S.A. can optimise production and adjust the production settings using a virtual prototype of the product, speeding up the process of fine-tuning production methods used in series manufacturing. This capability translates into a significant reduction in costs, a reduction in material waste, and an improvement in time-to-market for the new vehicle models. Josh Weiss, president of Hexagon's Manufacturing Intelligence division, says: “We're committed to helping SEAT S.A. stay at the forefront of the automotive industry by implementing innovative digital processes that transform agility in manufacturing and take control of quality from the start. By combining technologies such as automated quality inspection, connected quality workflows and virtual manufacturing, SEAT S.A. can supervise each production stage with significant savings in time, material waste and costs”. Daniel Cortina, Director of Quality at SEAT says: “At SEAT we are at a time of unprecedented transformation for our company towards smarter, more connected and efficient production, which involves the digital transformation of our production processes. Now, we'll acquire data about the quality of our parts faster and more accurately, and will also be able to improve manufacturing performance with them. This predictive approach to quality allows us to improve our customer satisfaction and significantly reduce the materials used in the manufacturing process, reinforcing our commitment to sustainability.”

The term ‘one-stop-shop' is often banded around the subcontract manufacturing industry. It's not until you find a company like Woodbrook Precision Ltd that you can truly understand what a single source solution provider looks like. The Lancashire manufacturer ventures beyond rivals' services and continually invests in the latest machine tools fully supported by advanced cutting tool solutions from CERATIZIT UK. The company is located in Ashton-Under-Lyne on the Northeast edge of Greater Manchester. It's plant list includes a complete array of manual and CNC 3 to 5-axis machining centres and multi-axis turning centres from renowned brands such as Mazak, XYZ, Leadwell and Bridgeport. The state-of-the-art plant list is supported by services such as grinding, plating, shearing, profiling, welding, laser cutting, gear cutting, heat treatment, powder coating and more. Rightly proud of its comprehensive services and recent investment in Mazak machine tools, Managing Director Stephen Hogg from Woodbrook Precision says that CERATIZIT has been instrumental in enhancing the productivity of the new equipment. The second-generation business was founded by Stephen's father more than 35 years ago. When Stephen bought the company 16 years ago, Woodbrook operated out of a small unit with a single CNC turning centre and a series of manual mills—all supported by various cutting tool vendors, with WNT (a member of the CERATIZIT Group) being one of the many. However, as Stephen has applied his vision and determination to the company, Woodbrook has evolved with a 2018 move to an 18,000sq/ft facility three times larger than the previous site. Plans are also afoot to add another 10,000sq/ft. This growth has stemmed from the business's progress in general subcontract machining into the oil & gas, aerospace, rail, and motorsport sectors. Woodbrook has evolved the sophistication of its machine tool purchases to serve these industries. Initially investing in 3-axis Mazak VMCs with rotary tables and turning centres with live tooling, more recent acquisitions have included two 3.5m bed Mazak VTC800/30SR 5-axis machines and a 5-axis Mazak CV5-500. This has seen work for overhead cranes, rail, and general subcon evolve to aerospace jigs and fixtures, critical subsea valves and manifolds, motorsport brake callipers, engine components and more. With an evolution driven by the expanding capabilities of its machine tools, Woodbrook has needed to rely more heavily on the expertise of its cutting tool suppliers. As the business has shifted from machining steel and aluminium to stainless, super duplex, titanium, inconel, carbon fibre, hastelloy and much more – CERATIZIT UK has risen through the ranks to be the cutting tool partner of choice. Stephen Hogg from Woodbrook says: “Over ten years ago, CERATIZIT was one of many suppliers, and as I took control of the business. It became evident that CERATIZIT had the best-performing tools and their service was far beyond anything else. As we continually ventured into more complex work and more challenging materials, we needed greater support and new machining strategies. CERATIZIT UK's Technical Sales Engineer Matthew Darbyshire has been with us all the way to provide the solution. It's been seamless, and it's pointless going elsewhere as Matt makes it so easy and ‘painless' for us.” “With numerous sales reps continually calling upon us, we asked Matt for a few tools to trial. The tools initially performed well, but for the relationship to blossom to a position where we now have thousands of CERATIZIT tools. This has been built on tool performance, product range diversity, supply chain continuity and most importantly, technical support, service and trust that has instantly been available. I can WhatsApp Matt with any drawings and queries and he'll deliver a solution imminently.” As a machine shop that typically manufactures prototypes in small batches, tracking continuous tooling improvement isn't always the priority for Woodbrook. However, you don't have to look far for quantifiable results with CERATIZIT products. Stephen says: “We recently implemented the CERATIZIT facing and parting-off tools, and it reduced the cycle time on a 400-off job from 1 minute 58 seconds to 1 minute 26 seconds. We also applied the Dragonskin CircularLine DLC-coated solid carbide end mills with impressive results. The Dragonskin tools have cut cycle times on an aluminium part from 3 minutes to 1 minute 20 seconds whilst more than doubling our tool life.” “On another 100-off repeat order stainless steel aerospace fixture, we needed to reduce our cycle times to maximise margins and reduce costs. Matt introduced a CERATIZIT UK high feed indexable end mill, and this reduced our cycle times from 38 to 26 minutes per part, with a tool life improvement of more than 20%. This was a significant saving on a long-running job.” However, the most significant saving wasn't from the cutting tools…. With the 100-off stainless job running through the business frequently, Woodbrook set up six vices in a line on the spacious 3.5m bed of its Mazak 5-axis VTC800/30SR. When each surface and cycle was completed, an operator would re-set the job to process the next face. With a total of four operations, the process was laborious. Stephen spoke with Matt from CERATIZIT, and the way forward was a bespoke workholding solution that was ‘Made in Sheffield' at the CERATIZIT UK Technical Centre and Headquarters. Stephen visited the CERATIZIT stand at MACH 2024. He realised that the only cost for CERATIZIT's bespoke service was the price of the aluminium tombstone billet and the cost of the four ZSG4-125 Centric vices that connect to the zero-point single riser tombstone system. Immediately impressed, Woodbrook Precision ordered a pyramid system to clamp smaller parts in its 5-axis Mazak CV5-500. The ZSG4-125 Centric vices with serrated jaws enabled Woodbrook to clamp on as little as 3mm of stock, permitting the subcontractor to hit all five sides of the stainless parts with confidence in the high-torque clamping forces of the vice. With five faces machined in a single operation, the following operation was to turn the parts over to complete the sixth surface. This reduced this 100-off repeat job from a four to a two-operation process, saving an additional 10 minutes per part. Stephen says: “This job took over one hour per part from start to finish. The tombstone and Centric ZSG vices immediately took more than 10 minutes off each part, with peripheral savings being longer running times without operator intervention. Reduced set-ups also improved our precision, repeatability and consistency over an entire batch of parts. We work 12 hours a day, six days a week, and the tombstone enabled us to set up a batch of four parts at the end of a shift to run unmanned for a couple of hours – giving us further savings.” “We're now using CERATIZIT for everything from our back-ends and collets to solid carbide and indexable tools ranging from drills and threadmills to end mills, turning and parting tools. We never thought we'd be turning to CERATIZIT for our workholding solutions, but just like the cutting tools – the quality and performance of the workholding solutions that come with a ‘Made in Sheffield' brand is far superior to anything else we've encountered.”

One of the biggest challenges for any machine shop is workshop air quality and the impact coolant mist has on staff. To stop coolant mist from impacting air quality in the workplace, Tooling 2000 Limited installed on-machine mist extraction systems from Filtermist. In addition to COSHH compliant clean air, the Birmingham subcontract manufacturer is also benefitting in other less obvious ways…. Founded back in 1996, Tooling 2000 offers everything from prototyping and development to 5-axis laser cutting, CNC machining, precision tooling and presswork for marquee customers like Rolls-Royce, JLR, Aston Martin, Magna, Bentley and many others. With a complete suite of Hurco CNC machines from the compact Hurco TM12i turning centre, and 3 and 5-axis VMX machines, to the large bed Hurco DCX42i, the company also invested in Filtermist extraction on its machines. This has improved air quality and enhanced productivity too. Senior Business Development Manager at Tooling 2000, Iain Bubb says: “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.” With more machine shops employing high-speed machining and high-pressure coolant systems that deliver fluid to the cutting edge, airborne coolant mist is a significant and growing issue for manufacturers. Iain says: “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. This creates 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. Iain says: “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.” Filtermist oil mist filters eliminate airborne particulate and subsequently the oily film from the machine tools, components and wider work area. The machine-mounted Filtermist FX5002 draws oil into a perforated drum that rotates at high speed and causes the mist to coalesce. Centrifugal force pushes the oil into the outer casing of the FX5002 where it drains back to the machine tool for re-use or collection. Simultaneously, the clean air is passed through a secondary high-efficiency after-filter to remove submicron particles that may have passed through the unit. Referring to the installation of the Filtermist technology, Iain says: “When we specify our machine tool purchases, we ask for the Filtermist system to be installed on the machines before delivery. We are a family-owned business, and we take our investments very seriously. So, when we specify a new machine, we want it delivered to specifications we require to support our business.” With the Filtermist FX5002 mist extraction systems fitted to its range of Hurco machine tools, Tooling 2000 finds maintenance of the technology easy to manage. Iain says: “We have a TPM (Total Productive Maintenance) System in place, so after a set number of hours of production the Filtermist filters are changed and cleaned with ease. 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.”

In recent years, Porsche Werkzeugbau GmbH in Schwarzenberg, Germany, has taken its mechanical machining to the highest technical level. Two large Starrag HSC machining centers Droop+Rein FOGS play a major part in this. The machines are used to finish press tools for moulding skin parts of vehicle bodies with the utmost precision and produce surfaces with grinding quality. A premium car manufacturer should have a premium engineering plant. To ensure that the Porsche Werkzeugbau GmbH Schwarzenberg plant fulfils all of the preconditions for this, €40million was invested over the last five years to develop the tool-engineering plant to the highest possible level following the transition from KUKA. Among other things, the Schwarzenberg-based company used this money to set up two new production halls, purchase a new 25,000kN servo press for production-related tool try-outs and invest in retrofitting and new machine tools – including two Starrag HSC centres of the Droop+Rein FOGS 35 68 N40C type. In addition to this, mechanical production was completely overhauled and the production processes were restructured. All of these measures were based on a solid foundation. Beforehand, the whole tool-engineering team analysed the entire process chain, from development and design to procurement, production and try-out of the tools, right through to the transfer to the operator pressing plant – including a fitness test for the pool of machines. An important detail that came to light was the realisation that when it came to mechanical machining, there was potential for improvement in the finishing of the tools, particularly in terms of accuracy, speed and surface quality. Lightweight construction results in tougher requirements Marco Franz, Head of Mechanical Production, points out some important reasons for this: “For some years, we have been experiencing a shift towards lightweight construction and, as the Porsche competence centre for forming technology in the moulding skin area, we were commissioned to develop the tools required for the conversion to an aluminium body. During forming, aluminium sheets respond much more sensitively than steel, which created big challenges for us when it came to tool engineering. Our existing machines were not able to meet some of the requirements”. Two new high-speed machining centres for finishing the pressing moulds should fulfil these new requirements regarding surface quality, accuracy and speed. According to Marco Franz, they should also help to make the process more efficient and economical, as well as greatly improving quality. The list of requirements contains fundamental preconditions such as process stability, availability and ease of maintenance, as well as characteristics that cannot be compromised, such as temperature stability. In addition, future-oriented specifications for the performance data of the spindles were defined. Lutz Kramer explains: “When you buy this kind of machine, you expect to use it for the next 10 to 20 years. During this time, several generations of new milling tools were developed that are more efficient and allow higher speeds. We must take all of this into account at the early tendering process.” With their list of requirements, the Porsche Werkzeugbau decision-makers set a high bar – and came to realise that not many manufacturers would be able to meet the requested standards. “During the technical discussions that we held with many different providers, we were soon able to tell who was able and willing to overcome the challenges. Some machine providers withdrew at an early stage, others were later unable to offer any acceptable solutions,” says the Head of Tool and Mould Making, Kramer. Premium machine tools from Starrag Ultimately, the decision-makers opted for two Starrag Droop+Rein FOGS 35 68 N40C high-speed machining centres. These 5-axis machine tools are designed for finishing, have an overhead gantry and offer traverse paths of 6.8 by 3.5 by 1.5m along the X, Y and Z-axes. The equipment includes a tool magazine with a total of 100 places that can be filled with HSK32, HSK63 and SK50 retainers, as well as an eccentric fork head with a 40kW milling spindle and a high torque of 700Nm, and three different motor milling spindles with speeds of 18,000, 40,000 and 65,000rpm. In addition, for one of the two machines, Marco Franz ordered a special 6,000rpm angular head that can be used for machining areas that are difficult to access. “With this range of spindles, the requirements of the coming years are covered”, Lutz Kramer is certain. More than a machine – Engineering precisely what you value There were other reasons for choosing the Starrag machines, in addition to the technical data, as Head of Tool and Mold Making Kramer explains: “We didn't just want to buy a machine, we wanted a solution for our tool manufacturing process. That is one of the main reasons why Starrag seemed to be the right partner. With the Droop+Rein specialists, we had the impression right from the start that they were listening to us, wanted to understand us and the thinking behind our processes, and wanted to use their expertise to help us” Once the machines were installed, the two companies began fine-tuning the workflow together, taking into account the characteristics of CAM, the control system and the machine. This was necessary because achieving the best surface quality requires a high level of accuracy on the path, even at the highest feed speeds. For this, it was important to illuminate the interfaces between CAM and NC and to work with experts from the control system manufacturer to optimally adjust their functionalities in line with the process requirements. This interdisciplinary approach and the combination of sophisticated drive optimisation in conjunction with the proven machine technology of the FOGS series was extremely successful. The result was not only a class-A surface but also a very high level of accuracy – at the highest path speeds of up to 16m/min on the free-form surface. The processes have been running stable ever since. Lutz Kramer is delighted: “It took a long time to achieve stable processes, especially when it came to the forming tools for aluminium parts because there are many factors influencing this. But Starrag assisted us until we were sure we had reached our goal.” Marco Franz adds: “I wouldn't have believed it at the start but Starrag was able to implement more than 90% of our wish list. So it was a good decision to invest in the new Droop+Rein FOGS machines. We are now faster and more precise and achieve – depending on the component and the geometry – outstanding surface accuracy.” The head of tool and mould-making confirms: “We are proud of what we have achieved with Starrag. With the Droop+Rein FOGS machines, we have attained the desired improvement in quality and were also able to reduce the manual bench work of the toolmakers by roughly 20% in the follow-up process. These are strengths that make us one of the top teams in the Champions League of large-tool-engineering plants.”  

Many subcontract manufacturers have the challenge of knowing which machines to purchase to suit the diversity of work that comes through the door. For other businesses, it's development and growth that dictate the purchasing decisions. For Ian Gibson, Managing Director of Vision Precision Engineering, the latter scenario led to investments in XYZ machine tools. Starting the business with his uncle, Dennis, they set about finding work - a significant challenge. Using existing contacts, they found an unlikely source of work making parts for coffee machines in Costa Coffee stores. “We were approached to make improvements to the in-store machines so that the baristas could not make mistakes in loading the cleaning products used in the machines,” says Mr. Gibson. This influx of work prompted the business to seek improvements in their manufacturing processes, leading them to XYZ for a solution to make parts faster than on their traditional milling machine. Mr Gibson continues: “Steve Cox, the XYZ Area Salesman regularly called in and, when the company needed to invest in new equipment, he helped select the right machine which was an XYZ 710 vertical machining centre complete with a 4th axis.” This investment created a new dilemma as making parts faster created a bottleneck in the secondary operations. This led to further investment in a smaller machining centre from XYZ to handle the increase in demand. “Even with two machines and 4th axis fitted to the mill, we were still falling behind in supplying parts to our customers so again we contacted XYZ to see how we could improve our manufacturing further,” comments Mr. Gibson. The answer was to invest in an XYZ TC 320 LTY-driven tool lathe. “The ability to produce milled and drilled features on our turned parts was taking up capacity on the original mill, so it made sense to purchase a machine that could produce our parts in one hit which is why we decided to invest in the TC 320 LTY.” With the hardened box way-built machine with its Y and C-axis, along with driven tool capability in place, Vision Precision set about getting the most out of its latest purchase. “Now we have this machine available to us, we have been able to quote for work that previously we could not tackle,” observes Mr Gibson. This is partly due to the maximum turning diameter of 320mm and the maximum turning length of 550mm. With a bar capacity of 78mm, it also means that Vision can produce more parts from bar rather than billets, and with a barfeed purchased for the machine, lights-out machining has now become a regular occurrence. “The machine just seems to tackle everything we throw at it.” Mr. Gibson states. “Big or small, it does it all, and the material removal rates are phenomenal on jobs from 20mm depths of cut when turning to drilling a 70mm diameter hole with a modular drill in super duplex material. When you consider we were only running at 200rpm when performing the drilling and it was only using 25% of the available spindle power it's a well-built machine with great power and it holds the tolerances we demand of it all day, every day”. Mr. Gibson also notes: “It's not only the machine that's important to me but the whole package. From sales through to the installation, training and ongoing support from XYZ', the whole experience has been second to none and that's why I also purchased a CT65 HD.” By posting about its work on social media, Vision has generated interest from companies looking to outsource jobs. Business is growing, which has led to a recent move to new premises. From modifications to coffee machines, Vision is attracting work from various sectors from green energy to defence.

How is the automotive industry meeting the lofty government goals that new diesel and petrol cars and vans will no longer be sold from 2030, and that all new cars and vans must be fully zero emission at the tailpipe from 2035? Will Stirling interviews Ian Constance, CEO of the Advanced Propulsion Centre Often mere words do not do the task justice. The transition to net zero automotive – think about that for a minute. The easy part is to visualise switching powertrains from petrol and diesel to electric (EVs), then designing and building processes for the mass volume manufacture of EVs – a huge engineering challenge. But this complexity covers materials, batteries and gigafactories, electric machines and drives, rare earths, power electronics, fuel cells, and more, such as their supply chain viability. Then there is the charging and hydrogen fuelling infrastructure. Supply chain security of key materials, including rare earth materials mined in just a few global locations, R&D investment in the right areas, technology scale-up, geopolitical risk, and market reaction to new technology. An important actor in this complex landscape is the Advanced Propulsion Centre (APC), the government agency tasked with managing funding programmes, judging applications and assisting companies that have good, low-carbon tech solutions. The APC administers the Automotive Transformation Fund, a £1bn+ fund to help eligible companies make the low carbon transition. It has run a suite of projects, funds and accelerator programmes since 2013. CEO Ian Constance needs to juggle all these balls, and the clock is ticking, but he spared 30 minutes for MTD magazine. Ian says: “The Advanced Propulsion Centre (APC)'s mission is to enable the UK to stay at the forefront of the global transition to smarter, safer, and importantly, more sustainable automotive and mobility solutions. The other part of APC is Zenzic, an agency investigating future-related, autonomous mobility – driverless vehicles.” What are the net zero automotive trends as we head towards 2025? “In the last 12 months, we've gone from a position of very high growth to flatlining and a bit of stagnation in the EV market, so what you're seeing there is a shift back towards HEVs (hybrid) and PHEVs (plug-in hybrids). I believe that is a short or medium-term shift and is driven by a few factors including rising populism in politics. But given the money and plans put into getting to net zero, we will find our way back to growth in BEV, battery electric vehicles. MTD readers are interested in the net zero automotive shift generally, and in manufacturing opportunities specifically. Recently the APC produced a report on the electric motor market, and the change in motor technology – indicating there is a slow shift from the dominance of permanent magnet synchronous motors to non-magnet motors like induction motors. Do both provide good opportunities for UK engineering businesses? “We have some very capable businesses that are scaling up here,” says Constance. “One of them is AEM, Advanced Electric Machines, based in the Northeast, who are developing magnet-free motors. In general, we have a very strong traction motor community in the UK comprised of various companies that are developing tech in this space, and a lot of them are using magnetic rare earth materials. There is Yasa in Oxfordshire, Protean in the Southwest who specialise in in-wheel electric motors, and there are plenty of others as well. So, the motor manufacturing opportunities are massive for the UK.” “Ford is investing heavily in Halewood, with support from the APC. They are turning this big factory from a manual transmission plant, clearly a technology that's intimately linked with internal combustion engines, over to electric drive units at high volume for export. Ford is doing that because it sees the UK as an important place to put that technology and create that mass volume.” “On the motor technology shift: Permanent magnet motors are generally high performance and are lower cost (than rival tech) at this stage. They need rare earth materials. The non rare earth magnet motors, and non-magnet motors (induction and electrically excited synchronous motors), are an important hedge against the volatility of rare earth material prices and supply, which is expected to go through the roof. That volatility and the geopolitical angle is a hedge that that many people want to make sure that they're on the right side of.” Rare earth reliability, and gigafactories for specialist vehicles A big, less visible part of the APC's work is research and policy work into securing these essential materials. As rare earth supply is dominated by China and a handful of countries in much smaller volumes, supply security is paramount. “You need to mine the ore, the raw stuff, in a clean and sustainable way, then you have to process the materials into rare earths, then into magnet materials, produce magnets, which are then used in the motor – it's a classic supply chain, with risks. We (the UK) are looking to create those supply chains back to friendly nations that we feel we can make long-term strategic partnerships with. The processing part of it is as important as the availability of the materials.” The mainstream net-zero automotive news has been dominated by gigafactories, so-called in reference to the capacity of the batteries made there. Building these factories in countries that manufacture EVs is essential, due to the dollar and carbon costs of shipping batteries, plus these are vast investments, and create thousands of jobs and supplier contracts. The UK's gigafactory picture is, some might say, behind its European peers following the loss of Britishvolt in 2023. Constance contests whether Britain is far behind the pack. “We (the UK) had the first gigafactory in Europe, a small one in the Northeast with just over one gigawatt hour (GWh) that supports the Nissan Leaf. Yes, the UK footprint is confined to two new massive gigafactory commitments, one which is Envision AESC and linked to Nissan, and the second is Agritas, part of the Tata Group, in the Southwest. Look at the potential of those two facilities, they could jointly produce over 70 GWh of battery cells. Our forecast is that by 2030 we will need around 90-95 GWh, so we are well on our way to fulfilling these requirements. “But these things are never that simple, are they? Two of our biggest vehicle manufacturers, Nissan and Jaguar Land Rover, will be certainly supported by those two gigafactories. We will need more to look after some of the bigger carmakers, but also very importantly, specialist vehicle manufacturers, which is such a strength of the UK; sports cars, luxury, and heavy-duty vehicles and off-road machines – all of those are going to need a supply of batteries. If people need a specialist vehicle, they might want a specialist battery. So getting into that specialist battery domain is a real focus for the future.” With batteries also come materials, and lithium is the primary base material for battery anodes and cathodes. But lithium, like rare earths, has a limited supply chain. “There are several different flavours of lithium battery. Beyond that, sodium is the next best element, but it has limitations. We are going to be dominated by lithium, particularly in the UK that has medium-to-high mass production vehicles. That's where the attention should be.” Hydrogen's changing role Hydrogen has had an interesting story. It was the wonder material for about three years, then media interest seemed to cool as the hype cycle shifted. How is it now developing in the UK car market? “We are increasingly asked to fund and look at projects involving hydrogen and hydrogen propulsion, much of that is around fuel cells,” says Constance. “Some of it is around hydrogen combustion that's more suitable for off-highway and construction.” “The APC's view is that fast forward another 10 years, most light-duty vehicles (vans and cars) will be battery electric. Then medium-duty trucks will have a mixture of battery electric and potentially hydrogen fuel vehicles, and for heavy-duty, long distance 40 tonners, etc – there's a big case for hydrogen combustion there.” There are three legs to this stool: the availability of the technology on the vehicle to do the job cost-effectively and efficiently, the availability of the infrastructure to support the delivery of whatever the energy medium is – hydrogen or electricity. And the third bit is, making the conditions right for the market. You need the three legs together.” Finally, what other manufacturing opportunities are there for subcontract companies in the EV transition? “Three areas, I'd highlight,” says Constance. “Giga-castings is a rising area of light-weighting and efficient vehicle manufacturing. Tesla reimagined the way cars are built by using massive front end and rear end castings rather than spot welding or bonding aluminium sections together. Can we develop more of that? Also the design of drives shafts is changing for an EV powertrain. There is growth of driverless pods operating in in secure space or in semi-secure space like airports. This is a step in completely reimagining a vehicle into lightweight, highly manoeuvrable modes of transport. Although these are complex machines, the barriers to entry here are lower than for developing a mass-market vehicle.”  

Founded in 1945, TSP Engineering was primarily established to serve the iron and steel industries by manufacturing mining machinery, mine cars and ingot moulds. Now, the company located on Britain's Energy Coast in Workington delivers high-quality, innovative heavy engineering solutions to nuclear, oil and gas, defence, renewable energy and construction sectors. The company recently encountered a challenge with one of its nuclear and reactor engineering customers - this led the company to find its solution from Quickgrind. With a colossal shop floor of 20,000m², TSP has the facilities to handle some of the biggest engineering and steel fabrication projects in the UK and beyond – but when it came to finding the right cutting tool solution, the company opted for a solution from the Tewkesbury based cutting tool experts. TSP was met with a nuclear reactor challenge and what drew the company to Quickgrind was its ability to offer non-standard length carbide tooling that won't be found in catalogues or brochures. During an initial consultation, Lewis Straughton, the Production Manager of TSP Engineering, revealed the company had always had a problem finish milling slots because the tools could never push to the required length. In the past, TSP had tried high-speed steel end mills with flute lengths upwards of 220mm. However, they had issues achieving the required tolerances. To overcome this, TSP reverted to the chain boring method. The critical nuclear components required slots machined to a tolerance of +/-0.1mm at depths of 220mm. However, the existing tools were witnessing pushing-off problems as well as creating spindle issues. This was not acceptable for the machining of high-value components. Retaining the in-house machining of the £2.5m contract was of paramount importance for TSP and risking the scrapping and re-working of components worth more than £500,000 was not an option. After partnering with Quickgrind, the two companies worked closely to develop a cutting tool solution and a suitable machining strategy that could finish the slots to the high surface finish and tolerance requirements. By adopting a specialist solid carbide end mill from Quickgrind with a new toolholder, TSP could achieve the required surface finishes and tolerances whilst the exceptional quality of the Quickgrind tools delivered consistently high performance and service life. As a manufacturer that has immense pride in its quality and certifications, TSP is ISO: 9001, ISO: 3834 Part 2, ISO: 1090 at execution level 4, ISO: 14001 and ISO: 45001 certified. The company also claims to be the first in the world to achieve the ISO: 19443 standard. Not only did the Quickgrind long flute end mills resolve the issues of meeting the tight tolerances, evacuating swarf from the deep slots and eliminating the spindle issue – the tools also delivered astounding cycle time savings. The Quickgrind end mills reduced the 260-hour cycle time to just 16 hours, yielding cycle time reductions of 244 hours per component.

As one of the world's leading manufacturers of model railways, PECO is a forward-looking family business that started trading back in 1946. Initially concentrating its manufacturing skills on the production of trackwork for model railway enthusiasts, the company has grown exponentially. To support its expansion, the Devon company relies on VISI CAD/CAM/CAE software from Hexagon in its design and manufacturing facility. Located on the idyllic South Devon coast, PECO is a company that has expanded from its humble beginnings of manufacturing individual components to producing HO/OO ready-made track and then on to all things ‘model railway'. This includes ‘Pecorama' one of Devon's leading tourist attractions that has a model railway exhibition and model shop, a ride-on miniature steam railway, a gallery and award-winning gardens as well as industry-leading model railway publications. As a company with a ‘fan base' as well as a customer base, PECO is a world-renowned brand in the model rail industry. From the foundations that stem from manufacturing a simple coupling, PECO now runs a facility that makes over 3,000 product lines. Discussing this, Simon Cockerham from PECO says: “We make everything that is part of the hobby building model railway industry. We have been in business since the 1940s and we started as a company making very small couplings that hook two pieces of rolling stock together. It has expanded from there to a business that makes everything from concepts right through to the final product.” With a manufacturing site that hosts state-of-the-art technology, PECO relies on VISI CAD/CAM/CAE software for its workflows. As Simon continues: “We use VISI throughout our manufacturing facility, from concept through to the final press or mould tool being created. We have numerous licences of VISI throughout our many departments and we also use VISI to generate laser-cut wooden kits for customers with textures upon them. It is also used to create the instructions that will guide enthusiasts and users on how to assemble the equipment.” “VISI has always been very good for our business as it focuses on just what you need to do the job. Some other software packages that we had before VISI had caused issues due to the high tolerancing of our components and the very deep nature of the machining processes that we have to undertake to achieve the geometries that we require in our press and mould tools.” As one of the world's leading PC-based CAD/CAE/CAM software solutions, VISI incorporates modules such as Modelling, Analysis, Mould Design, Flow, Electrode Design, Die Tool Design, 2.5, 3 and 5-axis Toolpaths, Blanks and Reverse. This provides PECO with the facility to create solid models; design, analyse, validate and prepare mould tool geometries as well as the pre and post-production analysis of plastic parts. With dedicated modules for creating electrodes, designing dedicated progressive die design and press tools, comprehensive machining strategies and even reverse engineering of editable solid models from scanned data – VISI provides the complete package for the company. As Simon adds: “One of the key reasons that we have VISI in our environment and we have been customers for almost 17 years – is because it is very reliable and comprehensive. We have an intimate knowledge of the VISI environment and systems throughout our experienced generations of designers and toolmakers who are here. This means we have the experience to support more junior members of the team here - but even we need assistance now and again because every engineer looks at things differently from time to time.” “Another key reason why we use VISI is down to the complexity of our products. We need jobs to be correct the first time. We also use very expensive machine tools from Roders, Sodick and Hurco as well as high-end peripheral equipment and cutting tools, and VISI has always kept us safe throughout the entire process of generating these tools.” The holistic Hexagon mould and die workflow removes blockers so the team can try new ideas. Simon explained: “We use VISI throughout most of our departments, especially within the wider ‘innovations department'. This means we use VISI for everything from design to producing wooden laser-cut kits for the factory to producing custom machinery for our production facilities. We also use VISI for all of our press and mould tooling too. The benefits of having VISI in the workplace are the integration between plot view, CAD/CAM, and the ability to create surface translations for mould flow analysis and laser ablation files. It streamlines integration between departments.” Many other features the business needs are all connected within a single environment, which makes PECO's training and application of VISI a lot easier for everybody concerned. Over the 17 years PECO has standardised its workflows on Hexagon's mould and die software its had a positive impact on its business. Simon concludes: “We know we have saved a lot of time and money with VISI. The savings are down to the VISI software having all of the components and modules that we require to take our products from concept through to production and export all around the world – all from under one roof.”  

As a leading name in the design, production and fabrication of engineered solutions, Manufax in Stockport manufactures jigs, fixtures and components primarily for the aerospace, defence, automotive and nuclear industries. Now in the third generation of the Rhodes family, Manufax has just invested in a large horizontal borer from Leader CNC Technologies. The investment in a Fermat machine from Nuneaton-based Leader CNC is part of an ongoing diversification strategy. As David Baines, Group Production Director for Manufax Engineering says: “Up to and during Covid, we were heavily into the aerospace industry with around 90% of our work in the aerospace sector. We suffered hugely during the pandemic, so we needed to diversify and we now do a third of our business in the aerospace market with another third in defence and the remaining third in the nuclear sector. With this diversity, we have seen the need to invest heavily in new technology for the future.” Looking at the company's plans for diversification, David adds: “The criteria we were looking for was a good horizontal borer and I found that the Fermat machine was a very good replacement machine with modern capabilities such as the rotary table that we have built into the machine. The quality of this machine builder is excellent.” Vince Heffernan, Leader CNC Technologies Technical Manager says: “The Fermat WFT 13 is the machine that has been supplied to Manufax. Fermat is a brand that has been around for over a hundred years and it now makes over 100 machines a year. As a machine builder, Fermat will cater to the specific needs of the customer, providing fully modular machines with up to 90 tools on the ATC or a robot loading system that can load an infinite number of tools. The Fermat WFT 13 has the option of different heads, so customers can have a 5-axis head.” The machine has a 2.6 by 1.8m table with 4 by 2.5 by 1.5m of travel in X, Y and Z axes with an additional W-axis that expands by 600mm. “The advantage of the W-axis is that customers can do some deep hole boring. The machine also has a large capacity where you can fit anything on the machine. You can always do a small part on a big machine but you can't always do a big part on a small machine,” continues Vince. David from Manufax adds: “The relationship with Leader CNC has been fantastic and they have helped us with the implementation of the machine and getting Fermat engineers over here to install and commission the machine.” Adding to this, James Leet from Leader CNC Technologies says: “We work closely with Manufax as the company trusts Leader CNC Technologies as a business that they can consult with on quite a complex issue. If we were positioned to sell hundreds of machines a year, we couldn't consult and support our customers - we are not positioned to do that. We are positioned to help companies like Manufax. The word ‘partnerships' is used a lot in this industry, but you cannot make installations like this happen without a partnership approach.” Concluding on the installation, David says: “This is our first machine from Leader CNC Technologies and it's very exciting for us to be collaborating with them - and we are looking forward to the future with Leader CNC.”  

As a subsidiary of the Nikon Corporation, Nikon Metrology has welcomed the recent comprehensive update to Volume 5.1 of the automotive measurement standards issued by the German Association of the Automotive Industry (VDA). The newly updated VDA standards cover a more comprehensive array of measurement applications within the automotive sector, addressing the industry's growing demand for more diverse and sophisticated metrology solutions. As Andreas Fuchs, Application Engineer at Nikon Metrology explains: “We already offer innovative, traceable measurement solutions based on national and international standards for the automotive industry. The new standard defines very precisely the procedures for evaluating the precise technology that we provide. After all, with the APDIS Laser Radar, our portfolio has featured a product for some time now that can also deliver traceable inline measurements as described in VDA Volume 5.1. Incidentally, those who use this technology no longer need a dedicated measuring room for a fixed CMM – enabling them to save a great deal of money, time and space.” The APDIS Laser Radar represents a USP with its proven ability to measure details at a distance without needing handheld probes, targets or surface preparation. This makes it ideal for automating repetitive inspection tasks with high accuracy. The system covers many manufacturing, industrial and research applications, including those that involve hard-to-reach features and are complex, delicate, or labour-intensive. The additional benefits of the APDIS Laser Radar include fast and accurate automated measurements with minimal set-up time for maximum productivity with flexible and portable installation. This allows for the absolute and accurate measurement of parts during production or wherever required, including directly on the production line. The APDIS Laser Radar, in particular, displays its strengths in the automotive industry. For example, the system can measure automotive features with absolute accuracy at high speed with no part preparation, whether inline or offline. With inline measurement, data can be collected in a much larger sample, resulting in a much more extensive data volume for process control. Therefore, it is wise to develop and use smart evaluation methods or systems and, in the process, adapt the reaction speed to the increased data volume. “These days, inline measuring technology tends to measure 100% of the parts, giving a very dense test sample with an extremely short response time and close to production,” says Fuchs. “When the part goes through, a real-time statement regarding the quality of the part is delivered immediately – meaning the response time, as well as statistical and general process control, are far better than before. A measuring room, on the other hand, only provides information about ongoing quality with a delay. In addition, there are no statements about the ongoing process, and production continues.” VDA Volume 5.1 appears to consider the trend that measurements are increasingly being made using traceable inline measuring systems instead of offline in the measuring room, making the implementation of suitability certificates for inline measuring processes in accordance with VDA Volume 5 more critical. VDA Volume 5.1 introduces an eight-stage model for evaluating inline measuring systems throughout their lifecycle. This model generates suitability certificates crucial for system release, ensuring compliance with automotive manufacturing standards. These certificates are significant in procurement as tenders for measuring systems regularly reference VDA volumes, highlighting the importance of standards in guiding industry-wide quality control and measurement practices.  

Hexagon's Manufacturing Intelligence division has launched its new digitalisation solution, Digital Factory that has been designed to help manufacturers build highly accurate digital replicas of their factories. It enables manufacturers to optimise floor plans and pivot production lines for smarter and more sustainable future factories. With open interfaces that enable digital twins of shopfloor assets, this could save a global manufacturing company £35 million per year* by avoiding costly mistakes. Hexagon has expertise in delivering accurate reality capture and surveying equipment, software to visualise, explore and simulate scenarios in 3D, and collaboration workflows. Digitalisation technologies are a proven technology and have been used for over two decades in civil infrastructure, architecture and public safety, but their potential has yet to be fully realised in manufacturing. Digital Factory is a future-ready alternative to traditional factory planning that empowers more efficient collaboration between manufacturing and operations teams from anywhere in the world. Digital Factory leverages a comprehensive portfolio of hardware and software solutions that includes Hexagon's range of reality capture technology – such as the Leica BLK2GO handheld imaging laser scanner, the Leica BLK ARC autonomous scanning module for robotic and mobile carriers and terrestrial laser scanners like the Leica RTC360. These systems allow manufacturers to capture and create dimensionally-accurate point clouds of the factory floor using the Leica Cyclone software portfolio and Hexagon's Reality Cloud Studio, powered by the HxDR, manufacturers can easily collaborate and quickly process data from Hexagon or a customer's preferred scanning hardware to recreate up-to-date 3D spaces. Hexagon offers complete workflows to ensure manufacturers achieve the maximum value from scanning the factory and processing the data into actionable 3D models for various applications to managing the data in the cloud. It will also provide remote team collaboration, facilitating remote collaboration among key teams at any time, using cloud-based tools with analysis and modelling capabilities with on-demand data. The system will facilitate the planning and remodelling of factory layouts with accuracy and detail, capturing precise measurements of a factory and creating an exact and reliable digital model that can be accessed anytime from anywhere. Additionally, by testing out new machines, factory floor layouts and workflows in the virtual 3D environment, companies can quickly identify feasibility and emissions considerations, enabling them to better understand the potential benefits of new technology and make future-ready smart factories a reality. Nicholas Lachaud Bandres, VP of Industry Solutions at Hexagon commented: “Hexagon has developed a deep understanding of manufacturers' needs. Digital Factory allows users to bring the physical world into an accurate virtual sandbox of their factories on-demand. Collaborating with their team and suppliers, they can consider ‘what-if' scenarios to shape more effective plant designs and layouts and oversee implementation with irrefutable and accessible 3D plans. We're making the digital factory more affordable and accessible, and we're excited to see how our customers apply this to ramp up and remain competitive with smarter factories.”

Barrs Court Engineering has recently invested in a new DN Solutions' DNM 6700 vertical machining centre from Mills CNC to increase its in-house milling capacity and capability. The Hertfordshire precision subcontract specialist has acquired a DN Solutions' Siemens 828D controlled DNM 6700 at the company's 11,500sq/ft facility in Rotherwas in June 2024. It is being used to machine complex parts in low volumes for a range of customers in the marine, renewables, nuclear, steam, automotive and yellow goods sectors. The DNM 6700 is also being used to finish machine fabricated parts prior to assembly. Barrs Court Engineering, established in 1983, regularly invests in new, advanced machine tools as part of a rolling, company-wide continuous improvement programme to increase productivity, performance and process efficiencies across all of its machining operations, and is no stranger to technologies supplied by Mills CNC. In 2001, Barrs Court Engineering invested in its first Doosan lathe, a Puma 300 and it has also acquired a sub-spindle, Y-axis turning centre from Mills CNC to strengthen its in-house turning capacity and capabilities. The DNM 6700 is, however, the first milling machine the company has acquired from Mills in its 41-year history. Almost 12 months ago, Barrs Court Engineering began a strategic process of rationalising and streamlining its business by creating three discrete machining areas in its machine shop - each one focused on a specific production model designed to meet different customers' machining needs and requirements. Explains Toby Kinnaird, Barrs Court Engineering's managing director: “The new manufacturing strategy is focused on growth, and has imposed a discipline across all our planning and production operations. We analysed our existing business, including what our customers expected and demanded from us and identified three different production ‘models' which would direct how we would organise our machine shop and manufacturing operations.” Barrs Court Engineering has at its disposal several dedicated machine tools with integrated automation for its low mix high-volume manufacturing operation which is predictable and is characterised by ‘scheduled' repeat business. Manufacturing bespoke, high-quality components in small batches has always been a particular strength of Barrs Court Engineering, and is perceived as a high growth area for the company. Often requiring a ‘turnkey' approach with machined parts characterised by their high precision, complexity and long cycle times, the company specifically acquired the new DNM 6700 machining centre to strengthen its performance in this high-value production area. “To increase our high-mix low volume machining capacity, we decided to invest in a new high-performance machining centre to replace two of our older machines that had limited capacity”, remembers Toby Kinnaird. “We were particularly looking for a machine with a larger X-axis to handle bigger parts which had been out of our reach.” Barrs Court Engineering compiled a ‘must have' technical checklist for its future machining centre investment and visited the MACH 2024 Show in April to identify a suitable machine. Continues Toby Kinnaird: “We visited Mills CNC's stand on the first day of the show, and discussed our requirements with their sales staff. They provided details on the DNM 6700 that was in stock at their Leamington facility and would be available for immediate delivery. After a short while negotiating the deal, we placed the order for the machine later that week.” The model acquired by Barrs Court Engineering is equipped with the 828D Siemens control with ShopMill software and features an 18.5kW directly-coupled spindle, a 1500mm x 670mm worktable and a 40-tool position ATC. Says Toby Kinnaird: “Our new DNM 6700 is powerful, fast, accurate and flexible. The Siemens Control is intuitive and easy to use, making programming and job setups quicker and more accurate. The integration of the 4th-axis table enables us to machine complex parts with intricate features in a single setup, avoiding the time and cost involved in re-fixturing operations and the potential for losing accuracy, and the inclusion of Renishaw workpieces and tool probes improves process efficiencies.

The demand for faster, cheaper, and greener aerospace solutions comes with challenges. CO2 emissions have been the main focus, but the impact of manufacturing operations is equally crucial. Fortunately, a solution is correctly applying coolant to maximise output, enhance process security and improve tool performance. Here, Henri Sevonen, Senior Industry Segment Manager – Sandvik Coromant, explains the benefits of high-precision coolant and tooling concepts. The role of coolants has undergone somewhat of an evolution. Machine shops have used coolants by directing tubes that flood the machining zone, particularly on the materials that need coolant to be machined. But now, by applying coolant with high precision accurately into the machining zone, new advantages are available. If coolant is to be applied effectively and make a difference, it needs to be applied as jets at high precision, in sufficient volume and directed correctly. Qualified applications can make a distinct difference in chip formation, heat distribution, surface integrity and tool wear. When applied correctly, precision coolant maximises output, increases process security and improves tool performance and component quality. The positive effects start at low coolant pressure, but the higher the pressure is, the more demanding material can successfully be machined. Precision coolant application can make a difference to machining in general, but when machining more demanding materials, such as heat-resistant super alloys (HRSAs) and titanium alloys, the practice makes a dramatic difference. Many modern CNC machines have coolant supplies at pressures of 70 to 100 bar. This is sufficient to incorporate high-precision coolant, which makes a noticeable performance difference. An essential basis for high-precision coolant use is modular tools to ensure quick tool changes for minimising machine stoppages. The modular Coromant Capto® tooling system is the basis for new standard high-precision coolant tooling. This modular platform designed with an internal coolant supply is also suited as the means with which to supply coolant at high precision. It is an established ISO standard and an option on many CNC machines with stationary and rotating tools. Turning tools with precision coolant are equipped to give accurate coolant jets with laminar parallel flow. The jets give rise to a hydraulic wedge between the insert and chip, affecting the chip form and flow and reducing the temperature in the machining zone. Employing nozzles, mounted close to the cutting edge, accurately projecting the high-velocity jets, forces the chip off the insert face and cools and breaks the chips into smaller lengths, helping to evacuate them. Benefits in finishing operations have been established even at lower pressures, down to ten bars in material including steel, stainless steel, aluminium and heat-resistant superalloys. Apart from higher security brought about by better chip control, precision coolant can bring about considerable tool life improvement and a potential for higher cutting speed. By applying precision coolant, 50% tool life increases can be the result. Precision coolant can play a vital role in ISO S machining. The effect of precision coolant can therefore provide the potential to raise performance by way of higher cutting speeds without the usual rise in temperature and loss in tool life. There is a clear cooling effect and not the higher cutting forces through higher feeds. For ISO S-classified materials, a 20% increase in cutting speed can be achieved while maintaining the same cutting length. Internal turning is also an area where precision coolant can play an important role in helping ensure good chip formation, as well as improving shearing properties in demanding materials such as titanium. In this way, the concept adds higher security and longer tool life to boring operations. When machining relatively large, deep holes with boring bars, such as in landing gear components, modular tooling at the back as well as the front end of the tool can be advantageous. Being able to change the small cutting head on the clamped bar provides quick, easy and accurate changing, adding considerable flexibility for various cuts in one set-up. The CoroTurn® SL combines damped boring bars with serrated locking heads for boring larger holes with depths of ten times the diameter and this is also equipped with precision coolant facilities.

Based in Silverstone, a short walk from the world-famous race circuit, Alitech Precision is a subcontract design, concept delivery and manufacturing company that specialises in the motorsport industry. To serve this demanding market, Alitech has invested in high-end machine tools, CAM software and cutting tools from CERATIZIT. Alitech opened its doors for business in 2014 with a 3-axis machining centre and CAM package. As the business evolved, it moved to fully simultaneous 5-axis VMCs. Specialising in the design of motorsport solutions and taking concepts through to manufacture, the company works with everything from high-performance road cars to F1 teams in the ‘motorsport valley'. With high-precision and lightning-fast turnaround times a customer pre-requisite, Alitech demands the same from its suppliers – that is why the company relies on CERATIZIT for its cutting tool solutions. Looking at how the company has grown since its inception, Alitech Precision Parts Ltd Managing Director Darren Cudd says: “We started with conventional entry-level machines and as we got into 5-axis machining, we quickly realised you get what you pay for. We haven't looked back since we bought our first Hermle machine and we now have four with a fifth machine on order.” Discussing CERATIZIT, Darren adds: “The relationship with CERATIZIT is not too different to what we have with our customers. We manufacture parts to a very high level and we need very good tooling to do that, especially some of the more specialised tools like long gun drills and bespoke cutters. We work closely with Nev, our CERATIZIT engineer, and we have an ongoing unofficial competition. If Nev gives me a number regarding machining parameters – I always have to try and beat it. Luckily, we know that our machines are more than capable of doing what Nev suggests, so we always try to push as hard as we can.” The Northamptonshire company machines a diverse range of materials and CERATIZIT is always on hand to meet any challenge. As Darren says: “We are on board with a lot of racing teams and this has changed the nature of our machining. For example, our pallet-loaded Hermle C22 UP machine spent 4.5 months straight, just cutting titanium through the winter rush. It's been a fantastic learning curve and Nev has been there all the way recommending the right tools. We got dialled-in on speeds and feeds pretty quickly and we are getting excellent tool life, which has been above what we were expecting to see.” As a forward-thinking company, Alitech is happy to sacrifice tool longevity for productivity rates. Commenting on this, Darren says: “Being in the motorsport industry, parts are often required in less than 24 hours, so we are always looking at the bottom line. The hourly rate of the machine is typically more than the cost of the tool cutting the part. So, it's simple math - if we're going to blow two tools to make a job in half an hour instead of 1.5 hours, it's a simple equation. However, the quality and longevity of the CERATIZIT tools always go beyond our expectations.” Looking at specific tools, Darren highlights the performance of the CERATIZIT 3-flute rippers, saying: “We have some large parts that are roughed on a 3-axis before 5-axis machining. The roughing cycle was around 4 hours and this is now down to less than 1.5 hours. This is credit to the length of the flute and how hard you can push the CERATIZIT rippers. We now find that we are limited by the power of the spindle rather than the tools.” As a company that operates around the clock, Alitech has invested in a CERATIZIT ToolSupply vending to ensure that production is always running. Darren says: “The vending has been a ‘game changer'. We can be running automated manufacturing on our 18 pallet machine and we may have 5 or 6 sister tools for each tool on that job. Even if we pre-order tools on what we think we will need, things don't always work out as you wish. It is here that the vending machine comes in as a safety net to make sure our machines are always running – its removed tool breakages as a ‘failure mode' from our business.” It is often said that Centro-P or ER32 toolholders are not suitable for rough machining, Alitech has not only debunked the myth, but taken it a step further – applying Weldon Lock toolholders from CERATIZIT to eliminate tool ‘pull-out'. Darren suggests: “Traditionally, you look at two factors when roughing. Firstly, can the spindle turn the tool, and secondly, will the tool take the stress before it breaks? We found the limits on both factors. We were pushing so hard that a third concern arose - are you pulling the tool out of the collet during machining? Centro-P's are fantastic but when you lean on them as hard as we do, they can pull out of the machine. To overcome this, Nev recommended the CERATIZIT Weldon shank collets. They drop straight into the Centro-P, lock onto the Weldon shank and we have achieved some pretty ludicrous numbers on how hard we can rough machine jobs.” “We also use the CERATIZIT shrink-fit system for machining the large complex jobs that other machine shops will shy away from. This includes jobs like engine blocks where we need very long series heat shrink holders to reach ludicrous angles and depths.” CERATIZIT tooling now accounts for 95% of the tooling supplied at Alitech. Recalling the incremental switch from a multitude of suppliers, Darren recalls: “Time is money and we are often here six or seven days a week. In the busy seasons, we really don't have a spare hour to call around cutting tool companies for products and support. The CERATIZIT website and App just make it so easy to jump on, find exactly what you want within two or three minutes, click ‘buy' and it's here the very next day. CERATIZIT really is a ‘one-stop-shop' and we now buy everything from end mills and ball nose cutters to specialist titanium drills, long gun drills, T-slot cutters, collets, shrink fit and much more.” Adding to this, Sales & Production Manager at Alitech Ben Philips comments: “When I joined Alitech, we were predominantly buying Centric-P's and heat shrink holders for HSK and BT40 machines, but CERATIZIT helped us to diversify from primarily aluminium machining to heavier metals and superalloys.” Looking to the future, Darren concludes: “We cannot get another ounce of machinery into our factory, so we have been holding off for the last year or two to try and make a big leap. We will make this huge leap to a site that would be five times larger than what we currently have, from 3,500 to 14,000sq/ft. As we evolve, our success will be reliant upon the strong relationships we have with both our customers and our supply chain partners like CERATIZIT.”  

Many people regard the lathe as the forerunner of modern machine tools. Its introduction which made turning operations possible, marked the dawn of machining. Today, turning is still one of the most commonly used machining processes, and lathes remain a substantial part of global machine tool sales. This is why turning tools make up a considerable portion of the product range for leading cutting tool manufacturers. It is not surprising that LOGIQUICK, ISCAR's latest campaign, brings new developments to the market with a significant focus on innovation in the field of turning. Some of the newly introduced products extend the existing families within ISCAR's turning line, while others offer solutions for advanced manufacturing. Such novelties not only reflect the trends of modern metal cutting but also aim to enhance the profitability of machining operations, particularly in turning. Several key features characterise the development directions in turning tools and this includes the following: • Higher Efficiency and Precision: This involves turning tools that can enhance productivity and precision, accelerate the overall machining process and minimise waste. • Advanced Cutting Materials and Progressive Coating Methods: Cutting-edge materials such as ceramics and cubic boron nitride (CBN) are becoming more common in turning tools. Through excellent heat resistance and durability, these extra-hard materials offer superior cutting speed when compared to traditional tungsten carbide. Concurrently, the need for rapid metal removal is driving interest in progressive coating technologies for cemented carbides. Innovative coatings can enhance cutting capabilities, extend tool life, and reduce wear. • Multi-Directional Turning Tools: These high-quality, versatile tools not only increase productivity and machining efficiency by reducing the number of tool changes but also minimise tool inventory, decrease machine downtime and maintain tighter tolerances. • Digitalisation: The Industry 4.0 approach underscores the importance of a turning tool's digital impact as an integral part of smart manufacturing. • Sustainability: Given the pressing nature of environmental issues, there is a growing demand for cutting tools that have a smaller environmental impact. This means they should be less energy-intensive and generate less waste. With the above in mind, the new products in ISCAR's turning tool line that are part of the LOGIQUICK campaign accommodate these criteria. Indeed, turning encompasses many external and internal machining applications, including longitudinal turning, facing, profiling, chamfering, grooving, parting and boring. Let's study ISCAR's most recent turning advancements and highlight their features. Advanced Cutting Material to Boost Turning Efficiency ISCAR has significantly broadened the range of available ceramic grades for ISO-standard turning inserts. The recent additions to the range have been designed to facilitate efficient machining of difficult-to-cut materials, particularly hard steel and cast iron (ISO H group of application). The newly introduced IC1017 carbide grade was specifically developed for machining challenging nickel-based superalloys. This complementary grade features a high-hardness submicron substrate and a PVD coating to enable turning superalloys at higher speeds. For cutting non-ferrous materials such as aluminium, copper, platinum, bronze, brass, and others (ISO N group of application). The product range has been enhanced with new turning and grooving inserts featuring a nano-composite diamond-like coating (DLC). Multi-Directional Benefits QUICK-T-LOCK is an innovative tool family designed for productive multi-directional cutting. This includes front and back turning, profiling, and facing operations, all achievable with just one tool. The family uses a new insert-clamping concept to provide exceptional stability during machining at extremely high feed rates. A notable feature is the advanced chipformer, specially designed for high-feed turning, especially in backworking machining (Fig. 1). V-shape CUT-V-GRIP inserts offer a versatile solution for bi-directional external turning operations. The inserts, suitable for installation on modified existing holders, are capable of entering narrow machining areas where common V-type ISO inserts cannot be used (Fig.2). The Boring Line When boring with a long overhang (usually more than five times bore diameters), vibration is a common issue. These vibrations can affect surface finish, reduce tool life, increase power consumption and limit performance. While changing cutting conditions is a typical method to reduce vibrations, it may not always be the best solution, as it can result in longer machining time. However, a new anti-vibration holder with an active vibration-damping mechanism offers an alternative approach to overcome this challenge. It enables a high level of productivity in various boring operations, from rough to finish. ISCAR's PICCO is a tool system primarily designed for machining small parts. This versatile system, which can be applied to a wide range of turning, boring, threading and drilling operations, is highly popular in workshops that manufacture various miniature components. A typical PICCO tool consists of a holder and a solid carbide cutting insert secured within the holder. The system has now evolved with the introduction of PICCO-INDEX, a family of steel and carbide boring bars designed to be mounted on existing toolholders. The bars are specially engineered to carry small ISO-standard indexable inserts (Fig. 3). The new addition offers a viable cost-effective alternative, particularly for rough and semi-finish operations for compact part production. Swiss-Type CNC Swiss-Type turning centres play a crucial role in modern manufacturing due to their precision, efficiency and ability to perform multiple operations simultaneously, such as drilling, milling, turning and knurling. They are instrumental in the production of miniature components required in several industries. This includes watchmaking, medical devices, automation equipment and electronics. Consequently, the development of more advanced cutting tools and toolholders dedicated to Swiss-Type lathes is a top priority for most tool manufacturers, including ISCAR. The LOGIQUICK campaign has also highlighted Swiss-Type machining tools. The new modular system, QUICKSWISS, provides a solution for most applications on the sub-spindle of Swiss-Type lathes. This system (Fig. 4), which features a height adjustment option, offers a wide variety of bases, holders, and heads for various turning operations. For grooving, parting, and recessing, the QUICK-2-CUT family shows promise. The tools in this family carry high-precision, narrow, double-sided inserts which are tangentially mounted on the tool from the side. The insert clamping concept ensures high rigidity and excellent dimensional repeatability. The targeted coolant, directed to the cutting zone, improves tool life and contributes to a better surface finish (Fig. 5). The LOGIQ-4-TURN family of turning tools with indexable double-sided inserts has been well-received in the market. In response to this positive feedback, the company has expanded the family range to include smaller-sized inserts, providing a cost-effective solution for Swiss-Type and compact lathes. In ISCAR's electronic catalogue, two new filter search options specifically related to Swiss-Type lathes have been added. These options allow for the search of modular adaptations to find more efficient tools for main and back tool posts. The LOGIQUICK campaign's turning package encompasses far more than the products currently under consideration. The company is gradually introducing new product families in quick succession and plans to allocate more time to analysing these new arrivals. Will they boost productivity and contribute to a rapid increase in customer profitability? ISCAR firmly believes the answer is a resounding ‘yes'.

Industry-leading computed tomography (CT) scanning technology provided by Nikon has been employed to uncover the secrets of a rare 17th-century pendant watch, part of the Museum of London's renowned Cheapside Hoard. The intricate details revealed by the scans have transformed the Museum's understanding of this unique piece of early modern technology, providing new insights into its mechanism, case, and historical significance. The heart of the goldsmiths' trade in post-medieval Britain was on the south side of Cheapside in the City of London. Here, on 18th June 1912, beneath a brick-lined cellar floor in a timber-framed building, workmen discovered a remarkable cache of almost 500 items of jewellery, gems and other precious Elizabethan and Jacobean objects. Probably buried in about 1640 at the onset of the English Civil War, the so-called Cheapside Hoard is now housed in the Museum of London and contains only one item that can be directly attributed. It is a gilt-brass pendant watch, made in Geneva between 1610 and 1620, bearing the signature of its maker, G Ferlite (Gaultier Ferlite). For a catalogue to be published to coincide with the opening of the new London Museum in 2026-2027, Hazel Forsyth, Senior Curator Medieval & Early Modern Collections responsible for the Cheapside Hoard, wanted to check a few facts and figures concerning recent further research on the watch. In 2023, she approached Nikon for assistance and was delighted when Alistair Watson, X-ray Sales Manager, suggested rescanning the watch. The watch movement had first undergone X-radiography and CT reconstruction in 2005, but the technology has progressed enormously since then and there was potential to discover much more detail. The latest investigation was undertaken by James Finch, Applications Engineer at Nikon's X-ray CT production, demonstration and subcontract inspection centre in Tring in February. The watch was scanned in a Nikon XT H 450 system equipped with a source having a 450kV rotating reflection target manufactured on-site. Scan parameters were 430kV, 100W and a 2mm tin filter was used. A total of 3,800 projections were acquired with a voxel size of 31.8 microns. Each exposure took 1,415 milliseconds, so the overall scan time was 90 minutes. Nikon's CT scans produce ‘staggering' results “The results were staggering. For the very first time, it was possible to see details that were blurred in 2005, or simply invisible. The results showed precise features and gear components and relative metal densities, including imaging of the areas which still retain gilding,” says Hazel Forsyth. “It was also possible to obtain precise measurements of particular features. Even more exciting was the possibility of scanning the case and movement so that we could virtually re-insert the mechanism into its original housing. This meant we could work out what its early 17th-century owner would have seen through some of the apertures in the dial. The latest images have had a transformative effect on our understanding of this important watch and its place in early modern horology.” The watch, designed to be worn around the neck, is intriguing because it has a reverse-set chapter ring; the numbers 12 and 6 are transposed so the wearer could read the time by inclining their head. Other interesting features include a piercing in the case for an alarm, as well as astronomical and calendar indications on the dial. When it was made, it would have been a very expensive, luxury item. Unfortunately, it is in poor condition. Most of the enamel on the dial is lost and the hinge and cover are missing. The dial is currently supported by a modern acrylic insert and the mechanism, which was removed for conservation reasons, is heavily corroded. Very little of the internal structure can be seen with the naked eye, which is why the detail revealed by CT scanning has been so valuable.

Sustainability considerations are currently ‘trendy' and Individual elements such as toolholding are often considered. However, if you want to act sustainably, you should not focus too much on finite details and look at the overall process. When it comes to sustainability, the product life cycle and the process in which it is integrated are critical factors. In machining, there are a lot of variables to consider such as the material, component geometry, quantities, type of machine, tools and clamping devices used. External circumstances such as the production location, the qualifications of the employees and automation must also be considered. Apart from materials, energy efficiency is probably the main factor that determines a sustainable process. Therefore, a promising approach is to look for the largest consumers and optimise their use. The machine tool offers savings potential as it consumes the majority of the energy used with its spindle and axis drives, peripherals and auxiliary units. When purchasing new machines, the user can significantly reduce consumption by paying attention to energy-saving components. Andreas Haimer, Managing Director and President of the HAIMER Group, explains: “In our production, we have learned that replacing an old machining centre with a new one using the same machining process requires around 30% less energy. As a family business, we pay a lot of attention to sustainability. In the last financial year, we invested a total of over €1m and we have saved over 250 tons of CO2.” Machining savings can be made with examples like CAD/CAM-optimised machining strategies. Andreas Haimer says: “A customer provided us with data on how he reduced machining time by 75% from 71 to 18 minutes per part by trochoidal milling with our HAIMER Power shrink fit chucks and the HAIMER MILL cutters. The change in machining strategy was accompanied by energy savings due to significantly lower power consumption. While the spindle load was 80-85% for 10 parts with a face mill that had a total energy cost of around €150, the trochoidal milling strategy with a spindle load of 8-10% and shorter cycle time reduced energy costs to €5 for 10 parts. This was a higher output with lower energy consumption per part produced.” The sustainability of toolholding Have you ever thought about how a tool holder could contribute to sustainability? Where a milling machine consumes an average of around 30kW, plus the power of hydraulic and pneumatic devices, automation equipment and robots - toolholding only plays a subordinate role. This is because the tool holder is a comparatively small detail, even if using a shrink-fit chuck with a marginal energy consumption. Looking at other clamping systems, the energy consumption during shrinking is higher in operational use than with a hydraulic or milling chuck. Looking at the entire product life cycle of a tool holder, which includes production, maintenance and disposal, a completely different picture emerges. The production of a hydraulic chuck requires significantly more effort and energy due to its complicated structure. There is also the soldering of the expansion sleeve, additional heat treatment to prevent the solder joint from breaking, as well as the effort required for cleaning, assembly and filling with oil. “From our experience, the energy required for production is around three times higher for the shrink-fit chuck,” explains Andreas Haimer. “In addition to shrink-fit chucks, we also have hydraulic chucks. Although their list prices are higher than shrink-fit chucks, they are the right solution for certain applications. However, they are not more sustainable. Our analyses show that a hydraulic chuck requires around 25kWh more energy to manufacture than a shrink chuck. In product life cycle terms, a shrink fit chuck with an energy requirement of 0.026kWh per shrink fit and the cooling cycle can be shrunk almost 1,000 times before it requires more energy than a hydraulic chuck.” The same applies to milling chucks, which are much more complicated and contain more components as well as grease and lubricants. Life cycle and process reliability are crucial. Haimer shrink chucks are maintenance-free and can be shrunk in and out an unlimited number of times, whereas hydraulic chucks and milling chucks have to be serviced every 2-3 years to check the clamping force. The contained hydraulic fluid or grease also makes environmentally friendly disposal more difficult than with shrink-fit chucks. As well as the life cycle, there are differences in terms of process reliability. But how is energy consumption calculated during the shrinking process? Heating a shrink-fit chuck takes about 5 seconds. The maximum output of a HAIMER Power Clamp shrink-fit machine is 13kW, but the average is 8kW. This means that a single, complete shrinking process consumes around 0.011kWh and cooling consumes 0.015kWh resulting in a total of 0.026kWh. If a kilowatt-hour costs 20 cents, shrinking and cooling costs a marginal 0.5 cents. How should the energy consumption be classified when considering the machining process with a power consumption of around 30kW? Assuming that a tool is in use for an hour and 1% machining time can be saved thanks to the high concentricity and rigidity or the improved milling strategies due to the slim contour holder, that would be 0.3kWh of energy saved. Andreas Haimer summarises: “The energy consumption per clamping process plays a negligible role compared to the issues of life cycle and machining strategy. Modern CAD/CAM-optimised milling strategies can save 75% of machining time. Machinists must focus on such processes if they want t sustainability and productivity.”

At Archway Engineering, a Leadwell V-50L 3-axis VMC performs some of the more arduous machining operations at the Elland-based company. On the shop floor of the West Yorkshire factory that manufactures drilling equipment for site investigation, mineral exploration, water well construction and environmental monitoring, the productivity of parts going through this machine has been doubled simply by changing the way workpieces are clamped. The transformation has been achieved by the September purchase of three US-made Chick OneLOKs from sole UK agent 1st Machine Tool Accessories, Salisbury. One of the units remains permanently at one end of the machine's 1,420 by 610mm table, where it has been clocked into a known position to within 10µm across the 152mm face of the clamp's fixed hard jaw. The other two OneLOKs may be removed to make room to mount a 4th-axis indexer, but they are quick to set up again relative to the permanently positioned clamp using a parallel bar. During frequent small-batch runs, it is a simple matter to secure three parts side by side, write a sub-program to machine the workpiece in the permanent OneLOK, probe the position of the parts in the other two clamps, repeat the sub-program twice at the appropriate offsets and run the complete cycle in one go. This process differs markedly from previous practices involving either bulkier conventional vices, only two of which would fit on the table or a lathe chuck for holding round parts, an arrangement so large that just one could be accommodated in the working area. The positions of all these former workholding setups were slow and laborious to establish accurately and in practice each machining cycle was executed individually. Another advantage of the Chick product is that it has a time-saving ratchet mechanism to allow the operator to adjust the position of the rear, moveable jaw in one swift action so that it almost touches the workpiece. A few turns of a handle move the jaw in the same direction over the last few millimetres to complete the clamping action quickly, contributing further to short setup times. The mechanism's novel squeeze clamping action with pull-down as the jaws close applies an equal and opposite force on both sides, resulting in repeatability to within 20 microns. A practical example of the time savings is in the production of a so-called TC shoe for a drilling machine, produced from an S355 hot-finish steel tube weighing 50kg. Setting up three billets in machined aluminium jaws side-by-side in the OneLOK takes 1.5 hours, compared with a total of four hours previously needed to clamp the parts individually one after the other in the lathe chuck on the VMC table. Furthermore, clamping forces were lower using this workholding equipment, as well as when employing conventional vices, compared with up to 26.7kN of retaining force exerted by a OneLOK. Therefore, feed rates previously needed to be slower, lengthening cycle times. The versatility of the new units to hold prismatic parts in hard steel jaws, or round parts in soft aluminium jaws machined to match the shape of the component being secured, sets the Chick product apart from conventional vices and underpins the elevated gripping pressure. Danielle Toner, production manager at Archway Engineering commented, “Most of our production involves one-offs or small batches, with individual cycles generally running for several hours. Being able to clamp parts of any shape so firmly in the OneLOK allows us to mill much more aggressively using high-feed inserted end mills and solid carbide drills. In one instance, an EN8 steel drive unit end plate that previously took six hours to machine is completed in one hour.” She explained that it is now possible to feed at 7m/min a 32mm diameter end mill rotating at 1,200rpm, whereas the previous maximum feed rate was 2 to 3m/min. At the same time, higher quality tools may be employed and the depth of cut has increased from 0.3 to 1mm. Additionally, because parts are held more rigidly and the OneLOK is of low-profile design, there is less vibration so tools last longer and the machined finish is better. It helps particularly with the production of the TC shoe as well as phosphor bronze sliding plates, both of which require features with a near-polished surface. Mrs Toner concluded: “The quicker setup times using the Chick OneLOKs and the faster machining cycles that their secure clamping means that a typical short batch of parts can be produced on the Leadwell in two days, compared with up to one week previously. I estimate that productivity across the parts produced on this VMC has increased by 100% and probably more. The machine operator is also more productive, as he has extra free time and can plan his work around the factory more effectively.”

When Wall Colmonoy needed to modernise its EDM machining capacity, the manufacturer turned to Sodi-Tech UK and the Sodick brand of wire EDM technology. As the industry benchmark in the manufacture of Colmonoy® surfacing and Nicrobraz® brazing products, precision castings, coatings and components, Wall Colmonoy had three key areas of concern in its wire EDM department. Installing a Sodick ALC800G Premium wire EDM machine resolved them all. The Michigan-based company with European headquarters in Pontardawe, South Wales had two machines with table sizes of around 300 by 400mm, so any large work outside this envelope either had to be subcontracted out or turned away. THE CHALLENGES Wall Colmonoy had deadlines and capacity challenges – it needed a more productive solution that could improve cutting times. The third challenge was overcoming poor precision levels. With existing EDM machines over 10 years old, Wall Colmonoy needed precision levels to within +/-5 microns. It was Sodick that had the answer with its ALC800G Premium wire EDM machine. Looking at why the company invested in a Sodick ALC800G Premium wire EDM machine, Wall Colmonoy Process Engineer Kevin O'Connor recalls: “Our existing machines were ageing, and the programming side of manufacturing became very dated. We were also facing increasing maintenance costs and machine downtime.” Supporting this opinion, Aaron Patton, EDM machinist at Wall Colmonoy says: “The programming was taking too long and the cutting process was extremely time-consuming. Another issue was capacity, we needed to put large parts on the machine, and we couldn't do this with our existing machines.” As Kevin O'Connor continues: “Sodick has had a relationship with Wall Colmonoy dating back 30 years. We went on a fact-finding tour of Sodick as well as other manufacturers to see if they could supply us with a suitable machine. We needed to know if they had a machine capable of cutting our specialist alloys. So, we took samples to Sodick for them to prove that the machines could do ‘exactly what they say on the tin'.” Adding to this, the Business Development Manager at Sodi-Tech, Mr Tony Berry says: “Wall Colmonoy needed a machine with a capacity to accept their diversity of parts in both dimensions and complexity. The existing machines were too small and the Sodick ALC800G Premium wire EDM machine has a worktable of 800 by 600mm, more than double the bed size of existing machines. By purchasing the Sodick ALC800G Premium wire EDM machine, Wall Colmonoy can manage larger parts, eliminating the need to subcontract work to external sources.” “The new ALC800G Premium has replaced one of the previous EDM machines and it is more productive than the two previous machines combined. This is a credit to both the productivity increase and the ability to run unmanned for extended periods overnight due to technology like the Smart Pulse electrical discharge power supply unit, Sodick's Smart Linear technology, the fixed Jet AWT wire threading and the iGroove Plus wire rotation technology. From a programming and operational perspective, Wall Colmonoy can now process up to four different parts simultaneously in a single set-up – and even multiples of those parts.” Confirming these points, Sodi-Tech UK Technical Sales Manager, Mr Conor Plaskitt adds: “The reason Wall Colmonoy decided to invest in the Sodick ALC800G Premium supplied by Sodi-Tech is to increase the capacity of what they can cut on the machine and take on larger components. This is one of only two machines of its type in the UK and from a market perspective, it really gives Wall Colmonoy an edge over their competition.” Tony continues: “They have now had the machine for almost a year and it has performed very well. I think Wall Colmonoy are now ready to progress. As part of the free packages that we provide, we can offer advanced training that incorporates things like angle cutting, cutting compound angles, machining unusual shapes and moving on to the machining of specialist alloys, which is exactly what they do here at Wall Colmonoy.” Looking back at the installation of the Sodick ALC800G Premium wire EDM, Aaron Patton, EDM machinist at Wall Colmonoy says: “When we took delivery of the machine there was quite a steep learning curve, but now we are running the machine confidently, the benefits are impressive. There is still an advanced course that we can undertake to further enhance our capabilities as well as maximise what we can get out of the machine.”

Mills CNC has recently supplied Tufcot Engineering Ltd with a new, large-capacity, multi-tasking lathe to enhance its machining capabilities. The 24” chuck DN Solutions' Puma 700LM II equipped with driven tooling and FANUC 0iTP control is one of the largest machines acquired by Tufcot in its 43-year history. Tufcot's relationship with Mills CNC began in 2005 with a Puma 240LC and now the company has purchased the Puma 700LM II, installed at the company's 50,000sq/ft facility in Sheffield in April 2024. Over the years, more investments with Mills have followed to consolidate its supply chain position and acquire new business. It ordered the new Puma 700LM II as well a new 21” chuck Puma 4100MC lathe to be installed in August. The latest additions will take the CNC lathes acquired from Mills CNC to 11 in total. “The high-performance lathes that Mills sells and supports are real workhorses. They are reliable and deliver the fast processing speeds and accuracies we need to meet our customers' demands,” says Tufcot's Managing Director, Greg Majchrzak. Since being installed, the new Puma 700LM II has been used to machine small batches of high-precision large diameter Tufcot® composite bushes and bearings for customers in the marine sectors. Tied up to tight tolerances, these parts have long cycle times and a range of intricate milled features. Tufcot® is a composite engineering material manufactured from synthetic fibres and thermos-setting resins. However, the company's core business is supplying finished products such as wear pads, bushes and bearings. The marine sector is important to Tufcot's growth ambitions. Says Justin Krebs, Tufcot's Operations Manager: “Our knowledge of composites and their application has helped highlight significant new business opportunities that we could exploit if we had larger and more sophisticated in-house turning capabilities.” Tufcot always had the capacity to machine large parts on its existing lathes, but the processes involved were more labour intensive and required more work handling. This had a knock-on and detrimental effect on the cost-per-part. As Justin Krebs continues: “Owing to the increased demand for Tufcot® composites, it made perfect sense to strengthen our turning operation by investing in a new large-capacity lathe to machine these larger parts. As a consequence, we approached machine tool suppliers with our plans and asked them to recommend their preferred solution.” Having gone through what was a comprehensive and detailed decision-making process, Tufcot ultimately opted to go for the Puma 700LM II from Mills CNC. The Puma 700LM II is a large-capacity lathe with a 900mm maximum turning diameter and a 3200mm maximum turning length. Says Greg Majchrzak: “The Puma 700LM II can handle large and small parts, and the driven tooling capability enables complex, high-precision features to be machined in a single set-up.” Delivering fast part cycle times and eliminating the need to transfer components between machines has helped improve productivity and process efficiencies. It has enabled Tufcot to win new machining contracts for larger components from new and existing marine customers that, before the Puma 700LM II investment would have been out of its reach. Continues Greg Majchrzak: “To protect the new business won on the back of the Puma 700LM II acquisition, we also decided to duplicate the investment by ordering a new, similarly specified 21” chuck Puma 4100MC lathe. This will enable us to continue to meet our production and delivery schedules should the Puma 700LM II be out of action for any reason. In effect, we are future-proofing this new business, and leaving nothing to chance.” In addition to investing in the two new lathes from Mills CNC, the company has also recently acquired two, new state-of-the-art CNC routers in 2022 and increased the size of its facility with the purchase of additional premises.

Specialising in the manufacture of precision components for the aerospace industry, subcontract machining firm Apel began investing in Citizen CNC turning centres in the 1980s to help raise efficiency. Founded in 1965, the company has over time continued to re-invest in modern, highly productive lathes purchased exclusively from Citizen Machinery UK. Nowadays, Apel operates nine Cincom sliding-head lathes and one Miyano fixed-head model at its Wilmslow facility. Together they produce around 50,000 components per month across more than 3,000 part numbers. Utilisation of these Citizen CNC lathes and related technologies has led to significantly increased levels of productivity and profitability. The technology that has contributed most to raising the efficiency of production at Apel is Citizen's proprietary LFV (low-frequency vibration) chip-breaking software, which is part of the operating system in the control of three of the six 20mm capacity Cincom L20s on site. When activated, the function breaks what would otherwise be long, stringy swarf into short, manageable chips. Around 50% of the material processed by Apel is aerospace-grade stainless steel bar. LFV is especially effective when processing this alloy. Paul Bowker, Apel's Quality Director said: “We were an early adopter of LFV in 2018 following a visit to Citizen Machinery's technical centre in Bushey to witness demonstrations. The function reduces the metal removal rate slightly, so we don't use it all the time, but it's really useful to be able to pick and choose when to program the function to start and stop. We switch it on mainly when turning stainless steel components on the LFV-equipped machines, especially when processing parts shorter than 25mm. It is normally chip breaking the metal for up to half of a typical cutting cycle.” He further explained that the decision to use LFV is also based on the surface finish required on components. Some customers' drawings stipulate a very high surface tolerance and machining with the LFV function switched on allows this to be achieved by turning alone. It avoids the need to centreless grind parts afterwards, thereby reducing unit manufacturing costs and raising profitability. Dimensional and surface finish tolerances on many component drawings can be met and maintained when using this facility. Apel also uses Citizen's adaptive guide bush (AGB) system. This automatically compensates for variation in bar diameter, preventing the stock from seizing in the bush. It also constantly maintains concentricity to prevent run-out issues. Downtime is avoided and tight machining tolerances are maintained. The system is used not only on the 20mm capacity sliding-head lathes but also on three 32mm capacity Cincom models on the shop floor. The aerospace sector is very busy presently and Apel is well placed to win work due to the quality management system it operates, competitive pricing and the many industry and customer approvals it holds. Exports account for 20% of turnover with India and Saudi Arabia being major overseas markets. The AGB systems ensure reliability during unattended operation by compensating for bar diameter inconsistency and preventing stoppages. Additionally, the LFV machines do not have swarf clogging the working area when processing stainless steel. It contributes further to reliability and eliminates the need for an operator to be in attendance to untangle ribbons from the components and tooling. Mr Bowker concluded: “Our nine Cincoms, as well as the Miyano for turn-milling larger components up to 50mm diameter, support all of our production and will continue to do so as we increase our volume of work in the expanding global aerospace industry.”

As a machine tool builder that manufactures high-end machines for the global market, Heller UK is frequently involved in turnkey projects for prestigious OEMs. On a recent project, the Redditch company enlisted the support of the cutting tool experts at Guhring. There has been a wide spectrum of tools used on this project for a leading manufacturer of Electric Vehicles (EVs), including the Guhring tool holders and tool vending technology. As part of the package to accompany the cutting tools, the EV manufacturer has selected a vast range of standard shrink chucks, hydraulic chucks and synchro-tapping chucks. The cutting tools incorporated in this project included a huge range of standard products, all carefully selected and tested to minimise cycle times while achieving tight tolerances. Whilst the standard range of Guhring products accounted for a significant element of the system integration project, it was the bespoke PCD combination tools that demonstrated Guhring UK's expertise as a one-stop solution provider. With the PCD combination tools manufactured at Guhring UK and Guhring Germany, the bespoke solutions were developed to achieve ‘one shot' plunging. The bespoke tooling aimed to reduce cycle times and adhere to the high surface finishes required – and maintain this over the life of the tool. Discussing the project, Guhring UK's National Sales Manager Chris Bush says: “It is a project and industry that is at the very forefront of technology. The end user typically specifies a machine builder and cutting tool supplier - in this instance, it was Heller and Guhring for the cutting tools.” Looking at how the process delivers a solution for the customer, Chris continues: “In Germany, we have a large project engineering team with over 200 employees. So, when we receive a CAD model of the customers' component and the machine capabilities, we can develop the cutting tools and machining strategy from that and create an optimised solution in conjunction with Heller.”   “This requires several meetings to discuss the machining strategies and how we develop the tooling to create a seamless solution from machine tool to cutting tool. At Guhring, we supply everything from toolholder to the cutting-edge and that also entails all the speeds, feeds and cutting strategies in conjunction with the machine builder. Once we supply all the cutting data and tooling sheets, we will then visit Heller and do all the initial run-offs to ensure all the cutting data is optimised and the machining strategy is working well.” Alluding to the overall project, Chris adds: “It has been a great partnership between Guhring and Heller and the current EV project is the biggest project we have collaborated on in the UK.” Discussing the project from a Heller perspective, Tad Forys from Heller Machine Tools UK says: “We delivered 22 machines in this project. That includes eleven 5-axis machines and 11 4-axis machines - all built in the UK. With this project, we have gone from a customer drawing to a fully automated production line. From the initial enquiry with the customer, our engineers here in the UK conducted comprehensive cycle time studies. Following on from that, we developed custom hydraulic fixtures to hold the parts; and we have used these fixtures because it is a high-volume electric vehicle application.” “This recent project that we collaborated on with Guhring has been a perfect demonstration of team work. When we talk about collaboration, it isn't just about working together - it's about aligning our values and expertise. The first two machines for the production line are here at Heller, so we can do the initial production ‘prove off' before the machines land on the customers' shop floor. Guhring has been with us for every step of the journey, clocking in tools, optimising speeds and feeds to make sure we have the most efficient process for the customer before the machines are delivered.” “From a Heller perspective, this project has been an outstanding success. Our end user is very happy. Everything has been delivered on time to a particularly demanding customer - and this has been made possible by a close working partnership with Guhring who have helped us every step of the way,” adds Tad. Discussing the tooling solution further, Guhring's Chris Bush adds: “Even though we are supplying the tools and tool holding for this project, we are also supplying the tool management vending solution. As this is a significant project with a large number of tools, we are supplying the vending machine with some add-on units. The proprietary software that Guhring programs and supplies with this can also be linked to the customer's ERP system. This provides complete synergy and automation for the end user from tool ordering with complete transparency of costing and cost centres by the operation, the individual machine and even by the operator. This system provides unparalleled transparency, so everyone can see the costs and where the costs are going.” “From a Guhring point of view, this project has been a great success and working together with Heller has been a true partnership, and a fantastic example of delivering a proven process to the customer on time,” concludes Chris