This is the audio version of the MTD magazine which is a magazine focused on metal cutting and manufacturing technologies.
Situated near Alva in Central Scotland, Qualtek Engineering serves everything from small customers to large international corporations with CNC machining services. Alongside its main manufacturing activities, Qualtek operates Bespoke Engineering, a specialist automotive division concentrating on restoration, classic cars, performance vehicles, and motorcycles. It is here that Microloc clamping technology is used. The nature of Qualtek's work demands versatility that traditional workholding solutions struggle to provide. Ewan Montgomery, who oversees operations, explains: “It's a very individual workshop with diverse needs. We specialise in restoration, classic cars, performance cars, and motorcycles, which means we're constantly dealing with different projects needing different tooling approaches.” This diversity extends to tooling manufacture. “A good example is working on a classic car cylinder head with modern machinery,” Montgomery notes. “Buying old-fashioned face cutters commercially is hard to get and hugely expensive for standards that we don't really need. Manufacturing our tooling became a cost-effective solution.” To accommodate substantial automotive components, Qualtek invested in a HAAS VF4SS machining centre. “The machine size is really to accommodate the size of materials that we're working with—engine blocks, cylinder heads, etc. You need a certain size of footprint; otherwise, if they don't fit, you can't work,” Montgomery explains. Discovery of the Microloc Solution The introduction of Microloc workholding proved transformational. “Microloc was completely the solution that we didn't know we were looking for,” Montgomery admits. “Very soon after I bought the machine, I'm buying a Microloc system, and it's really one of the best things we've ever done.” Technical Advantages The Microloc system achieves exceptional accuracy through its integer location methodology, where components are clamped against fixed jaws, providing precise location in X, Y, and Z axes. The system maintains repeatability accuracy of ±25 microns, achieved through case-hardened jaws ground to ±10 microns relative to tenon keys. “The system is designed for machinists, and it's designed to minimise setup time and provide micron-level accuracy,” Montgomery explains. “There's nothing else out there that delivers this kind of modular setup that Microloc provides.” The precision aspect is crucial for automotive restoration work. “The accuracy, as we understand from manufacturing our own tooling, just a few microns out is enough to scrap a part,” Montgomery emphasises. One significant advantage is eliminating traditional setup procedures. “Traditional clamp vices have to be set up, have to be clocked in if you've got multiple operations,” Montgomery notes. “Things can move because it's friction clamping, not keyed clamping, and you've got lots of variables, including temperature, user, and everything else that can go wrong.” Modular Flexibility The modular design allows clamping elements to be rotated through 90 or 180 degrees, enabling four-edge clamping configurations. Individual clamping modules deliver exceptional holding power. “The clamping force on these is unbelievable. I think we're approaching a ton of pressure,” Montgomery reports. “You can place them anywhere on your table within 3mm of movement.” “It doesn't matter if it's a metre-long part or if it's a 100mm long part, you'll find a clamping place that will accommodate that width or length,” Montgomery explains. “You can have as many of these Microloc clamps as you wish on the table. You can have nested systems for repetitive work.” System Configuration and Fourth Axis Integration The Microloc baseplate mounts using bore tenon adaptors that locate into precision 16mm bores. The baseplate features precisely spaced, conical zero-point locations that accept tenon keys of various workholding elements. Integration of fourth-axis capability opened up new possibilities for complex automotive components requiring specific angles. “A lot of the machining originally was done off-centre,” Montgomery explains. “This particular manifold is at 45 degrees and using the fourth axis and the HAAS VF4SS machine accuracy, we can get that exactly to 45 degrees straight away.” Customisation and Service Support Rather than a standardised package, Microloc provided a tailored solution. “It's a custom solution to suit a customer's needs. It's not a defined package. It can be made larger, smaller, wider, whatever, just depending on customer demand,” Montgomery notes. Service support extended beyond supplying the system. “Microloc provided tenons to fit our vices to make them quick release as well, so that we don't really have any setup time now,” Montgomery explains. “When we have no clocking-in required, just simply mount them on X or Y-axis, and if that's what you need, it will be instantaneous. It's a five-minute job, and you're ready to go.” Operational Efficiency and Quality Improvements Time savings achieved through the Microloc system have directly impacted operational efficiency. “The old way of doing it would be to set up a manual table, an indexing table, and you would be there for a very long time trying to get that right. Obviously, time is money,” Montgomery reflects. Perhaps most revealing has been the insight into historical manufacturing standards. “The conventional machining on older engines from around the world was not accurate, to say the least,” Montgomery observes. “When you are doing things like cylinder boring with a machine that can measure so accurately, you understand that the tolerances that things were made to were quite poor. We can make them better now than they were when they came out of the factory.” For Qualtek Engineering, adopting Microloc workholding has represented a fundamental shift in operational capability. The combination of precision, flexibility, and efficiency has enabled the company to tackle increasingly complex projects whilst reducing setup times and improving accuracy. In an industry where precision measured in microns can determine success or failure, the Microloc system has provided the foundation for sustained growth and enhanced capabilities in both general manufacturing and specialist automotive restoration work.
As an automotive supplier manufacturing up to 20,000 parts per day, the Hirschvogel Group operates at the pinnacle of automated series production where optimised cycle times are essential. By using Vericut simulation and optimisation software, machining processes can be analysed and optimised for series production in advance. From Village Forge to Global Manufacturing Leader Founded in 1938 as a village blacksmith in Denklingen, the Hirschvogel Group has grown into a global leader in producing and refining highly formed steel and aluminium components for the automotive sector. With around 6,000 staff across nine plants worldwide, generating €1.21bn in revenue and producing 342,000 tonnes of steel and aluminium annually, the company supplies well-known car manufacturers with technically advanced, ready-to-install components. Today, Hirschvogel ranks among the world's largest automotive suppliers in hot and cold forging of steel and aluminium, plus subsequent machining. Its customers include all major automotive manufacturers and suppliers worldwide, with the company producing components and assemblies for drivetrains, transmissions, chassis, bodywork, fuel systems, combustion engines and electric motors. Development Partner and Manufacturing Specialist A clear trend shapes modern automotive manufacturing: “The components we develop are constantly becoming lighter whilst also needing to withstand high loads,” explains Peter Zotz, responsible for machining process development at Hirschvogel's Schongau plant. Hirschvogel brings extensive experience and innovation to highly stressed, weight-optimised parts and components. From forged parts to ready-to-install components, the family-owned Bavarian company provides everything from a single source. “We are a development partner and manufacturing specialist for the automotive industry. Besides forging, machining plays a major role in production,” says Zotz. As a cost-sensitive supplier dealing with high volumes, every penny and second counts. “That's why we've been using Vericut since 2013. It allows us to identify errors and optimise our manufacturing processes before actual machining even begins.” Zotz emphasises the critical importance of advanced optimisation: “Thanks to the process reliability gained through Vericut, we are able to optimise the machining of formed steel and aluminium components.” Vericut as a Key Component of the Process At Hirschvogel, all machining programmes are written manually as NC code using an editor. “This is the fastest process for our needs,” says Philipp Berchtold, responsible for programming at the Schongau site, explaining this unconventional approach. As components become lighter, more complex and must be delivered ready for installation, machining challenges increase. To verify and optimise these programmes, Hirschvogel relies on Vericut. Because each part is optimised as much as possible, Hirschvogel uses a wide range of control types and machine tools. “Vericut is completely independent of control systems, and we can test and optimise our parameterised programmes at our desks before a single chip is cut,” Berchtold explains. For him, “The simulation and optimisation software Vericut is a firmly established and indispensable part of our process workflow.” “For the user, it's the safest way to simulate real machining using a virtual machine,” adds Dirk Weiß, responsible for sales in Germany and Austria at Vericut. Hirschvogel's product development process divides into distinct phases. In the quotation phase, space analysis of the production system takes focus. “Here, critical tools, clamping devices, loading/unloading and turret swing-outs are checked,” explains Berchtold. Once the system concept is finalised, the process development phase begins. “Each machine or control uses its own defined programme structures consisting of up to 150 subprogrammes,” says Berchtold, illustrating the complexity. Depending on the situation, existing programme structures may be reused or must be newly created or adapted. In the third phase, the component's suitability for series production is reviewed by the responsible department and in-house automation technicians. After final approval, Vericut performs collision checks and process optimisation. “We focus on smooth production flow with no downtime to avoid any delays during actual machining,” Berchtold explains, adding: “And all of this happens before the part even reaches the machine.” The simulation takes only a few minutes. “If an error is found, you can fix it and continue simulating from that point,” adds Weiß. Comprehensive Data Package for Production The programming department at Hirschvogel creates a comprehensive data package for each part for series production use. It includes the programme structure, the programmes themselves, a reviewer file for feedback from production colleagues, and a machine setup sheet. “This data package speeds up setup and programme adjustments, which leads to significant cost savings,” says Berchtold, pleased with the results. This systematic approach ensures seamless transition from development to production, minimising potential errors and maximising efficiency throughout the manufacturing process. Further Optimisation with Advanced Capabilities Thanks to the process reliability provided by Vericut, Hirschvogel optimises machining of forged steel and aluminium parts for the automotive industry before production begins. “We are currently testing additional feed rate optimisations using the Vericut Force module, which we expect will yield another productivity boost,” says Berchtold. Force is a physics-based optimisation method that determines the maximum safe feed rate for given cutting conditions based on cutting force, spindle power and maximum chip thickness. Weiß reinforces the importance of this capability: “In series production, every second counts—manufacturing processes must be optimised and machining operations pushed to their limits. With Vericut and the Vericut module Force™, we offer highly cost-effective support in this area.” Together with Vericut, Hirschvogel is also working on achieving even more detailed cycle time analyses. “We aim to reduce theoretical cycle time deviation to under one per cent,” concludes Weiß, highlighting the precision and reliability that makes Vericut an indispensable tool for modern automotive manufacturing.
Machined Component Systems (MCS) PLC stands as a centre of manufacturing excellence in the heart of the Midlands, operating from its facility in Redditch. This innovative and progressive subcontract-machining specialist has built a reputation for delivering precision-engineered machined components to diverse industry sectors, including automotive, petrochemical, environmental, transport technologies, marine, healthcare technologies, and white goods. Founded by Warren Gray's father, MCS has been under Warren's leadership for the past decade. During that time, the company has transformed from a traditional engineering firm into a sophisticated manufacturing hub. This has been possible with investment in cutting-edge technology that includes three Hanwha sliding head turning centres from Dugard. Enforcing the message of what sets Worcestershire-based MCS apart is Warren's unwavering investment philosophy. “We're very proud of the people that we employ. Without the people and the investment that we've made in the machine tools, you are nothing. It is what takes the company forward, and we've just invested in CAD/CAM software to parachute the company forward, and we're training four people on that at the moment.” Warren Gray's approach to automation demonstrates a deep understanding of manufacturing progression that has followed a journey from manual to automated operations. “Sliding head turning centres use barfeeds for automation anyway, but when you are making larger components on fixed head lathes, you may have started by opening and closing the door and actually having the billet in your hand with a person and hand feeding the machine. We've actually taken that away from the person by investing in collaborative robots, industrial robots, and then moving it even further, you then go on to machine tools with it, with its own pallet pool to increase the automation.” Opting for Dugard… By 2022, MCS faced a critical decision regarding their sliding head capability. “We'd had some very good sliding head machines from another manufacturer over a number of years. Those machines were beginning to age, and we went out to three or four sliding head manufacturers, and we went to each of them with the same suite of parts, asked them to tender and provide a complete turnkey proposal for those parts, and Dugard won.” The selection process wasn't simply about specifications or price comparisons. Warren insisted on a comprehensive evaluation that would reveal real-world capabilities. “Dugard invited us down to Brighton. I took my lead setter and a senior sliding head machine setter as well. The three of us went down to Brighton. We spent the whole day reviewing Dugard as a company, and also looking at the Hanwha machines in action, and on the back of the quotation they put together, they won our business.” This hands-on approach reflects Warren's belief in involving his team in critical decisions. By bringing his lead setter and senior sliding head machine setter to Brighton, he ensured that the people who would work with these machines daily had input into the selection process. What distinguished Dugard in Warren's evaluation was their complete approach to customer service and a level of support infrastructure that clearly resonated with Warren's emphasis on reliability and long-term partnerships. The company now has three Hanwha machines, the XD20II-V NHY, the XD26II-V NHY and the XD38II-R NHY. The 6-axis turning centres have a diameter capacity from 20 to 38mm with an ability to turn parts up to 545mm long. The Hanwha sliding head range features a comprehensive lineup ranging from 3 to 42mm diameter capacity, powerful high-end CNC units, comprehensive tooling platens and configurations, and what stands out against competitor machines is the high-rigidity machine structure. This construction philosophy sees Hanwha make the machines 20 to 30% heavier than competitors' machines of similar capacity. This additional mass translates into performance benefits, with customers reporting massive improvements in heavy cutting capabilities, tool life, and reduced cycle times. The proof of any investment lies in its real-world performance, and Warren's assessment of the Hanwha implementation is unequivocally positive. “The Hanwha machines have come into this business, and they are very, very good machine tools, and we are very happy,” he states with evident satisfaction. “We serve a vast array of different industry sectors, and the Hanwha's serve all those industry sectors which are automotive, environmental, medical and domestic gas. So, these machine tools could be making any industry components at any time,” Warren explains, highlighting the versatility that makes this investment so valuable to MCS's diverse customer base. The phased implementation approach that Warren adopted allowed MCS to validate performance, optimise integration, train personnel, and prove return on investment before committing to additional machines. This methodical approach reflects his broader management philosophy of making informed decisions based on evidence rather than speculation. Warren's philosophy on quality is deeply embedded in the company culture. “Quality is not an option,” he states. This commitment to measurement excellence is complemented by the precision capabilities of the Hanwha turning centres, creating a complete quality ecosystem that ensures consistent, repeatable results across all production runs. The collaboration between MCS, Dugard, and Hanwha represents more than a simple supplier-customer relationship; it exemplifies how strategic partnerships can drive manufacturing excellence when built on shared values of quality, reliability, and customer service. Warren Gray's methodical approach to vendor selection, combined with Dugard's comprehensive customer service and Hanwha's innovative technology, has created a synergy that benefits all parties. Warren's assessment of the partnership remains overwhelmingly positive: “The Hanwha machines are very, very good machine tools, and we are very happy.” This success stems not just from the technical capabilities of the machines but from the alignment of values between MCS and Dugard.
Established in 1967 by Reginald Newnham and now under third-generation family leadership, Newnham Engineering Limited has undergone a remarkable transformation from traditional machining to cutting-edge 5-axis manufacturing. Through investments in DMG MORI machine tools, this West Sussex-based company has acquired a DMU 75 monoBLOCK, DMU 100 FD duoBLOCK, and a CMX 70 U. Operating from their modern facility on Lancing Business Park, Newnham serves demanding sectors including oil and gas, surveillance, F1, and specialised industrial applications. What distinguishes them in today's competitive landscape is their commitment to ‘machining excellence', backed by technology investments that have fundamentally reshaped their capabilities and market positioning. The Technology Foundation The DMU 75 monoBLOCK serves as the cornerstone of Newnham's 5-axis capabilities. This machine handles workpieces up to 840mm in diameter, 500mm in height, and 600kg. Its 20,000rpm spindle capability and monoBLOCK construction provide the precision and versatility essential for complex aluminium components that dominate Newnham's production. “It was quite a smooth transition into our latest 5-axis machine, the Monoblock 75,” Lawrence Newnham explains. “Like all the pain we come through with learning how to use the new CAM system, how to use full 5-axis, how to use zero pointing, and using all of that efficiently as well. Going onto the Monoblock 75 it was so smooth.” The DMU 100 FD duoBLOCK is capacity expansion with the ability to handle workpieces weighing up to 2,200kg. This 4th generation duoBLOCK machine delivers 30% more precision, performance and efficiency compared to previous generations through FEM-optimised structure and enhanced components. The dramatic capabilities become evident when Lawrence describes processing large aluminium billets: “Currently, the part on the machine is one ton. We'll shy of that, and it finishes up about 250kg. So, a 75% material reduction there. We can fill a bin up in probably 45 minutes – that's how quickly we can remove material.” Completing the trio, the CMX 70 U brings 5-axis precision to smaller applications with its C-frame design and mineral cast bed construction. The machine features 750 by 600 by 520mm travels, handles components up to 350kg, and operates with a 12,000rpm spindle delivering 13kW power and 83Nm torque. Business Transformation Through Strategic Partnership Newnham's evolution illustrates the challenge many manufacturers face transitioning from indexed 5-axis machining (3+2) to full simultaneous 5-axis operations. “We started with three plus two, and then we took this big jump to a DMG MORI DMU 100 FD duoBLOCK, it's a hell of a machine,” Lawrence noted. This technological leap required significant investment in CAM programming expertise, and setup procedures. However, the learning curve ultimately positioned Newnham with capabilities that differentiate it from competitors. Phil Newnham reflected on the transformation: “The components we do these days are night and day in technology compared with what we used to do. It's just really exciting.” The partnership with DMG MORI extends beyond equipment supply to comprehensive support. Philip Clapp from DMG MORI described the collaborative approach: “Lawrence and Phil turned to me one day and said, ‘can you come and see us?' We've got an absolutely great job, a big part, and we want your help and your partnership to develop the process and make sure we get the right machine for this customer.” This partnership model encompasses application engineering to match machine specifications with customer requirements, process development for optimising cutting parameters and tooling strategies, comprehensive training ensuring operators maximise machine capabilities, and technology road mapping for future investments aligned with market evolution. The DMG MORI investments have fundamentally expanded Newnham's addressable market and strengthened customer relationships. Perhaps most significantly, the technology has enabled them to solve previously intractable manufacturing challenges. “We've got this customer up the road to us that has had these large components made throughout the world, and they've never been made right,” Lawrence explained. “So, we ended up getting this DMG MORI machine, and now we have the capability to make the parts, and to make them correctly to the customer specification.” The company now confidently supplies oil and gas applications requiring complex valve bodies and pressure vessel components with tight tolerances, surveillance systems needing precision housings and mounting systems, Formula 1 projects where lightweight aluminium components must meet exacting standards, and specialised industrial equipment including high-precision parts for milking machines. Technical Excellence and Advanced Features The three machines provide comprehensive capabilities through advanced technical features such as high-pressure cooling systems that are crucial for machining aluminium components, improving chip evacuation, extending tool life, and maintaining dimensional accuracy during extended cycles. The larger machines utilise HSK 100 tooling systems, providing superior rigidity and repeatability compared to traditional tapered spindles. A Model for Manufacturing Evolution Newnham Engineering's transformation demonstrates how manufacturers can navigate the transition to advanced manufacturing through strategic technology. The partnership between Newnham and DMG MORI illustrates that success in today's competitive manufacturing environment requires more than advanced equipment. From a family business founded to a technology-enabled precision manufacturer serving Formula 1 and other demanding industries, Newnham's journey provides a roadmap for manufacturers seeking to advance their capabilities in an increasingly competitive global marketplace.
A process for complete machining of stator housings for electric motors, developed by Chemnitz machinery manufacturer NILES-SIMMONS and tool manufacturer MAPAL, has reached series production. Suppliers and OEMs now use it to produce components for drives in battery-powered electric vehicles and hybrid models. Both manufacturers recently proved in a development project that highly cost-efficient and precise production of stator housings is possible on a pick-up lathe. The parts feature external ribs for cooling circuits and are installed in the larger motor housing. Whilst NILES-SIMMONS used a converted modular lathe during development, a machine specifically designed for stator production has now entered the market. The basis for development was the vertical machining centre from the RASOMA brand, which, like NILES-SIMMONS, is an NSH Group brand. The RASOMA DZS 400-2 indicates operation with two workpiece spindles. For series production, the machine features side-mounted pickup and drop-down areas for finished parts. Components are supplied and removed via conveyor belts. With manual assembly, 10 to 20 components can be buffered through automation, allowing multiple systems to operate simultaneously while workers attend to other processes. “We've realised highly simple automation as standard. No robots or blocks on the machine are required.Operators can place parts directly on the pallet belt,” explains Thomas Lötzsch, Sales Manager at NSH TECHNOLOGY. The machine integrates easily into existing production environments, with compact installation dimensions of 7.50 by 2.60m. The RASOMA DZS 400-2 design was developed in collaboration with LTH Castings, a partner with extensive casting experience and expertise in machining complex, high-quality, thin-walled pressure die-cast aluminium components. The design, therefore, directly incorporates practical experience and user requirements. Complete machining in two clamping systems Finishing occurs on the vertical machine in two clamping systems. A clamping device picks up the workpiece from above and moves it to various machining stations. At a re-clamping station, the part is rotated 180 degrees and picked up by the second workpiece spindle for finishing. During second clamping, machining of the next component begins simultaneously at the first pick-up. The process begins with pre-roughing the component's various inner diameters. The tool remains stationary whilst the workpiece rotates. “Unlike conventional turning with a blade, machining with a four-blade ISO boring tool on an HSK-A 100 spindle takes just a quarter of the productive time,” says MAPAL regional sales manager André Ranke. The inner tool also rotates. Tool speed and workpiece speed differences produce cutting speed at the inner blades. The bell-shaped outer tool remains stationary. The component is placed in the gap between inner and outer tools for machining. This patented process reduces forces on the clamping system, avoiding the need for complex workpiece clamping devices with vibration-damping for precise machining of thin-walled components. “When designing the tool, particular attention was paid to the large chip volume and significant forces generated, as simultaneous inner and outer diameter machining is unusual,” explains Michael Kucher, Component Manager E-Mobility at MAPAL. During finishing, only the fine boring tool is driven whilst the component remains stationary. This prevents non-rotationally symmetrical workpiece shapes from causing material imbalances with negative impacts. The workpiece is then re-clamped and the outer area previously clamped in the flange area is machined. The re-clamping station can also relax the material before fine boring. The machine has two tool revolvers for driven tools carrying out further machining based on component requirements. Faster and more stable than expected “The RASOMA DZS 400-2 combines turning speed for pre-machining inner and outer contours with fine boring accuracy for finishing inner contours,” says Daniel Pilz, Project Leader at NSH TECHNOLOGY. With machine, tool technology, and process serialisation, positive prototype results were improved further. Process reliability exceeded expectations, allowing the targeted cutting speed of 700 m/min to be increased. “For aluminium machining, NILES-SIMMONS' experience positively impacts tool technology and machine reliability,” explains Michael Kucher. The RASOMA DZS 400-2 achieves much shorter chip-to-chip time than milling centres because all tools are already in the working area. This reduces non-productive time. Using this technology, studies anticipated 50% cycle time reduction. Parts were initially measured, current guidance recommends testing one part per shift. Daniel Pilz uses figures to demonstrate this is more than adequate: “The RASOMA DZS 400-2 with special MAPAL tools achieves a process capability index over 1.67 for critical characteristics such as cylinder shape, diameter, and concentricity, meeting industrial specifications.” Customers already using the machine achieve annual outputs of up to 180,000 components in a three-shift operation. Success at high volumes LTH Castings in Slovenia is among the first to adopt the serial process for stator production on the RASOMA DZS 400-2. The traditional casting company has over 100 casting cells and processes raw parts on more than 250 CNC machining centres. Around 3,800 employees work across six sites. Dr Primož Ogrinec, CTO of LTH Castings, says: “With our all-in-one solutions from design to series production, we're a key strategic partner for the automotive industry. Our range includes components for drives, motors for battery-powered electric and hybrid vehicles, steering and braking systems.” Robots load and unload the RASOMA DZS 400-2 machines in ultra-modern production. Like most automotive suppliers, LTH Castings produces components for various vehicle models. The RASOMA DZS 400-2's flexibility, which only requires retooling of the clamping device and tool, makes it suitable for stator housing production. “With a single system using the new process, an optimal solution, tailored to manufacturer-specific needs in both quantity and quality, was developed and brought to series production maturity,” says André Ranke. Stator housing production can be carried out for diameters up to 500mm and components up to 500mm in length. “Every housing type we've seen can be manufactured on the RASOMA DZS 400-2—and we've seen plenty,” says Thomas Lötzsch. The project team was surprised when a major car manufacturer's housing design required an internal component indentation. The sample component from MAPAL, specially designed for the process, didn't present this challenge. Yet MAPAL quickly had a joint solution ready with NSH Group specialists: instead of the tried-and-tested fine boring tool, an ultra-precise actuating tool with four slides from MAPAL's product portfolio created the desired inner contour. Machine-side, a connection designed in coordination with MAPAL was ready within days and achieved series production maturity during the ongoing order. With tightly networked development structures, both companies react quickly to newly developed contours. New benchmark for low costs per part The RASOMA DZS 400-2 with MAPAL tool technology has become established in series production, addressing quality issues seen on traditional turning and milling machines. Thomas Lötzsch describes cases where required shape and position tolerances were not met with reliable processes, resulting in up to 50% scrap. When quality was sufficient, cycle times were inefficient, leading to higher workpiece costs. A proven manufacturing process was missing. As price competition is tough among automotive suppliers, RASOMA DZS 400-2 development focused on minimising unit costs from the outset. This goal was achieved through high machine availability, short cycle times, machined component quality, and production with reliable processes.
Servicing manufacturers in the medical, oil and gas, aerospace, automotive, MOD, and F1 sectors, Rushden-based R&G Precision Engineering Ltd prides itself on the level of service it delivers to its customers. To meet its clients' tight deadlines and quality demands, the company founded 50 years ago has invested in a series of multi-pallet machining centres from Matsuura. However, the shop floor at R&G Precision looked different four years ago from how it is today. Enzo Chiarelli from R&G Precision Engineering Ltd says: “We recall looking back to our first multi-pallet lights out machine and thinking back to when we were first looking at it – we were thinking ‘this is never going to work'. Now, we are predominantly lights-out multi-pallet machining, and the plan for the next 3-4 years is to swap more single spindle and single pallet machines for the multi-pallet variants.” “It's nice to sit at home now and think, ‘I am making money.' With the RiMM software, you can control that. So, when your team says the machine was running all night, you can come in and look at the RiMM system and say – oh yeah, it was running at 2am this morning.” Thinking back to 2020, Enzo recalls: “I remember thinking, ‘What have I done? It's such a big investment with lights-out machining. It's worked, and it's a journey we're so glad we started. It's exciting and gives us a vision of where next.” With a machine shop filled with Matsuura machines like the MX330, the company was nervous about diving into ‘lights-out' machining. Recalling what the company has learnt, Enzo says: “I did a lot of research, we had to weigh up the pros and cons. The pros are running when nobody is here with multiple set-ups. The cons are all around making sure you got the process right – as you can have tool breakages, blockages, you could have coolant issues and a multitude of other variables – and that is always a worry.” “We also had to think ‘how do you start' – do you go slowly and build up or go in straight at the top? However, it was all about learning from the first machine for us and learning about how to get to a complete lights-out process that gives you the confidence to say, ‘OK, I know what I'm doing now. I have to prove out every job during the day for 2 to 3 weeks before swapping out and making the switch – and that is what we did.” Now with 8 Matsuura machines, Enzo recalls the first machine: “That was an ES-450HII machine that is still running, and for us, that was an investment in a company that we'd never done business with before. The sales rep pushed me towards lights-out machining, which is how we got to eight machines.” The company progressed to buying the Matsuura MX330 multi-pallet machines acquired for a batch of work the company had at that time. However, that was two years ago, and the company has since changed direction. As Enzo adds: “The Matsuura MX330 machines were bought for smaller components in repeat orders we were doing at that time. That work increased, so we bought a second MX330 with 10 pallets. However, Dominic from Matsuura asked us why another MX330 was needed.” “We sat down and showed Matsuura the portfolio of parts in the pipeline, and he instantly said no, you need a MAM. So, we purchased a MAM72-63V, and it worked. Now, we will continually show Matsuura the portfolio of parts we have, and they will tell us what machine to buy – and it works well.” “The contract we bought the MX machines for is completely separate from a new contract that has arrived. The first contract ran for four years and continues to run, where we machine repeat orders for 50 to 100 parts a month. The other contract we had to invest in with another five Matsuuras is a 15-year aerospace contract that will run until 2035. That is a contract where I sat with Dominic and said, ‘You have to advise me on whether we need to invest in the MX range, the MAM machines or other models.' I'm glad we took his advice, we opted for a MAM35 and a MAM63, which also gave us a size difference. On the MAM63 machine, we can do larger parts and a mix of smaller parts. On the multi-pallet machine, we can do everything, and we have no downtime at all.”
According to Pralhad Thapa, Department Manager at Mitutoyo Europe, an expert in dimensional metrology and automation: “We are confident we can address these issues for our customers, providing unattended measurement solutions that are easy to operate and available at a reasonable price.” In a presentation, it was this opening gambit that embodies both the philosophy of the new SmartMeasure AL system and Mitutoyo's commitment to precision. Building upon decades of expertise in CMMs, this turnkey solution addresses the fundamental pain points expressed by customers across diverse industrial sectors. Predicting the Market Demands The persistent shortage of skilled manpower has created operational bottlenecks, whilst increasing quality demands have elevated the importance of precision measurement. Traditional approaches that rely heavily on manual intervention and specialised expertise are proving inadequate in meeting the evolving demands in the face of a skills crisis. Mitutoyo's SmartMeasure AL emerged from extensive customer consultations across European markets. Industry feedback consistently highlighted specific requirements: systems capable of easing labour shortages, reducing human error, providing stable measurement capabilities, supporting high-mix production environments, and enabling unattended operation during night shifts and breaks—all whilst maintaining cost-effectiveness. The industry isn't asking for much there, then…. Developing SmartMeasure AL as a standardised product, rather than a bespoke project-based solution, represents a significant strategic shift. Thapa explains this fundamental change: “Our goal with SmartMeasure AL is to develop this fully automated solution as a product, so that our customers can order it from our website, our B2B shop, or through other means. This approach enables reduced development costs, shorter delivery times, and more competitive pricing compared to traditional custom automation projects that Mitutoyo has delivered over the past three decades.” System Architecture and Core Concept SmartMeasure AL employs a three-component architecture comprising a CMM, an industrial robot system, and supporting infrastructure including racks, pallets, fixtures, sensors, and integrated software. This modular philosophy allows for flexible configuration according to specific customer requirements whilst maintaining standardisation benefits. The system's operational principle centres on a 12-part pallet rack configuration. When an operator initiates the measurement cycle, the integrated robot retrieves parts from designated positions, transports them to the CMM and returns them to the rack with a clear indication of pass/fail status. This automation eliminates the need for continuous operator supervision whilst maintaining measurement accuracy and traceability. Central to the system's intelligence is Mitutoyo's ESPRIT software platform. Unlike conventional automation systems that rely on PLCs requiring specialist expertise, ESPRIT provides an intuitive graphical user interface accessible to operators with basic technical knowledge. As Thapa emphasises: “We really focused on developing the graphical user interface, because we know operator knowledge is limited and the market has a skills deficiency.” Technical Specifications SmartMeasure AL demonstrates versatility through its compatibility with multiple Mitutoyo CMM models, including the CRYSTA-Apex S series (544, 574, 776, 7106, and 9106 configurations). The robotic component utilises FANUC CRX series of collaborative robots, available in two payload configurations: CRX-10iA/L and CRX-20iA/L with 10 and 20kg payload, respectively. This dual-option approach ensures optimal matching between robot capability and workpiece requirements. Importantly, Mitutoyo maintains openness to alternative robot manufacturers, allowing customer preference integration where requirements exist. Advanced Software Features and Capabilities The ESPRIT software platform incorporates several features designed to enhance productivity and operational efficiency. Multiple part measurement capability allows simultaneous measurement of several small components within a single 250 by 250mm pallet, particularly beneficial for manufacturers where part sizes permit batch processing. The re-measure functionality demonstrates the system's intelligence. Following overnight automated measurement cycles, operators can selectively re-measure only those parts flagged as non-conforming, eliminating unnecessary repeat measurements of acceptable components. RFID technology provides part tracking and traceability where each component's measurement history can be automatically logged and integrated with broader quality management systems to provide audit trails. Real-time connectivity capabilities facilitate integration with external systems, including ERP platforms and manufacturing execution systems. This connectivity supports Industry 4.0 initiatives and enables data-driven decision making. Closed-Loop Manufacturing Integration SmartMeasure AL's closed-loop manufacturing capability represents a significant advancement in process control. The system automatically analyses measurement data and calculates necessary tool offsets for upstream CNC machining operations. When deviations are detected, ESPRIT software automatically transmits correction values to the relevant CNC machines, enabling real-time process optimisation. This closed-loop approach reduces setup times and scrap rates through proactive process control. The automatic feedback mechanism minimises the time between problem detection and correction implementation, crucial for maintaining tight tolerances in high-volume production environments. Competitive Advantages SmartMeasure AL's primary competitive advantage lies in its product-based approach rather than project-based delivery. Customers can order complete systems through standard commercial channels, including Mitutoyo's B2B platforms, enabling predictable pricing, standardised delivery schedules, and reduced implementation complexity. Thapa notes the market reception: “The feedback has been very positive. When customers came and saw our product, they said, ‘Unattended measurement. The GUI is very simple to use, and an operator with minimum knowledge can operate this fully automated system.'” The system's compact footprint addresses space constraints, and despite incorporating a complete CMM, robot system, and part handling infrastructure, SmartMeasure AL requires minimal floor space. Cost-effectiveness extends beyond initial capital investment. The elimination of PLC programming requirements reduces implementation and maintenance costs, whilst the intuitive ESPRIT interface minimises operator training requirements. Future Development and Expansion Mitutoyo's roadmap for SmartMeasure AL encompasses expansion across the company's broader product portfolio. Future developments will extend automation capabilities to laser measuring machines, contour and roundness measuring systems, and surface texture measurement equipment, creating a comprehensive automated measurement ecosystem. Thapa confirms: “We will continue to develop this product and expand to support other products from Mitutoyo. We will continue to support our customers in the field of factory automation, help them and understand their pain points and see where Mitutoyo technology can increase productivity.” Conclusion Mitutoyo's SmartMeasure AL represents a paradigm shift in automated measurement solutions. By addressing critical industry challenges, including skilled labour shortages, quality demands, and operational efficiency requirements, the system provides a comprehensive solution. The product's success lies in its synthesis of proven measurement technologies, intelligent software platforms, and flexible automation capabilities within a standardised, cost-effective package.
At the core of lightweight, high-speed and energy-efficient electric and hybrid vehicles, composite materials play a crucial role in manufacturing advanced components. However, working with composites demands more than just selecting the right materials; it requires a new generation of precision tooling. The Composites Challenge Composites such as carbon fiber-reinforced polymers (CFRPs) and glass fiber composites (GFRPs) are not easy to work with. Their multi-layered structure, fiber orientation and abrasive nature make them resistant to traditional machining techniques. Unlike metals like steel, composites don't deform, they fracture. That means every cut must be calculated, every edge protected, and every tool enhanced. “The challenge with machining composites is that your cutting tool needs to be both sharp and abrasion-resistant at the same time. It is a delicate balancing act,” said Chris Stewart, Kennametal Key Account Manager. Diamonds are Forever Diamonds aren't just a luxury; they are essential in composites machining. One of the most significant innovations from Kennametal is the introduction of KBDM PCD Face Mills. These polycrystalline diamond tools are a high-density platform designed for faster machining cycles and precise surface finishing of composite components. Their extreme hardness and thermal stability enable them to stay sharp, providing clean, delamination-free finishes on critical parts such as battery enclosures, structural panels, and motor housings. Additionally, the KD1400™ and KD1425™ grades, when combined with the cutter bodies, offer improved wear resistance and edge strength. Drilling Stacks Drilling into composites—especially when combined with metal layers—requires tools that can manage heat, resist wear, and maintain hole integrity. Kennametal's DAL drills can be used in all combinations of stacks such as CFRP-Ti-Al, CFRP-Ti, CFRP-Al, and also straight Ti or Al. They feature a double-angle point design and minimise burrs when exiting the metal side of the stack. Routing with ROCO Routing operations, which are vital for trimming, profiling, pocketing, side milling, and slotting composite parts, have also experienced significant innovation. Kennametal's ROCO burr router geometry pushes cutting forces both upward and downward, reducing delamination during side milling and slotting. Meanwhile, the down-cut routers from Kennametal produce clean top-surface finishes by pushing chips downward, making them ideal for visible parts where aesthetics and surface quality are important. “ROCO routers have seen great success across a range of composite materials and applications,” said Katie Myers, Kennametal Marketing Product Manager. “Our geometry paired with our new KCC05A CVD diamond coating grade is providing exceptional tool life and the ability to run at higher cutting parameters.” Additive Manufacturing in Tool Design Manufacturers are also leveraging additive manufacturing to create custom tool bodies with internal cooling channels and optimised weight distribution. These 3D-printed tools are lighter, more rigid and capable of handling complex geometries, especially in deep cavity applications like electric motor housings. For example, Kennametal's 3D printed stator bore tool for machining aluminium e-motor housings is capable of machining three large diameters in just one operation. The tool features airfoil-shaped arms with internal coolant channels, enabled by additive manufacturing, which improves chip evacuation and cooling. It also includes carbon fiber components to further reduce weight and improve handling. Additionally, Kennametal's RIQ inserts are ideal for machining large diameters, while the RIR inserts deliver precision for smaller diameters. When paired with Kenionic™ tool holders, these inserts form a high-performance reaming solution. Beyond the Shop Floor The influence of these tooling innovations extends far beyond the shop. By enabling the efficient processing of composites, advanced tools contribute directly to vehicle performance and sustainability. Lighter components reduce energy consumption and extend battery life. Precision machining minimises material waste and rework. And smarter tools help manufacturers scale production while maintaining quality and consistency. Some of the latest tools are embedded with smart sensors that monitor temperature, vibration and wear in real time. These tools communicate with CNC systems to dynamically adjust cutting parameters, reducing the risk of tool failure and ensuring consistent part quality. In high-volume EV production environments, where production time and repeatability are paramount, this level of intelligence is becoming a real competitive advantage. Longevity in Composites Tooling In high-demand manufacturing environments, tool longevity isn't just a convenience; it's a requirement. The future of composites tooling lies in deeper integration with digital manufacturing ecosystems. As EV and hybrid vehicles become more sophisticated, the tools that shape them must also evolve to become faster, smarter and more adaptable. Tooling is no longer a behind-the-scenes operation; it's now a critical part of the overall metal cutting strategy. “Innovation is our priority,” said Myers. “With all of the advancements being made in composite materials, our tools are constantly evolving to continue to provide a high level of performance and reliability in materials outside of the metals we've traditionally worked with.” Conclusion With advanced solutions like PCD face mills, stack-optimised drills, innovative router geometries and additive-manufactured tool bodies, manufacturers can meet the growing demands of composites machining head-on. The proper tooling just doesn't cut it anymore. It must accelerate production, improve quality and support sustainability.
According to the International Energy Agency's (IEA) World Outlook, the clean energy transition and the rise of electric vehicles (EVs) could lead global demand for fossil fuels to peak before 2030. As nations worldwide shift away from fossil-fuelled engines and towards an electric future, automakers are making a shift of their own, starting with their machine setups. Here, Swetapadma Mohanty, Senior Development Engineer, Gear Machining at Sandvik Coromant, explores the machining methods that will prove key to the automotive industry's electric future. Another prediction made by the IEA is that, by 2030, the global electric car stock will expand to almost 350 million vehicles. That's more than 60% of vehicles sold. To accommodate the rise in EVs, automakers are turning to alternative machining methods. One such method is power skiving. Common gear machining challenges Before diving into power skiving and its machining considerations, let's think about the common challenges associated with gear machining. The machining of gears for internal combustion engine (ICE) vehicles and EVs can differ in certain aspects due to the distinct characteristics and requirements of these two types of vehicles. For instance, while ICE vehicles often have complex multi-speed transmissions to optimise power delivery, EVs typically have a single-speed or limited number of fixed gear ratios. Other distinguishing features include torque characteristics, noise and vibration considerations and weight and size constraints. Machining gears, for any vehicle type, presents several machining challenges. To ensure proper meshing and transmission accuracy, gears require tight tolerances with high machining precision. Gears must also be designed to minimise noise and vibrations during operation in order to maintain batch consistency and ensure tool maintenance is key to achieving high production volumes. Popular gear machining methods include hobbing, milling, shaping and broaching. However, these methods often have limitations such as lower flexibility in handling various gear types, longer cycle times and challenges with specific gear geometries. Hobbing is particularly popular for cutting spur and helical gears and is most suited to smaller production runs and for producing gears with various tooth profiles. For mass production, gear shaping is a preferred method as it can achieve high dimensional accuracy in shorter cycle times. But these machining methods are incredibly specialist. Broaching and hobbing, for instance, must be carried out on a specialist machine, with a totally different machine required for shaping. Then there are all the other steps required for successful gear production — milling, turning, finishing, quality inspection and so on. What does that mean for manufacturers? Multiple machines set ups, limited flexibility, lengthened lead times and a costly machining process can all be consequences of a gear machining process that's not catered to our increasingly electrified world. Enter power skiving. If we're to get 350 million EVs on our roads by 2030, automakers must turn to machining methods that can accommodate. This is where power skiving comes into play. As a continuous process that uses a specialised cutting tool to remove material from a gear blank, power skiving boasts several benefits over traditional methods like hobbing and shaping. First, power skiving typically provides higher precision and tighter tolerances compared to traditional process. It's well-suited for producing gears with complex profiles, including helical gears and non-standard shapes. Traditional process may have limitations in achieving intricate tooth forms, especially when dealing with high helix angles or specific gear geometries. Generally, power skiving is faster than traditional gear machining processes and, as it removes only the necessary material to form the gear teeth, the waste produced is minimal. A core driver for its use in EV production is power skiving's flexibility — it's suitable for various gear applications, including those with specific performance requirements. Manufacturers can therefore adapt to different gear types more easily than they can with traditional machining methods. With reduced set ups in multitask machines with power skiving, higher quality can be reached. Crucially, power skiving is performed on a multitask machine. Performing multiple activities on a single machine will reduce set up times, improve accuracy, increase throughput and streamline programming. For those currently using multiple machines to execute traditional gear machining methods, however, upgrading to a multitask machine for power skiving requires some investment. It will be up to manufacturers to weigh up the pros and cons of their machining set-up, but there's one thing we cannot deny — the pace of electrification isn't going to slow down. To compete in an evolving, competitive market, flexibility, adaptability and process efficiency will be fundamental. Tool selection If power skiving is the right machining method for automotive's future — what are the right tool choices? Let's start with the gear milling tools themselves. Tools should have tight tolerances to ensure accurate machining and to produce gears with uniform quality. A good gear milling tool should also be heat-resistant to maintain its cutting performance and prevent premature wear, with a design that facilitates proper chip evacuation to ensure smooth cutting operations. The CoroMill®178 and CoroMill®180 family of gear milling tools meets those expectations. For internal and external gears, capable of machining both cylindrical spur and helical gears from roughing to finishing, CoroMill® 178 is a key part of a successful power skiving setup. It is best used in applications where high-volume, high-rpm machining with long tool life is required, while CoroMill® 180 is ideal for general use on shoulders or small diameters. These tools offer the highest tool accuracy, regarding run-out and pitch, compared with indexable tools, providing a superior finishing profile of the gear and spline. In one customer success case, by replacing a traditional process with power skiving using CoroMill® 178, cutting time was reduced and tool life increased significantly. With annual growth in production, the customer was able to save over 100 hours of machining time each year. It's not just about cutting tools with Sandvik Coromant. Customers receive tooling and application support, along with a service offering that includes technical feasibility consultancy. For example, our ESCO software is another vital component of our power skiving portfolio, enabling high-quality and precise production of power skiving tools. InvoMilling® is a vital part of Sandvik Coromant's gear machining portfolio. As part of the CoroPlus® Tool Path software, InvoMilling® is a process used for machining external gears, splines, and straight bevel gears with exceptional flexibility. This makes it highly suitable for small batch production and situations where short lead times are essential. The solution takes advantage of multitasking machines and machining centres' capability to produce various gear profiles using the same set of tools. As the world prepares for an electrified future, automakers must consider their manufacturing techniques. While traditional gear machining methods have long served the industry, thriving in a changing and increasingly competitive environment requires flexibility. Power skiving provides that flexible, adaptable approach — all while delivering finished components of the highest quality. As market leader, Sandvik Coromant is also focusing on high-level sustainable Power skiving tools and reducing CO2 footprints.
2025 is already proving to be a memorable, standout year for leading precision motorsport subcontract specialist, Northants Precision Ltd. In addition to acquiring two more DN Solutions' Lynx 2100 lathes from Mills CNC, the company has successfully completed its relocation to larger premises, increased its headcount, and secured new machining contracts. Led by owner and Managing Director Daniel Green, Northants Precision continually aims for excellence. The machines, an 8” chuck, long-bed Lynx 2100LMB with driven tooling, and a 6” chuck, 2-axis Lynx 2100A, were installed at the company's new 3500sq/ft. manufacturing facility in Kislingbury, Northampton, in January and June 2025. Both machines are equipped with powerful, high-torque spindles, servo-driven turrets, rigid roller-type LM guideways, and hydraulic tailstocks. The Lynx 2100A offers a maximum turning diameter of 350mm and a turning length of 330mm with its 15kW/6000rpm spindle and 12-station turret, while the long-bed Lynx 2100LMB provides a 300mm turning diameter and 510mm turning length, featuring a 15kW/4500rpm spindle, 12/24-station turret, and 6000rpm driven tooling capabilities. The new machines are positioned adjacent to four previously acquired Lynx lathes, a Lynx 2100B (2022), a Lynx 2100MB (2021), a Lynx 2100LMB (2021) and a 10-year-old Lynx 220LSY. Together, these six FANUC controlled machines, three with driven tooling capabilities, provide Northants Precision with a formidable in-house turning and milling resource. All feature the advanced FANUC iPlus control with 15” touchscreen iHMI, making them ideal for meeting the accuracy needs and fast turnaround demands of motorsport customers. Since installation, the new Lynx lathes have been machining a range of small, complex, and high-precision engine, chassis, sub-frame, and gearbox components for F1, WEC (World Endurance Championships), WRC (World Rally Championship), and supercar customers. Parts machined on the Lynx lathes are typically washers, nuts, bolts, and top hats. They are characterised by tolerances of +/-5 microns on specific features, a flatness of 0.01mm, and strict surface finish requirements. These parts are machined in small-to-medium batches from solid bar stock. The primary materials processed include heat-treated stainless steels (13-8PH and MP35N), titanium 6242/6246 alloys, and aluminium. Part cycle times range from just a couple of minutes up to 10 minutes, and to ensure accuracy, concentricity, and flatness, parts are securely held using Hainbuch collet chucks. Daniel Green: “Machining and supplying hundreds, sometimes thousands, of identical high-precision and performance-critical parts from hard, difficult-to-machine materials to exacting quality standards is commonplace for us. But to achieve this consistently requires reliable, high-performance machines and proven CAD/CAM, machining, and inspection processes. We have invested significant resources to ensure we have all of these in place.” Northants Precision regularly monitors its performance to identify potential production bottlenecks and address them before they become problematic. The company's success in securing small part machining contracts from new and existing customers, including recent contracts won directly with F1 racing teams, prompted capacity reviews at the end of 2024 and during Spring 2025, ultimately leading to orders for two new machines. Daniel Green continues: “F1, and motorsport in general, is demanding and challenging. You always have to be ‘on top of your game' and constantly meet customers' quality and lead time requirements from day one. Failing to do so quickly tarnishes your reputation and means your days as a supplier in the sector are numbered. Our positive experiences with DN Solutions Lynx 2100 lathes and Mills CNC's pre and after-sales services meant that, on both occasions, we made Mills our ‘first port of call', ultimately investing in the new Lynx 2100A and Lynx 2100LMB.” A typical machined part is an engine housing washer component made from 10mm diameter pre-cut titanium bar stock supplied in 42” lengths. These parts are machined to completion in medium-sized batches (600-off) using two of Northants Precision's Lynx 2100 lathes positioned opposite one another to create a flexible manufacturing cell, operated by one member of staff. Front-end ID and OD turning are performed on a Lynx 2100 (two-axis) lathe, where a bar puller ensures a reliable process and continuous production. After the initial operations, which take about 2 minutes per part, the semi-finished parts are individually loaded into the Lynx 2100LM for back-end processing. This involves machining an angled groove or chamfer on each part, which takes approximately 30 seconds. Says Daniel Green: “We strive for excellence across the board. Everything we do, from our in-house CAD/CAM, machining and inspection to any outsourced processes - is integrated and carefully controlled.”
In automotive manufacturing, speed and precision aren't luxuries—they're survival tools and ‘every turn of the spindle counts'. Threading, grooving, and deburring may seem like small elements in the bigger picture of vehicle production, but get them wrong, and entire lines grind to a halt. Few tooling providers have tuned their offering so tightly to the demands of this environment as VARGUS. With its VARDEX threading systems, GROOVEX grooving solutions, and SHAVIV hand deburring tools, VARGUS has positioned itself as a crucial partner to the automotive industry and the supply chain around the globe. From transmission cases to ‘e-axle' housings, automotive driveline components depend on precise threads and flawless sealing grooves. The VARDEX threading tools handle high-volume work in ductile iron, aluminium, and alloy steels with remarkable repeatability, whilst the GROOVEX tools can cut retention and O-ring grooves with predictable and stable tool life—keeping scrap rates low in critical sealing areas. This process stability is critical in high-output environments; a single defective groove or off-spec thread can trigger costly line stoppages, and manufacturing sites running modular VARGUS systems frequently report reduced tooling SKUs, faster changeovers, and fewer burr-related rework and post-operation hand finishing. The rise of electric vehicles has reshaped machining challenges with the arrival of thin-wall battery trays, intricate coolant channels, and delicate motor housings. Thread milling is known to minimise cutting forces, which protects lightweight aluminium structures from distortion. It is here that the compact GROOVEX tools from VARGUS enable intricate sealing features in cramped, high-value components. The result is faster adaptation to evolving EV designs without complete retooling. Manufacturers notice the difference with predictable tool life that reduces unplanned production stoppages and makes OEE more stable. Consistent quality is also maintained with micron-tight profiles maintained over long runs. Additionally, end users have simplified inventory with fewer unique SKUs for threads and grooves. In addition to this, VARGUS has a range of digital tools available through its application software that has become a secret weapon for engineers in APQP and PPAP phases. With it, teams can select the right tool by standard, pitch, and material and also access proven cutting data with the added benefit of generating tool strategies quickly with cutting ‘trial-and-error' time before production launch. Automotive manufacturing is a balancing act of volume, accuracy, and efficiency. VARGUS's precision tooling and digital support help manufacturers keep that balance, turning once-fragile processes into robust, repeatable production steps. In a sector where every second matters and quality is king, VARGUS has become more than a tooling supplier—it's a partner in keeping the wheels of industry turning. The latest addition to the company's portfolio is the new VARGUS bell shape tool, a high-speed external threading system designed for the automotive and valve industries. Suitable for threading manifolds and fuel filters with extreme precision and cycle times, it features short toolholder movements, multi-flute toolholders, easy clamping, a dovetail clamping system and an enclosed holder structure. All this delivers shorter cycle time and higher productivity, faster feed rates, convenient insert assembly, improved rigidity and accuracy and much more.
Starting a business requires risk-taking. “It's like a motorcycle race. If you don't want risks, you might miss your chance to win,” says Randy Gevers, CEO of GRT-Tech. Passionate grinder Randy Gevers knows his stuff. Before founding his company, he enjoyed years of success in motorcycle racing. But his success story begins with his father, Antoon Gevers, who instilled a love for engines and metalworking, especially grinding. After years of working together, the Gevers family took the plunge in 2016 and started their own business. The first machine Randy bought was a conventional grinder, with others quickly following. Fittingly, their initial customers came from the KTM community, as the family had built an extensive network through racing. Today, customers from aerospace, medical technology, tool and mould making, trust the Gevers, alongside navy suppliers and semiconductor industry suppliers. “Theoretically, we could survive on semiconductors alone,” says Randy. “But a company shouldn't become dependent on one sector.” The range of materials at GRT-Tech extends from steel, various stainless steels, brass and copper to ceramics and plastics. Typically, small batches of up to around 50 pieces are manufactured, but individual parts and prototypes are also produced. Precision Demands Better Equipment Randy quickly realised that machining complex workpieces, such as those used in tool and mould making or medical technology, reached its limits with conventional grinding machines. After moving to their current location in 2018, he purchased a powerful, used KELLENBERGER KEL-VARIA CNC universal cylindrical grinding machine. Right from the start, we received many requests for grinding complex workpieces,” says Randy. “But we could only accept around 10% of them. I couldn't, and didn't want to, continue like that.” The decision wasn't difficult—both Gevers knew and valued these machines from their previous employer. The KEL-VARIA, a predecessor of today's premium KELLENBERGER K1000 series, embodies the highest machining and surface quality. It has very high static and dynamic rigidity that ensure the machine delivers precise and efficient operation. Expanding Capabilities Following a positive experience, another KELLENBERGER machine was quickly shipped to Heeswijk-Dinther: a universal internal and external cylindrical grinding machine KELLENBERGER K100. René van der Peet from BMT Bridgeport Machine Tools, which represents KELLENBERGER in the Netherlands, served as a consultant. The KELLENBERGER K100 is available with centre distances of 1,000/600mm and a 200mm centre height, designed for workpiece weights of up to 150kg. High grinding wheel drive power ensures increased productivity, while the Z-guide maintains high profile accuracy. The C-axis with direct drive offers greater precision in non-circular grinding. Randy selected the longer 1,000mm overall length for greater flexibility in part sizes, along with a grinding head variant featuring two external grinding spindles, one internal grinding spindle, and a tactile measuring head. The high-frequency spindle, with a speed range of 6,000 to 40,000 rpm, includes an internal coolant supply. “I'm fascinated by the machine's high, reliable accuracy. Added to that are my years of experience, which ultimately makes the difference for the customer,” says Randy, adding with a laugh: “A machine can't advise on how best to manufacture a workpiece.” Mastering Complex Challenges Challenging workpieces are a daily task at GRT-Tech, such as components that combine copper and cast iron with the roughness of less than 0.15µm. “We could achieve 0.05µm, but that's not necessary in this application,” explains Randy. “Cast iron is very porous and brittle; the grinding stone clogs quickly and must be dressed continuously, but not too often. It's about finding the right balance. The more experience and sensitivity a grinder has, the more precise such workpieces will be. This component is very expensive due to material combination and upstream processes like turning, milling and EDM. The grinding process must be perfect first time.” “The more complex the workpiece, the higher the precision requirements, the greater my motivation to perfect it,” says Randy. He simply loves a challenge—no longer at the racetrack, but with his machines, for his customers' benefit.
While car production is slow, factory activity is building strongly to decarbonise automotive as carmakers target 2030 for going all-electric. Subcontractors could be eligible for the new DRIVE35 government programme, which could offer some companies grant funding to help them lighten and decarbonise their products, says Will Stirling. Based on cold numbers, little has changed in the automotive sector since MTD's last report in March. In 2024, UK vehicle production was at its lowest level since 1954, excluding the disruption from Covid. And in the first half of this year, carmakers posted another 12% drop to just 417,200 vehicles manufactured, the lowest number since the early 1950s. The causes are well-known: weak global demand and the cost of the transition to low-carbon vehicles. But SMMT, the motor industry business group, is forecasting a bounce back in 2026 and there is evidence from several quarters that they are right. First, note that what we see on the roads is not an accurate reflection of changes happening in the factories of Britain. Only 4.75% of the 34 million cars on UK roads are fully electric, rising about one per cent a year, according to EV consultancy Zapmap. For new sales, by July 254,666 new fully electric cars had been sold, a 21.5% market share of all new cars registered this year and 57,745 more fully electric cars than were sold at the same point last year. The proportion of new electric cars has grown from 11.6% in 2021, to 19.6% in 2024 – so, decent if unspectacular progress, reflecting buyers' reticence with cost, and charge point/range anxiety. A new EV grant and falling prices could boost sales. Many buyers lacked incentives until now. Lower-cost EVs from Renault and Chinese brands, along with a £3,750 Electric Car Grant and EV Chargepoint Grant, might increase sales,” says Professor David Greenwood. However, the full grant applies only to cars with the lowest CO2 footprint; others receive a reduced £1,500 discount. Currently, no UK-made or sold cars qualify for the full grant, experts at BBC Top Gear say. Manufacturing activity is different to cars on the road, however. In the UK, about 80% of what we buy is imported and 80% of what we make is exported, and there are some very different drivers at play affecting manufacturing. Across the board, EV and low carbon vehicles and their component makers are ramping up fast. Jaguar Land Rover recently stopped making the XE, XF, and F-Type models as it shifts to an all-electric ‘reimagine' brand, reducing production at Jaguar sites temporarily. However, this should be offset by Nissan increasing output in Sunderland, including new models like Qashqai, EV Leaf, and Juke, despite closures elsewhere. Overall, manufacturing volumes are expected to rise later this year, with Nissan among several automakers investing in factory expansions. Factory and product investments pick up UK Export Finance has underwritten a £1bn export development guarantee to Ford UK, aimed at supporting Ford's global transition to EV production. The loan, provided by Citi and several lenders, helps fund aspects of its transformation to EV powertrains, and it follows a £380m investment in its Halewood manufacturing plant, to switch from producing transmissions to electric motors. Steel frames have been erected at the site of Agratas's new battery gigafactory in Somerset, marking the start of the next phase, the vertical build. 17,000 piles had been placed in the ground by the end of June. Agratas says that 100% of the steel used for the build is sourced from British suppliers. Astemo UK, a subsidiary of Japanese car parts maker Astemo, will build a new production line for inverters for next-generation EVs at its Bolton plant. The total investment, which includes support from government's Automotive Transformation Fund, is £100 million and it will secure an estimated 220 jobs. Production is scheduled to begin in April 2027. Rolls-Royce will be fully electric by 2030, starting with the Spectre coupé, followed by an electric SUV in 2027 and a new luxury saloon replacing the Phantom. They are building a £300m extension to the Goodwood factory to increase capacity and support electric vehicle manufacturing, investing in future demand. The government launched DRIVE35, a long-term £2.5bn programme supporting low-carbon vehicles. It includes £2bn in funding to 2030 and £500m for R&D to 2035, a ten-year commitment to UK automotive innovation. Here's the good bit: subcontract manufacturers that make car parts and are focused on lightweighting are ineligible for DRIVE35 funding. Three main funding priorities are: supporting innovation, accelerating start-up and enabling transformation – so if a company's work fits broadly into any of those categories, it has a chance of winning an award. How are SME metal forming companies responding on the ground? “Full electric transition is still way off, but a lot of our members have already started to adapt what they do to supply into the new generation of vehicles – many of them with significant success,” added Stephen Morley, President of the Confederation of British Metalforming. His organisation represents more than 200 companies involved in fasteners, forgings, pressings and precision metalwork, a vital part of the industry that makes products that go into many critical automotive applications. “There are many opportunities and UK firms are renowned for their resilience and ability to pivot to make the most of them. But Steve adds “I'm afraid there is a big ‘but' though.” “We are achieving all of this despite a tsunami of external factors out of our control, some of which are self-inflicted by a government that is supposed to be backing industry. The change in steel safeguarding quotas - introduced at the drop of a hat by Business Secretary Jonathan Reynolds in July - was against Trade Remedies Authority (TRA) and has caused major disruption and financial hits to our sector. Our members have reacted furiously to this decision.” While the ambition is grand, regulations that hamper SME efficiency and the disconnect between government and business pervades and risks slowing any recovery as the electric shift beds in. Expect car production to rise in 2026 While the numbers and order books today are low, for many, there are legitimately brighter days ahead for the car industry. The UK has a beneficial tariff rate (relative to the EU) for exporting cars to the US of 10%, but this applies only to the first 100,000 vehicles imported into the US. Beyond 100,000, the higher tariff of 27.5% applies; however, it's still a relative boost for UK-made luxury brands. Prof Dave Greenwood adds, “The measures announced for the automotive sector in the industrial strategy (that include reduced energy costs, R&D grants, Investment Zones, etc) should all position well for longer-term future growth in manufacturing.”
In the rapidly evolving automotive industry, turbocharged engines have become increasingly common due to their ability to improve engine performance, fuel efficiency, and reduce emissions. However, machining the high-precision components of a turbocharged engine presents considerable challenges. ISCAR offers cutting-edge solutions specifically designed to meet these challenges, ensuring superior performance, efficiency, and cost-effectiveness. Turbocharged engines typically require the machining of complex geometries and hard-to-cut materials such as titanium alloys, heat-resistant stainless steel, and high-temperature alloys. These materials are chosen for their durability and capacity to withstand extreme conditions, but are notoriously difficult to machine due to their hardness and propensity for rapid tool wear. Achieving the high levels of precision required for turbo engine components is crucial for optimal engine performance. Engine downsizing is a prevailing trend in the automotive industry, with turbochargers now commonly found in both large diesel and gasoline engines. Turbochargers can significantly boost an engine's horsepower without a substantial increase in weight, providing high performance and additional benefits for modern vehicles. However, turbochargers present challenges for original equipment manufacturers (OEMs), as they must endure extreme operating conditions, very high temperatures, and high-speed revolutions per minute (rpm). These demands drive OEMs to explore new materials and technologies. ISCAR's extensive global industry experience positions the company at the forefront of providing higher productivity, profitability, and performance gains. In the field of turbochargers, ISCAR presents innovative solutions and stable processes for turbocharger-related components. ISCAR views OEMs as high-priority customers and is committed to building long-term partnerships. The company's goals include recommending efficient and economical solutions, delivering high-quality products, and providing long-lasting support. ISCAR has developed a comprehensive range of cutting tools and solutions specifically designed for the challenges of machining automotive turbo charged engines. These solutions focus on enhancing productivity, extending tool life, and achieving exceptional surface finishes, all while maintaining cost-efficiency. Engineered for high-feed and high-efficiency milling, ISCAR's indexable milling cutters are ideal for both roughing and finishing operations (Figure 1). Their robust design ensures stability and precision, even in demanding machining conditions. The use of advanced geometries and coatings helps mitigate issues related to high temperatures and tool wear. Designed for machining hard materials, ISCAR's endmills offer exceptional durability and precision. Available in various geometries and coatings, ISCAR's solid carbide endmills cater to the specific needs of turbocharged engine component manufacturing, providing solutions for high-speed and high-accuracy applications. ISCAR offers a wide range of turning tools optimised for machining high-temperature alloys and other challenging materials. These inserts are designed to minimise tool wear and provide excellent chip control, ensuring smooth and efficient machining processes. The advanced insert geometries allow for reduced cutting forces, contributing to improved tool life and surface finish. Grooving operations are critical in the manufacturing of turbocharged engine components, where precision and surface quality are paramount. ISCAR's grooving tools are designed to handle the rigorous demands of machining hard-to-cut materials and complex geometries. ISCAR offers a wide range of indexable grooving inserts tailored for machining high-temperature alloys and other challenging materials (Figure 2). These inserts are engineered to deliver exceptional wear resistance and superior chip control. The inserts are available in various geometries and cutting edges, optimised for different grooving applications, ensuring smooth and efficient material removal. ISCAR's grooving holders are designed to offer maximum stability and accuracy during machining. The holders feature durable clamping mechanisms to securely hold the inserts, reducing vibrations and extending tool life. Their innovative design allows for easy insert replacement, minimising downtime and boosting overall productivity. ISCAR uses state-of-the-art coatings on its tools to improve performance. These coatings deliver better wear resistance, lower friction, and enable higher cutting speeds, thereby boosting productivity and prolonging tool life. Coated tools also help achieve smoother surface finishes, which are vital for turbocharged engine components. Nano-layered coatings, such as TiAlN and AlTiN, offer improved thermal stability and resistance to oxidation, crucial for high-temperature applications. Recognising that each turbocharged engine component may have unique machining requirements, ISCAR offers customised solutions (Figure 3). ISCAR's engineering teams collaborate closely with clients to develop tools and machining strategies tailored to specific needs, ensuring optimal results and efficiency. This approach allows for the integration of advanced tool paths and machining parameters, maximising performance. ISCAR is at the forefront of digital transformation in manufacturing. The company's innovative tools and digital solutions enable real-time monitoring and data analysis, allowing manufacturers to optimize machining processes, reduce downtime, and increase overall efficiency. By integrating Industry 4.0 technologies, such as IoT-enabled tool management systems and predictive maintenance platforms, ISCAR helps clients stay competitive in a rapidly evolving market. Choosing ISCAR's solutions for machining automotive turbo engines provides several key advantages. Firstly, with innovative tools and technologies, machining processes become faster and more efficient, reducing cycle times and increasing productivity. Longer tool life and improved machining performance lead to lower overall manufacturing costs, providing significant economic benefits. Additionally, ISCAR's solutions ensure high-quality finishes and precise machining, essential for the demanding specifications of turbo engine components. Efficient machining practices result in less waste and reduced energy consumption, contributing to more sustainable manufacturing processes. In the competitive automotive industry, ISCAR stands out as a key partner, offering cutting-edge solutions for machining turbo engines. By addressing the unique challenges of machining advanced materials and complex geometries, ISCAR not only meets the industry's current demands but also paves the way for future advancements. With a commitment to quality, efficiency, and innovation, ISCAR continues to drive the machining industry forward, helping manufacturers achieve new levels of performance and success.
The manufacturing landscape is shifting as energy costs and environmental responsibility become as important as speed and quality. Brother's Blue Technology leads this change, optimising machine design to minimise waste in time, resources, energy, and space. Peter Smith of Whitehouse Machine Tools, Brother's UK distributor, says it marks a paradigm shift in machine tool investment evaluation. MTDCNC spoke to Peter to find out more… Do your machine tools reduce energy consumption—benefitting manufacturers' bottom line and the environment? “The Speedio series of machining centres from Brother certainly do. They use patented motor technology to capture and redeploy power, and they use less air, a dual benefit of Brother's Blue Technology approach.” The Blue Technology Philosophy: Eliminating Manufacturing Waste Brother's Blue Technology eliminates waste throughout manufacturing, focusing on efficiency across the entire machine cycle. It emphasises the importance of how efficiently a machine produces, recognising modern competitiveness depends on this. The foundation of Blue Technology lies in Brother's ‘low-mass, high acceleration' design philosophy, which Smith describes as fundamental to achieving superior efficiency. “The machines use Sanyo Denki drives—the world's fastest reacting servo motors. They have a very special design with IPM interior permanent magnet technology that essentially harness energy like you would get from an F1 car. It's beautiful, really, the way that it works. So the acceleration and deceleration characteristics of the machine mean that the motors are creating lots of energy, but then they can harness that energy and redistribute it back into the machine.” This energy regeneration technology marks a breakthrough in machine tool efficiency. During typical machining processes, the electrical energy produced during spindle and axis deceleration is usually converted into heat and lost. Brother's IPM (Interior Permanent Magnet) servo motors recover this energy and redirect it back into the machine system to establish a regenerative cycle Real-World Energy Performance: The 80% Reduction Achievement Smith's most compelling evidence for Blue Technology's effectiveness comes from extensive real-world field testing conducted with wireless energy and air monitoring equipment measuring actual consumption. “Using the wireless monitoring technology on a customers 40 taper 5 axes, we've run the same program/parameters on a Brother, 5-axes. Running the same parts on both machines, the Brother actually achieved almost 90% energy saving.” This extraordinary 90% energy reduction translates into substantial financial benefits. Smith calculates the economic impact with precision: “If you take an average energy tariff in the UK, the Brother over the other machine doing the same job saves between £5,500 to £6,000 per shift per year. So, if we're operating a double shift, over a year, electricity savings will be £11,000 to £12,000. Over a five-year period, which is generally how people finance machines, manufacturers will save £55,000+.” “These savings compound across multiple machines. For manufacturers operating five machines on double shifts, the annual energy savings rise to £275,000 over a typical five-year financing period. In an era of volatile energy prices, these reductions provide both immediate cost benefits and long-term economic stability.” Brother's own documentation supports this data, with official testing demonstrating 80% energy reductions in a variety of cutting applications compared to typical BT40 spindle machines. This performance stems from multiple on machine technological innovations working in collaboration, rather than any single efficiency improvement. The Four Pillars of Blue Technology Efficiency Brother's Blue Technology reduces waste in four areas, improving efficiency. The first focuses on eliminating time waste with high-acceleration / deceleration servo systems, optimised dynamics and rapid tool change times (0.7 seconds). Smith notes: “It's not about the rapid rate. It's about acceleration rates. Most machining centres operate around 0.6 to 0.8G axes acceleration, Brother Speedio' are much faster at up to 2.2G.” These performance characteristics deliver healthy cycle time reductions, between 20% and 70% depending on the application, compared to 40 taper technologies. The second pillar targets resource waste through efficient coolant systems, LED lighting, and reduced compressed air consumption. Brother's mechanical tool change system exemplifies this approach, requiring minimal pneumatic assistance compared to traditional alternatives. “The whole tool change is mechanical using a linear cam mechanism. Air is only used briefly to clean the spindle taper. That's a huge saving when you look at air consumption,” Smith notes. Energy waste elimination forms the third pillar, incorporating IPM servo motor technology, energy regeneration systems, and optimised control algorithms. The fourth pillar addresses space waste through compact machine designs that deliver equivalent or superior capability within significantly smaller footprints. Advanced Motor Technology: The Heart of Energy Efficiency Brother's energy efficiency is founded on IPM motor technology. Smith states: “IPM interior permanent magnet servos respond quickly to rotation and stop, enabling efficient cutting with less power. Unlike normal induction motors, it starts instantly and efficiently.” IPM motors incorporate permanent magnets embedded within the rotor, providing superior efficiency and responsiveness compared to induction alternatives. This design enables rapid acceleration and deceleration whilst minimising energy waste during speed transitions. The energy regeneration capability represents perhaps the most innovative aspect of Brother's motor technology. During deceleration cycles, the IPM motors function as generators, converting kinetic energy back into electrical energy. This recovered power is redistributed throughout the machine system, reducing overall grid consumption. The technology effectively transforms what was previously waste heat into useful energy, creating a regenerative cycle that compounds efficiency gains throughout extended operation periods. Brother's dedication to motor efficiency covers all machine axes. The Sanyo Denki servo drives for the linear axes offer quick response, ensuring energy efficiency benefits both positioning and cutting. Control System Integration Brother's D00 control system plays a crucial role in Blue Technology implementation, incorporating specific features designed to minimise energy waste during non-productive periods. Smith highlights the system's comprehensive approach: “A variety of functions such as auto coolant off, auto machine lights off, and auto power-off are installed to ensure power saving.” The control system's 1000-block look-ahead, sub-micron control capability enables optimised toolpath execution that minimises unnecessary acceleration and deceleration cycles. By analysing upcoming machining operations, the system can optimise spindle speeds and feed rates to maintain efficiency. The D00 control incorporates an energy monitoring application that enables real-time visualisation of power consumption, helping operators identify opportunities for further efficiency improvements. This transparency allows manufacturers to understand exactly how their machining strategies impact energy costs. Compressed Air Efficiency: The Often-Overlooked Savings While electrical energy consumption receives primary attention, compressed air efficiency represents another significant cost reduction opportunity. Smith emphasises this often-overlooked benefit: “It doesn't use a great deal of it, but the bit that it does use is obviously critical.” Brother's mechanical tool change system exemplifies the compressed air efficiency approach. Unlike traditional tool changing systems that require significant air consumption for each operation, Brother's mechanical system requires only minimal air for chip clearing. The mechanical approach reduces air use during tool changes. While conventional systems need compressed air to stop the spindle quickly, Brother's system keeps it moving, eliminating this energy waste. For manufacturers operating multiple machines, compressed air savings can represent thousands of pounds annually. The efficiency gains also reduce compressor sizing requirements for new installations, providing capital cost savings beyond operational benefits. The Hidden Economics The total cost of ownership analysis shows advantages of Blue Technology adoption. Beyond energy savings, manufacturers see reduced maintenance. The mechanical tool change system wears less than pneumatic options, and IPM motors' efficiency decreases heat and bearing stress. Factory costs compound the economic benefits of Brother's compact designs. Smith calculates that Brother machines typically require 25 to 30% less floor space than equivalent BT40 systems. In high-value manufacturing, this can save thousands. The reliability benefits further enhance the total cost of ownership (TCO). “Brother machines are built for lights-out three-shift running. So our advice is run them flat out.” Environmental Responsibility Brother's Blue Technology addresses rising corporate environmental standards by reducing CO2, supporting sustainability goals, and offering cost savings. Smith recognises the growing importance of environmental performance: “Companies' efforts to promote energy saving bring a variety of values for their business operations. Amid global calls for carbon neutrality, promoting energy saving and contributing to decarbonisation will lead to an increase in corporate value.” For manufacturers pursuing environmental certifications or carbon trading schemes, the measurable efficiency improvements provided by Blue Technology offer valuable documentation. Overcoming Traditional Thinking Despite the compelling economic and environmental benefits, Smith acknowledges market perception of BBT30 Blue Technology, due to historical misconceptions and early adoption of 40 taper technologies, needs to be more open minded. “Engineers typically operate on personal experience or that or their peers and the UK market was an early adopter of 40 taper technology from manufacturers like Bridgeport & Cincinnati. Brother BBT30 Blue Technology has advanced so far in the last decade in efficiency and cutting capability, 40 taper users who have become uncompetitive now have the opportunity to regain a competitive edge with Brother” Smith continues: “We get too carried away with brand loyalty. Not one machine tool manufacturer has all the answers, furthermore buyers become fixated on a deal rather than TCO. WMT CNC & Brother are developing a method of predicting TCO for machine investments so buyers can take a long-term investment decision at the point of purchase. The journey to market transformation requires manufacturers to assess machine tool investments through thorough economic analysis rather than relying on past preferences. Smith's approach stresses empirical testing: “Supply us with your ISO programme. We'll run it, and we'll give you our honest opinion about whether a BBT30 taper Brother could improve the ROI.”
In July, we discussed our visit to the Hexagon event at Mills CNC, where Hexagon's Nexus platform was shown. The event also alluded to how Pro Plan AI demonstrated 70 to 75% programming productivity improvements. With such impressive statistics and other products on show, we wanted to dig a little deeper into the production intelligence solutions. By Rhys Williams Real-Time Production Intelligence with Datanomics Zoltan Tomoga, Product Manager for Hexagon's Production Software Business Unit, detailed Datanomics' comprehensive approach to production monitoring, emphasising its zero-operator-input design that sets it apart from competing solutions. “Most machine monitoring solutions require the operator to tell the solution why the machine is stuck. The problem is, if you've got a big list of reasons, operators will often select the first one, always a broken tool, as opposed to the coolant or whatever. Whereas Datanomics is completely no operator input.” The system's connectivity architecture enables comprehensive data collection without disrupting workflow. “Each machine has an Ethernet port that will connect to a network, and then you can pull information off of it, as well as push information to it. With our CAM software, we typically push the program through the Ethernet,” Zoltan noted. Datanomics serves three distinct user categories with targeted interfaces designed for specific operational needs. For management, ‘you are mainly interested in OEE. You want to see how much of your shop is utilised.' The primary focus targets shop floor managers who require intelligence: “Every morning at six, we send out the coffee cup report, so when they arrive, the night shift is still there. They can open a report, see what's happened and talk to relevant operators.” The Factory Mate AI enhancement offers instant problem diagnosis capabilities, enabling immediate corrective action. “A shop floor manager just arrived at the factory. There was one machine which didn't perform very well. They hit the factory mate icon, and it will give them the top three downtime events. In this case, we were waiting for an operator. That was the second one as well, and the machine was stuck,” Zoltan demonstrated. For process engineers requiring deeper analysis, Datanomics offers comprehensive historical data capabilities that facilitate continuous improvement initiatives. “In EdgeCAM, if I generate an NC code, I can put what EdgeCAM says is going to be the cycle time. However, if the feed override, or the rapid wasn't set to 100%, it might start to differ. The target for one part was 56 minutes, but we are actually running on 59 minutes recently. However, Datanomics thinks we could run that part in 45 minutes and improve on efficiency,” Zoltan explained, demonstrating how the system identifies specific optimisation opportunities. Tooling insights provide strategic procurement intelligence. “You will see which tool you use the most, and make a decision if you want to adjust speeds and feeds on that tool.” Benchmarking Progress: Quantifying Industry Digital Maturity The benchmarking initiative previously discussed in MTD May Issue with Jason Walker, Hexagon's VP of General Manufacturing, has collected substantial industry data over twelve months, revealing concerning gaps in digital adoption across manufacturing operations. The results confirmed extensive manual processes that create competitive disadvantages. “More than half of manufacturers are still using a manual process, which typically involves whiteboards and Excel spreadsheets and a lot of manual planning,” Walker revealed. Most of the upstream processes for winning work, like quoting and planning, are very much done manually.” Production intelligence gaps create significant profitability challenges for manufacturers who are unable to track actual versus planned performance. “Understanding the utilisation of the machines on the shop floor probably comes all the way back to the quoting process and understanding the profitability of your business, because if you're quoting that a part is going to take two hours to machine, and you have no traceability to see who did that part or whether that batch of 1000 parts did actually take two hours each. Or did they run at two hours and five minutes, which makes a large difference over the batch,” Walker explained. The competitive implications of slow processes are significant for business sustainability. “Ultimately, many of these companies, when they are winning the work, it's because they've under-quoted on a job which further erodes their profitability,” Walker observed. External pressures are accelerating transformation requirements. “Lockheed Martin has a model-based enterprise playbook for suppliers. Lockheed are actively saying to their supply chain, if you aren't going to adopt these new technologies that are going to allow you to manage the digital thread through the digital models that we're going to provide you with, then ultimately, you will be losing out on work in the future,” Walker shared, demonstrating how OEMs are making digital transformation mandatory. Quantifying Digital Transformation Benefits The event demonstrated how digital manufacturing solutions deliver measurable business improvements across multiple operational areas that justify investment through concrete returns. The integration of solutions presented in Part One—Nexus connectivity, Pro Plan AI programming acceleration, and Paperless Parts quoting automation—creates compounded benefits when combined with real-time production intelligence from Datanomics. Pro Plan AI's 70 to 75% reduction in programming time enables manufacturers to complete days of work in mere minutes while capturing institutional knowledge from experienced programmers. This capability, combined with Mills CNC's DNX 2100 launch aimed at reducing setup time, exemplifies an industry-wide shift towards efficiency optimisation. Paperless Parts transforms quote-to-cash cycles from week-long manual processes into 24 to 48 hour automated workflows, enabling customers to secure 25% more business through quicker response times. The platform removes resource constraints by alleviating quoting burdens from owners and managers. Datanomics provides real-time production intelligence without requiring operator input. This enables shop floor managers to identify and resolve issues through immediate problem diagnosis and historical trend analysis. The system's ability to compare target and actual cycle times reveals optimisation opportunities, such as identifying potential efficiency improvements. The benchmarking data reveals that over half of manufacturers still rely on manual processes for critical business functions. Looking Forward: Measuring Manufacturing's Digital Future The convergence of AI-driven programming, automated quoting systems, and real-time production intelligence generates combined benefits that surpass the capabilities of individual solutions. Manufacturers adopting comprehensive digital workflows can realise simultaneous enhancements in quote win rates, programming productivity, and production efficiency while tackling workforce challenges through knowledge capture and skills augmentation. Hexagon's platform approach allows manufacturers to implement digital transformation incrementally, measuring benefits at each stage while working towards comprehensive integration. The partnership with Mills CNC illustrates how technology providers and equipment manufacturers can collaborate to achieve measurable business outcomes that justify digital investment through quantifiable improvements in productivity and profitability. Concrete business metrics will measure success in this digital transformation: quicker quote turnaround, higher win rates, reduced programming time, improved production efficiency, and enhanced workforce productivity. Manufacturers achieving these measurable improvements—through solutions like those demonstrated at the Mills CNC Technology Campus—will define the competitive landscape for the next decade of industrial production. Meanwhile, those failing to adapt risk losing business to more digitally capable competitors as customer requirements continue to evolve towards integrated digita
For nearly forty years, Pendennis Shipyard has established itself as a global leader in building, refitting, and restoring fully bespoke superyachts from its 14-acre waterfront site in Falmouth, Cornwall. The esteemed shipyard employs over 550 skilled craftspeople across various trades, including machining, fabrication, electrical work, and joinery, all working within cutting-edge facilities that feature a 150m dry dock, two 90m construction halls, and an enclosed non-tidal wet basin. The company's machining operations have been consolidated into The Digital Manufacturing Centre (DMC), a facility capable of producing everything from 2mm diameter pins to components for 8m booms. This centralisation has enhanced their capabilities, with Workshop Manager Jack Chuter now able to efficiently coordinate both replacement parts for existing vessels, which account for 60% of the centre's work, and collaborate with surveyors and designers on new components that must be both functional and aesthetically pleasing. Pendennis started their CNC journey in 2015 with an XYZ SMX 4000 bed mill, chosen specifically for its conversational programming capabilities while keeping manual operation options. “We didn't want to jump straight into full CNC machining,” explains Jack. “The SMX 4000, with its conversational programming and manual capability retention at a great price point, was perfect for developing the workshop.” This strategic approach proved successful, immediately enhancing both efficiency and accuracy while broadening the scope of parts that could be manufactured. The success of this initial investment led to the purchase of a ProTURN SLX 555 x 1m CNC lathe the following year. However, as demand for superyacht refits continued to grow, Pendennis recognised the need for more advanced machinery to meet increasingly difficult requirements, including tighter deadlines and more demanding materials. Recent additions include the XYZ 1100 HD vertical machining centre and XYZ TC 400 slant bed turning centre, investments driven by evolving industry demands. “We needed machinery that could tackle everything from aluminium and phosphor bronze through to 316 stainless, 17-4 Duplex and Nitronic 50-60 with ease,” notes Jack. “Reducing cycle times was important, but equally crucial was developing multi-tasking capabilities by running machines unattended during production.” The XYZ 1100HD, with travels of 1.1m by 610 by 610mm in X, Y, and Z axes, proves ideal for machining tough, sea-resistant materials. Its hardened box section slideway construction and BT40 spindle taper, combined with a 21kW spindle motor delivering 5-10,000 rpm, provide the power and versatility needed for superyacht applications. Similarly, the XYZ TC400's 400mm maximum turning diameter, 600mm turning length, and 78mm bar capacity provide flexibility for both single components and larger batches. Its 32kW spindle motor, which delivers a maximum of 3300 rpm, has already proven invaluable for the workshop's expanding needs. The DMC employs three highly skilled machinists alongside apprentices who benefit from Pendennis's award-winning training scheme. This mix of manual XYZ lathes for simple work and apprentice training, Prototrak-controlled machines for one-off and simpler parts, and Siemens-controlled equipment for complex, high-volume work creates an ideal learning environment. Programming combines CAD-CAM for 90% of milling tasks with conversational software for turning operations. Investment in XYZ machinery, alongside CNC waterjet and 5-axis router equipment, has not only enhanced in-house capabilities but increased the shipyard's appeal to young talent. With nearly a third of the workforce having completed apprenticeships at Pendennis, growing their own expertise remains integral to success.
NDT Equipment Limited, a valued customer of Close Brothers Asset Finance, has secured finance to upgrade its machinery and handle an increasing workload. Customer background Founded in early 2022 by Daniel Lenton and Katie Loydall, NDT Equipment Limited specialises in manufacturing fully traceable ultrasonic calibration blocks. These blocks ensure the accuracy and reliability of ultrasonic flaw detection equipment and are essential for identifying flaws in metals, composites, and other engineering materials. They serve a wide range of industries, including oil and gas, nuclear, aerospace, automotive, and general sales, both in the UK and international markets. Over the past three years, the business has expanded to offer subcontract work alongside its engineering products. Providing innovative machinery When the company was in its early stages, Dan bought Doosan and XYZ CNC machines for manufacturing. However, after rapid growth, Dan required a new machine to further enhance their capabilities, resulting in an order (while attending MACH 2024) for a new Matsuura MX-330 PC10 multi pallet, 5-axis, vertical machining centre. The machine now means NDT can offer bespoke innovative solutions and manufacture anything from prototypes to medium and large batch work. Oliver Shaw, Area Sales Manager at Finance for Industry, has worked closely with Daniel and Katie since they started the business, and created a bespoke Hire Purchase deal that meant NDT could access the new machinery without upfront costs. The finance solution breaks the cost into manageable monthly payments, supporting the company's continued growth. Result: This deal marks a significant milestone in NDT's journey, positioning them at the forefront of innovative engineering solutions. Oliver Shaw, Area Sales Manager, said: “It's always a pleasure working with Daniel and Katie. Watching the growth of their business from the start, I'm excited to see what's next for them, and we are cheering from the sidelines!” Daniel Lenton, Co-Owner of NDT Equipment Ltd, added: “We're delighted with this deal. Access to this type of machinery puts us at the forefront of the industry and allows us to provide innovative solutions that go beyond traditional tooling and work holding.” Products and services are subject to eligibility, status, terms and conditions and availability. All lending is subject to status and our lending criteria. The right to decline any application is reserved. For more information please visit: closeassetfinance.co.uk/s/ggs
With civil aerospace primes targeting production rates of 75 per month by 2027, and NATO members increasing defence spending to over 2.5% of GDP, business is brisk in the aircraft and defence sectors. The Paris Air Show in June showcased several UK companies that are investing during strong business conditions, says Will Stirling. Bathed in blazing sunshine, Paris Le Bourget Airport hosted the 55th Paris International Air Show from 16 to 22 June. A large UK pavilion featuring over 50 exhibitors joined thousands more. Aerospace is on the rise – the aerospace, defence, security, and space sectors contributed £42.2bn to the UK economy last year, marking a 10.4% increase from 2023. Defence is also poised for significant growth: Britain's defence spending will increase to 2.5% of GDP by 2027, up from approximately 2.3% in 2024, representing an additional £6bn per year. Furthermore, the government aims to elevate spending to 3% of GDP, potentially adding a staggering £20bn annually on top of the 2.5% baseline by 2030. A large fraction – likely over £20bn annually by 2030 – will be allocated specifically to equipment and weapons programmes such as missiles, submarines, nuclear infrastructure, drones, tanks, and factory expansion. ADS, the aerospace, defence and security industries business group, hosted nearly 100 companies at this year's Paris Air Show, predominantly manufacturing firms that produce everything from machined components, roll forming and composite structures to avionics and AI-powered digital engineering. MTD examines some of the exhibitors' news. Faster composite production for wing tips iCOMAT is a Gloucester-based advanced manufacturing company that has developed an automated composite production process, the Rapid Tow Shearing (RTS) process. Working for aerospace primes and defence customers, the RTS, which enables defect-free fibre steering for composites, is helping to advance new lightweight, high-performance structures. The company is one of several innovative SMEs working with GKN Aerospace on a new £12m R&D programme to develop and demonstrate next-generation composite wing and flap structures, called ASPIRE – Advanced Structural Product Integrated Airframe. The project will deliver three full-scale composite wingtip variants for structural testing to ultimate load, allowing the consortium to validate new technologies in highly relevant test conditions. Each wingtip variant will represent a different structural philosophy and technology set. Variant one is a bonded assembly with multiple parts, aligned with GKN Aerospace's design approach. It will validate the manufacture of three wingtip variants. The ASPIRE consortium includes Carbon ThreeSixty, iCOMAT, Lineat, Pentaxia, and the University of Bath, with support from agency Axillium and co-funding from the Aerospace Technology Institute. ASPIRE will also develop an optimised composite flap. The flap demonstration will feature a pre-preg manufacturing approach with RTS skins provided by iCOMAT, tailored fibre-placed brackets from Carbon ThreeSixty, low-energy out-of-autoclave curing moulds, and press-cured ribs. A key programme milestone will be achieving TRL6, Technology Readiness Level 6, for the press-curing of composite ribs. “ASPIRE is a perfect example of the power of UK collaboration to drive aerospace innovation,” said John Pritchard, president for civil airframe at GKN Aerospace. “By bringing together specialist SMEs, academic expertise, and GKN Aerospace's industrial leadership, this programme will accelerate the development of high-rate, sustainable composite wing technologies.” Martin Baker For nearly 80 years, Martin Baker has designed, manufactured and fine-tuned ejector seats in the UK in Denham, Middlesex, and at locations globally. In that time, these devices have saved more than 7,700 aircrew members' lives from over 90 air forces. The seats are fitted to programmes including the F-35 Lightning II, Eurofighter Typhoon, F-16 (some versions) and BAE Systems Hawk. At Paris, the company showcased the flagship US16E ejection seat. The Lockheed Martin F-35 Lightning II aircraft is the company's biggest programme, and the US16E seat equips all variants of the F-35. More than 1,500 US16E seats have been delivered for 12 international F-35 operators; the US16E has saved the lives of 10 aircrew to date. The US16E seat became the genesis for the new Mk18 ejection seat range, with improved ejection performance, reducing the risk of ejection and minimising life cycle costs. The new technology has allowed safe ejection for aircrew with nude weights as low as 46.7Kg (103lbs) and ejection up to speeds as high as 600Kts for aircrew wearing Helmet Mounted Displays, a common peripheral in modern combat operations. Martin-Baker is offering the Mk18 seat range to all the new aircraft trainer and fighter aircraft programmes. The company has doubled its headcount in the last 10 years, and 28 apprentices are enrolled across the business. Complex aerospace systems need AI As aviation becomes more deeply sophisticated and data-reliant, data analytics companies must coordinate. Aerospace engineering companies are prolific users of simulation software to test component performance in different scenarios. AI (artificial intelligence) means you can explore designs 1,000x faster than physics-based simulation, according to Altair Engineering, which was acquired by Siemens in March. In Paris, Altair demonstrated how its solutions are helping the aerospace sector from concept through production to in-flight performance. It applies AI to combine several powerful technologies: digital engineering, smart factories, certification by analysis, digital maintenance, repair and overhaul, and digital twins. “AI, data, and connectivity are no longer future concepts — they are today's competitive advantages,” said Dr. Pietro Cervellera, senior vice president of aerospace and defence, Altair. “Our technologies are helping the aerospace industry achieve next-level performance, sustainability, and innovation breakthroughs.” Demonstrations showed how engineers can reduce design cycles, optimize structures for weight and strength, and improve aircraft performance using intelligent, AI-assisted modelling tools. Beyond the marketing, however, the use of AI in simulation has an essential role in democratising engineering. These solutions empower government agencies and startups to deliver advanced programmes quickly. The Altair Aerospace Startup Acceleration Program gives young companies enterprise-grade tools to bring novel technologies to market faster. Altair has recently partnered with the Campania Aerospace District in Italy to provide over 150 SMEs and startups with access to AI simulation tools, empowering them to work at the same technological level as OEMs and tier-one suppliers. Rocket science inspires students to manufacture The continued growth of the aerospace, defence, and security sectors requires a skilled talent pipeline. ADS also supports Race2Space, a multi-university and company initiative that engages young people in designing and building rockets and space systems. Announced at Paris, Carrie Waters, 18, a first-year physics student at Durham University, has spent the past year helping to build a powerful, 600kg thrust liquid-fuel rocket engine. She is a member of Durham University Spaceflight, a student-run rocket launching team competing in this year's Race2Space. In July, the team will ‘hot fire' their engine at the Westcott Space Cluster during the final stage of the competition. In this crucial test, the engine will be securely mounted and ignited horizontally while connected to pressurised fuel systems. The engine must demonstrate its ability to perform under extreme conditions—delivering the correct thrust, flow rates, and structural integrity—before being launched as part of a future rocket. It's like Heinz Wolff's The Great Egg Race on Rocket Fuel. “I'm really excited, I've never done anything like this before,” said Carrie. “I can't wait to see whether what we've designed and built actually works. It's very daunting. I've had a great time working with the team and learnt so much.” Carrie believes that initiatives like Race2Space are vital for helping students from all backgrounds turn academic learning into career opportunities. She hopes to one day work for organisations like Skyrora or the European Space Agency, contributing to rocket and satellite missions.
The aerospace industry stands at the intersection of extreme technological demands and cost-efficiency requirements. With aircraft manufacturers like Airbus and Boeing projecting the production of 42,500 new jets over the next 20 years, the need for precision machine tools and cutting tools has never been more critical. Aircraft construction is an intricate process that involves a complex array of materials, each presenting unique machining challenges. Aluminium alloys dominate the industry, comprising approximately 60% of aircraft components, while titanium and advanced composites play critical roles in structural and performance-critical areas. Aluminium alloys, particularly from the 2xxx, 6xxx, and 7xxx series, offer an ideal combination of lightweight properties and structural integrity. These materials require sophisticated machining approaches that balance material removal, surface quality, and dimensional precision. High-speed cutting (HSC) technologies have emerged as a vital solution, enabling manufacturers to address the demanding requirements of aerospace component production. It is in this area that Walter is innovating with its cutting tool solutions. Aircraft construction involves a complex array of materials, each presenting unique machining challenges. As aluminium alloys comprise approximately 60% of aircraft components and require sophisticated machining approaches, Walter's high-speed cutting (HSC) tools, such as the M2131 and M2331 milling cutters address the specific challenges the industry faces with these materials. The two insert sizes allow for depths of cut of 15 to 20mm, achieving chip removal rates of up to 11 litres per minute. Both milling cutters work almost seamlessly when repositioned, resulting in smooth surfaces even during pre-finishing. The dense, smooth PVD coating of the cutting edges makes them extremely stable and also ensures that there is hardly any cutting edge build-up. The creative design of the insert seat secures the insert against the high centrifugal forces that occur during high-speed cutting. At the same time, internal cooling channels deliver the coolant directly to the cutting edge to extend tool life and ensure exceptional chip evacuation. Titanium Alloys: Conquering Difficult Machining While aluminium alloys are used for fuselages and wings, titanium alloys, such as TiAl6V4 or Ti5553, are employed where an exceptionally high degree of rigidity is required, such as in landing gear components, struts, or flap tracks. The hardness and low thermal conductivity of titanium necessitate high requirements for the cutting tools, particularly regarding process reliability. Rapid cutting edge wear and low cutting parameters make machining titanium parts very time-consuming. Companies that succeed in reducing the machining time per component maintain a clear competitive advantage. Here, the Walter BLAXX M3255 helical milling cutter provides breakthrough solutions. The innovative geometry of both the milling body and the indexable inserts ensures that the maximum number of teeth can engage with the material, while the soft-cutting insert geometry results in positive cutting behaviour that consequently reduces machining times and offers higher metal removal rates. Heat management poses challenges when machining titanium alloys due to their low thermal conductivity; therefore, an optimised coolant supply to the cutting edge is essential. The Walter BLAXX M3255 is designed to create excellent chip clearance space that guarantees reliable chip removal, even at high cutting rates. The tangential positioning of the two or four cutting-edged indexable inserts allows for maximum cutting power and enables the machining of forged components, where the peripheral zone of the forged skin presents extreme challenges for the tool's edge. Ideal for rough machining applications, the Walter BLAXX M3255 helical milling cutter reduces titanium machining time by approximately 22% and extends tool life by around 100% through its innovative insert geometry and optimised chip clearance, which maximises material engagement and removal. Superalloys: Ceramic Cutting Technology Correlating with the well-filled order books is the requirement placed upon engine manufacturers and the supply chain for machining heat-resistant superalloys (HRSA). Here, too, shorter machining times are highly desirable. The cutting speed of carbide milling cutters on HRSA materials is typically around 50m/min. However, ceramic cutting tools push the boundaries with cutting speeds of up to 1000m/min, a 20 times improvement. The SiAlON ceramics offer excellent possibilities for this, as they are less sensitive to temperature fluctuations than whisker-reinforced ceramics, making them the first choice for milling operations in HRSA. The interrupted cutting during milling causes the temperature at one cutting edge to vary, and the use of coolant can further increase the temperature difference. In the worst-case scenario, the so-called ‘thermal shock effect' occurs, leading to cracks and even fractures. Dry machining is therefore recommended when machining superalloys with ceramic milling cutters. A positive side effect is that the ecological footprint of the milling operation is improved because lubricants are not required. Blisks are classic components made of nickel-based alloys. These bladed disks are often rough machined using carbide milling cutters. However, the machining time for this can easily exceed 30 minutes with conventional milling cutters. A ceramic milling cutter with a high feed geometry can machine the same features in just ten minutes. Feed rates of up to 9500mm/min can be achieved in a heat-resistant nickel-based alloy with a hardness of 44HRc and a tensile strength of 1400N/mm²; such machining values would be expected in aluminium, not HRSA. For HRSA machining, Walter introduces revolutionary ceramic milling solutions such as its MC075 high-feed geometry end mills. Available in a range of options including screw-in ConeFit interfaces, the MC075 ceramic end mills can deliver cutting speeds of up to 1000m/min utilising advanced SiAlON ceramic technology for superior temperature resistance. Future-Forward Strategies: Near-Net-Shape Unlike the automotive industry, where mass production dominates, the quantities required in the aerospace industry are comparably small, with the largest manufacturers like Airbus only producing around 750 aircraft a year. This makes ‘tool-free' production of components using 3D printing a feasible alternative, especially as the process enables the production of complex and stable components. Furthermore, it reduces the weight of conventionally manufactured components by up to 55%. This subsequently reduces the consumption of raw materials by up to 90%. From a machining perspective, there are also developments in this area that significantly optimise component production in terms of technology and costs. Fuselage sections, wings, tail units, engine components, and other complex assemblies are now being forged or 3D printed as close as possible to their ‘Near Net Shape'. It means significantly less material has to be removed. This not only saves material and machining time but also reduces waste - and thus enables more efficient manufacturing. Technological Integration The question of whether machine tools will still be needed in the future could well be asked in view of developments such as 3D printing or contour-based manufacturing. The answer is a resounding yes! Almost all 3D-printed workpieces require subsequent machining because their surface quality is usually insufficient for the components to be fitted directly. This is caused in no small part by the so-called ‘staircase effect' that occurs in the powder bed process typical of 3D printing. Heat treatment of steel components can also result in hardening distortion, which must be eliminated. Furthermore, support structures must be cleanly removed. All of these factors make cutting tools indispensable – now and in the future. The Economic Impact of Walter Solutions As an industry leader, Walter has proven the merits of its technical advances in the aerospace sector throughout the manufacturing supply chain. For the production of aluminium structural components, a major aerospace manufacturer implemented Walter's M2131 milling system for producing aluminium wing ribs. The result was a material removal rate (MMR) increase from 5.8 to 11 litres per minute with a 46% decrease in total machining time. Furthermore, the groundbreaking tool geometries of the M2131 system improved tool life by 35%, resulting in a 28% reduction in cost per component. Similar improvements have been witnessed when machining titanium Ti5553 landing gear components. By adopting the high-feed Walter BLAXX M3255 system, end users have benefitted from cycle time reductions beyond 22% when rough machining. Tool life improvements that are double the performance compared to the previous solution have subsequently yielded an overall 31% reduction in tooling cost per component. The machining of superalloy engine components is a particularly challenging niche where Walter once again excels. When machining blisk components from Inconel 718 (44HRc), the Walter MC075 ceramic milling system has delivered a machining time reduction from 30 minutes to 10 minutes per blade pocket, tripling throughput with existing machine tools and achieving machining cost savings of 65% despite a higher tool investment. As the aerospace industry commits to CO2-neutral operations by 2050, Walter's tooling solutions support this narrative of sustainability and efficiency, contributing significantly with innovations that reduce energy consumption, minimise coolant and lubricant usage, enable more efficient manufacturing processes and support lightweight component design. Conclusion Walter demonstrates that advanced tooling is not just about cutting metal—it's about enabling the future of aerospace technology. By combining innovative materials expertise, cutting-edge tool design, and a commitment to efficiency, Walter is helping aircraft manufacturers push the boundaries of what's possible. Walter continues to innovate in response to evolving aerospace requirements with digital integration tools such as its tool management systems that increasingly incorporate digital capabilities. This now reaches far beyond the cutting tool to incorporate comprehensive digital twins of tooling systems for unparalleled tool data management, AI-assisted cutting parameter recommendations, and predictive maintenance tools for monitoring and forecasting tool wear for optimal utilisation rates. Readers can and download a free copy of the complete aerospace whitepaper: ‘A balancing act between high technology and cost efficiency' here: https://pages.walter-tools.com/en-download-whitepaper.html
In the realm of modern manufacturing, precision and efficiency are paramount. ISCAR consistently pushes the boundaries of innovation with its Polycrystalline Diamond (PCD) and Cubic Boron Nitride (CBN) tools. These advanced materials are transforming how industries approach machining to provide significant advantages. PCD tools are renowned for their hardness and wear resistance, making them perfect for machining non-ferrous metals, composites, and abrasive materials. ISCAR's PCD tools are designed to provide precision and superior surface finishes, essential in industries such as aerospace, automotive, and electronics. The benefits of ISCAR's PCD tools include extended tool life, as PCD's exceptional hardness ensures that tools retain their cutting edge for longer periods, thereby reducing the frequency of tool changes and minimising downtime. Furthermore, cutting speeds can be increased. With PCD tools, manufacturers can operate at higher cutting speeds, thereby improving productivity and reducing cycle times. ISCAR's innovations in PCD tooling feature specialised geometries that improve chip control and heat dissipation, further optimising performance in demanding applications. ISCAR's CBN tools represent another cornerstone of its cutting-edge solutions, specifically designed for machining hardened steels, cast iron, and superalloys. CBN ranks second only to diamonds in hardness, making it an ideal material for tools that must maintain their integrity under extreme conditions. An essential advantage of using CBN inserts is the ability to replace the slow and costly grinding operations of hardened parts. Turning with CBN inserts significantly lowers the cost per part compared to grinding. ISCAR recognises that customers are shifting their finishing processes from grinding to turning with CBN inserts, particularly in the automotive industry. In grinding operations, size tolerance specifications exceed the capabilities of turning, while surface finish requirements are excessively stringent for hard turning. In hard turning, the size tolerance specifications surpass the turning capabilities, showcasing a complex geometry that makes single-point turning more practical. This method features relatively high metal removal rates, dry machining, faster machine setup, and shorter cycle times, facilitating both inner and outer diameter machining on a single machine. CBN is chemically passive when used in ferrous materials. CBN is a synthetic material produced by a high-temperature and high-pressure process. The finished product consists of one carbide layer and one CBN layer. The combination of the two materials is called a cubic-boron-nitride (CBN) wafer. CBN was developed to compete with the finish-grinding process of hardened ferrous materials (45-68 HRC) for economical cutting of 80 to 250m/min. CBN is also used in cast iron machining applications, allowing for extremely high cutting speeds of more than 1000m/min. Cutting tools made from CBN sintered materials are produced by mixing CBN with ceramics as hard as diamonds. Together, these materials are sintered at extremely high pressures and temperatures. Due to its low affinity and high hardness, sintered CBN delivers enhanced cutting performance, particularly for high-speed machining. The key advantages of CBN tools are: Superior Hardness and Strength: CBN tools withstand high temperatures and maintain sharpness even when cutting hard materials. This is essential for industries like automotive and aerospace, where hard turning is standard. Improved Productivity: The durability of CBN tools allows for higher cutting speeds and feeds, translating to faster machining processes and increased throughput. Reduced Tool Wear: With exceptional thermal and chemical wear resistance, CBN tools last longer than conventional carbide tools, leading to long-term cost savings. ISCAR's commitment to innovation is evident in the development of multi-tipped CBN inserts featuring enhanced edge preparation, ensuring optimal performance in the most challenging machining environments. ISCAR's insert types are designated as: MT Type - Mini-Tipped Multi-Cornered/Single-Use Inserts. These single-use inserts are designed to enhance machining efficiency by fully utilising each cutting edge. With a smaller and more economical CBN tip, they significantly reduce costs by providing more cutting edges per insert. The multi-cornered design features a single piece of ISCAR-CBN mounted on every usable corner. Single-sided inserts utilise the top corners, while double-sided inserts make use of both the top and bottom corners. Available in various shapes, square and diamond-shaped inserts, known as ‘Quadro', offer 4 corners, whereas triangular inserts, referred to as ‘triple', provide 3 corners. MM, MF, MR Chipbreakers Type CBN Inserts: ISCAR offers a variety of MT chipbreaker geometries tailored to provide optimal solutions for each specific application, ensuring excellent chip control in hard machining. These chipbreakers effectively prevent long chips and possible workpiece damage, while maintaining a stable and reliable production process. The MF-type inserts are customised for fine to medium cutting, MM-type inserts are perfect for medium machining, and MR-type inserts are intended for roughing operations. L Full Edge Tipped Inserts: Designed for productivity, these full-edge tipped CBN inserts come in various shapes to suit different machining needs. Triangular-shaped inserts feature a full edge tipped with CBN, while square-shaped inserts offer right or left-hand full-edge tipped CBN options. These inserts provide increased stability, enhancing overall machining performance HS Type Half Solid CBN Inserts: These inserts feature a top layer of CBN with a carbide base, offering multiple cutting edges. The high hardness achieved through a special binder results in excellent wear resistance, impact resistance, thermal stability, and chemical stability, making them ideal for metal processing. They provide exceptional cost performance, saving 30 to 50% compared to carbide inserts. The solid material ensures high mechanical strength, making it a superior cutting tool material for extreme conditions. These inserts lower machining costs, require fewer tool changes, and are 5 to 10 times more efficient than carbide and ceramic inserts. Solid CBN inserts are versatile and can be used across diverse industries. They are particularly effective for cast iron and hardened steel workpieces, including automotive engine components, brake discs, brake drums, pulleys, cylinder blocks, cylinder liners, pumps, and cast-iron rolls. For hardened steel, they are suitable for industrial gears, wind power bearings, drive shafts, crushing hammer cylinders, and slurry pumps. S Type Full Solid CBN Inserts are designed for aggressive machining conditions, offering numerous advantages such as excellent wear resistance, impact resistance, thermal stability, and corrosion resistance. They provide strong thermal stability and are ideal for high-speed machining, particularly roughing. These inserts save 30 to 50% compared to carbide inserts while delivering superior surface quality, enabling turning instead of grinding. The solid material ensures a high degree of mechanical strength, making it a superior cutting tool material.
The machining of advanced materials presents challenges that demand specialised tooling solutions. CERATIZIT has now developed two milling systems that meet the specific requirements of difficult-to-machine materials: the MonsterMill ISO-S for nickel-based alloys and titanium, and the MaxiMill S-Power for cast iron applications. A Monster That Conquers Nickel-Based Alloys The machining of nickel-based alloys such as Inconel, Hastelloy, and Waspaloy present significant challenges. CERATIZIT's redesigned MonsterMill ISO-S range addresses these challenges through a carefully engineered carbide substrate, advanced coating, and optimised geometry. The geometry has been specifically adapted to minimise heat and the polished chip flutes work in conjunction with an optimised coating to reduce friction. The irregular cutting edge pitch, combined with a variable helix angle, effectively minimises vibration during operation. This design feature significantly enhances machining performance while helping to prevent catastrophic tool failure. Microgeometry plays a crucial role in the tool's performance. The precision-engineered preparation of the cutting edge reduces cutting forces while stabilising the edges. The design takes into account regrindability from the outset, offering clear advantages in the reconditioning process. The DPX22S Dragonskin coating represents a significant technological advancement. Applied in 4 to 6 microns layers, the coating provides thermal stability through its specialised layered structure. Four-edge cutters come in two different lengths with diameters ranging from 3 to 20mm, available with both HA and HB shank configurations. Five-edge variants offer diameters from 3 to 16mm with similar shank options, while the new six-edge configuration covers diameters from 6 to 16mm with HA shanks. Corner radii options range from 0.2 to 5mm for the four and five-edge variants, with the six-edge version providing 0.2 to 2mm radii. Optimised Cast Iron Machining Cast iron also presents its own set of challenges. Here, the MaxiMill S-Power series addresses these issues through a high tooth count design utilising double-sided indexable inserts. The key innovation lies in the tool's ability to support an optimal number of cutting edges. The 88-degree setting angle enables a high tooth count while preserving small chip spaces, accommodating 12 teeth on a 63mm diameter cutter. The double-sided indexable inserts boast eight actual cutting edges crafted from carefully selected substrates and finished with DRAGONSKIN coatings. This design maximises insert utilisation while ensuring consistent performance throughout the insert's lifespan. The inserts are peripherally ground to achieve precise tolerances and a superior surface finish. Available in standard diameters ranging from 56 to 125mm, the MaxiMill S-Power accommodates maximum cutting depths of approximately 8mm while maintaining efficiency through its high tooth count. The system is optimised for GJS, GJV, and GJL cast iron grades, with recommended feed rates between 0.08 and 0.15mm. The indexable insert range includes ISO P/K classifications with M cutting edge geometry, offering corner radii of 0.4, 0.8, and 1.2mm to meet various application requirements. Grade options encompass CTPK220, CTCP230, and ceramic variants to suit specific material and operating conditions. While the MonsterMill ISO-S addresses the thermal and mechanical challenges of aerospace-grade superalloys, the MaxiMill S-Power tackles a completely different set of problems encountered in high-volume cast iron production. Where the MonsterMill ISO-S utilises advanced geometry and coating technology to withstand the extreme conditions of nickel-based alloy machining, the MaxiMill S-Power leverages mechanical design advantages to improve cast iron processing.
Machining aerospace alloys presents challenges to tool performance. A comprehensive strategy is essential to achieve optimal performance while avoiding process-limiting issues. These alloys are ideal for high-stress components due to their strength and heat resistance. However, their poor machinability stems from high strength and low thermal conductivity. Effective strategies encompass optimising cutting parameters, utilising advanced tool materials and coatings, and employing efficient cooling and lubrication techniques. Implementing precise toolpaths and chip evacuation can significantly enhance performance. “The biggest issue when machining high-temp alloys is heat,” says Danny Davis, Senior Staff Engineer Solutions at Kennametal. “We need to take special care in managing the heat through correct speeds, coolants, coatings and substrates.” Where is the heat coming from? Heat generated during cutting does not dissipate easily into the workpiece or chips when compared to other materials. This forces the tool, and sometimes the part, to bear the thermal burden. Every machining operation is essentially a thermal system where electrical energy enters the spindle and converts into kinetic energy (tool rotation and movement) and heat (from plastic deformation). During chip formation, three distinct phases occur: Rubbing, involving pure friction Plowing or plastic deformation, where approximately 90% of energy becomes heat Shearing, where actual chip separation occurs but still generates significant heat “Thermal energy is the biggest factor damaging the cutting edge,” said Steve George, Senior Manager, Product Design Engineering at Kennametal. Ways to Manage Heat in High-Temp Alloys Use tools designed for efficient cutting by reducing specific cutting energy—the energy required to remove a unit volume of material. Tools like HARVI™ I or HARVI II reduce cutting energy through optimised geometries and coatings. Deploy advanced coatings such as Kennametal's KCSM15A grade, engineered specifically for high-temp alloys. Its smoother, thinner layer retains a sharper cutting edge while enhanced abrasion resistance makes it ideal for aggressive nickel-based alloy conditions. Increase lubrication with high-pressure coolant systems or minimum quantity lubrication (MQL) to reduce thermal loads, particularly at high cutting speeds. Lubrication cools and separates contact surfaces, directly reducing energy converted to heat during rubbing and plowing stages. Use tools made of insulating materials like ceramics or certain coated carbides. Since high-temp alloys have poor thermal conductivity, heat stays near the tool. If the cutting tool conducts heat better than the workpiece, it absorbs more heat and wears faster. Minimise contact time during chip formation. Traditional milling involves constant contact, increasing heat due to extended machining time. Dynamic milling uses smaller radial engagement and keeps the cutter moving with less surface contact. Coolant and Lubrication Best Practices High-temp alloys require strategic coolant management: Water offers excellent heat transfer but poor lubrication. Combat abrasion with coolant rich in extreme pressure (EP) additives. Air aids chip evacuation when coolant isn't viable. Neat oils provide superior lubrication but are reserved for extreme cases due to maintenance requirements. Placement matters as much as volume. Ensure coolant hits the cutting zone directly—poorly aimed nozzles waste coolant and leave tools vulnerable. Tools like the HARVI IV series offer through-tool coolant delivery. “Higher coolant concentrations help reduce abrasive wear and manage heat when machining high-temp alloys,” said Katie Myers, Product Manager Marketing at Kennametal. “High-pressure through-tool coolant ensures effective heat removal and chip evacuation, crucial for tool life and part quality.” Using Ceramic Tools in a Dry Environment Ceramic tools offer unique advantages when machining high-temp aerospace alloys. Their extreme temperature resistance makes them well-suited for dry cutting where traditional carbide tools struggle. “When we discuss ceramic tools, we're almost always talking about dry cutting,” explained George. “You need careful setup because ceramic tools are much more sensitive to tool path and workpiece geometry.” Managing heat without coolant is key with ceramics. George noted, “Heat is obviously a big concern with high-temp alloys, but ceramic likes heat. We want to generate heat and eliminate it quickly.” George advised avoiding re-cutting and ensuring good chip evacuation to prevent premature wear or failure. He suggested specific motion strategies: “Step the walls of pockets. As you step down, move away from the wall with each pass. This keeps the tool away from the heat zone and helps prevent excessive burr formation.” Effective Approaches for Solid End Milling of Aerospace Components Pocketing Techniques and Methods of Entry: Many aerospace parts feature deep, complex pockets requiring proper entry strategy and cutter selection, especially in materials prone to work hardening and thermal stress. “Pocketing is one of the most common aerospace operations, but it can be tricky with high-temp alloys,” said George. Plunge entry works best for small pockets with limited space. HARVI I TE or HARVI II TE solid end mills plunge directly into material, offering high flexibility for tight spaces. Ensure cutting forces don't exceed machine capabilities. Ramp entry suits deeper pockets and allows more aggressive cutting. Straight angle ramping can significantly reduce cycle times but requires machine rigidity to withstand higher forces. Helical interpolation provides the most stable and efficient pocketing strategy due to lighter depth of cuts. Corner geometry requires careful consideration. Oversized tools can cause excessive radial engagement in tight corners, increasing wear and chatter. “If you have a half-inch radius corner, use a three-quarter-inch diameter tool, maybe even 5/8,” said George. “Use a small enough tool to follow the corner arc without gouging or over-engagement.” Minimising Chatter and Maintaining Rigidity: Chatter often stems from machine-tool interface issues with high-temp alloys. Even the best tool can fail if the spindle or machine lacks rigidity to absorb cutting forces. “Chatter occurs when there's too much movement between tool and part, leading to inconsistent cuts and tool wear,” explains Myers. “The best way to reduce chatter is ensuring your machine has sufficient rigidity.” If chatter persists despite adjusting stickout and tool selection, reduce depth of cut to lessen cutting forces instead of slowing feeds and speeds. This keeps vibrations in check without impacting cycle time. “Even with a robust machine, combining long stickout and weak spindle can lead to chatter. It's about balancing tool size, rigidity and cutting force,” George says. Cutting Parameters and Tool Life Tool longevity directly relates to cutting parameters. Running tools at correct speeds, feeds and chip loads ensures maximum tool life while preventing premature wear. Speed is crucial when machining high-temp alloys—too fast burns through tools quickly. Chip thickness is equally important. Light radial engagement without proper feed compensation leads to rubbing rather than cutting, generating excess heat and accelerating wear. Wall Stiffness and Support Geometry When machining features like blisks, isogrids, or blades, geometry plays a critical role in maintaining part stability and minimising deflection. Adjacent or curved walls often reinforce features, offering opportunities to exceed standard roughing rules. “The curvature of the blade actually adds stiffness to that part,” said Davis. “These rules are guidelines. If the wall has curvature, adjacent walls, corners, or bottom radii—all add stiffness.” Conclusion Machining aerospace components from high-temp alloys demands more than just the right tools—it requires a comprehensive strategy addressing heat, rigidity, toolpath planning, and part geometry. Using the right strategies keeps you ahead of the solid end milling curve in machining complex aerospace parts.
As nickel-based alloy parts become increasingly prevalent in the aero sector, the demand for optimised cutting tools grows. Nickel-based materials exhibit poor machinability, adhere to cutting tools, and consist of abrasive particles within the alloy. These issues result in poor productivity when using carbide tools. Henri Sevonen, Senior Industry Segment Manager – Aerospace for metal cutting specialist Sandvik Coromant, explains how new ceramic end mill technology has emerged to meet these requirements. Most aerospace parts are made from heat-resistant super alloys (HRSAs) and nickel-based alloys, which impose specific demands on engineers tasked with machining spools, turbine disks, combustion casings, and blisks. While many utilise solid-carbide end mills, these tools have limitations in performance. In the global arena, aerospace machine shops are looking for next-level technologies to deliver a step-change in productivity and/or tool life. Ceramic end mills can provide that very leap, offering up to 20-30 times more machining speed than solid-carbide tools. Such gains can be achieved because ceramic cutters retain their hardness at the high temperatures which arise when machining nickel alloys. The brazed ceramic CoroMill® 316 exchangeable-head end mill for roughing serves as a productive solution for aero engine applications involving ISO S materials. Firstly, the exchangeable head concept provides inherent process flexibility. Additionally, a six-flute version with a straight corner radius is available, delivering productive side milling, alongside a four-flute version for face milling. The ceramic substrate allows for a different cutting process in comparison with traditional solid-carbide tools. Importantly, the unique S1KU SiAlON grade is purpose-designed for the superior machining of nickel alloys, and is supported by negative geometry that provides a tough cutting edge. The latter also features a T-land for stable operations. SiAlON carries a chemical composition of aluminium oxide and silicon nitride (Al203+Si3N4), a combination that promotes high wear resistance, even at elevated temperatures. A stable set-up is recommended in all cases, and always without coolant application; machine shops should use pressurised air instead, as coolant would simply burn at the high temperatures involved. Furthermore, the use of coolant promotes thermal shocks and negatively affects tool life. Importantly, high spindle speeds of at least 13,000rpm are required. Additional recommendations include the use of down milling, as well as a programmed tool path that maintains the tool in constant contact with the material. It is clear that nickel-based alloys will play a vital role in the future of aerospace manufacturing. However, there are many challenges facing those tasked with producing aerospace engine components. It's only through continued tooling innovations, such as ceramic end mill technology, that aerospace machine shops will be able to optimise the machining process.
With skilled labour in short supply everywhere, it is becoming increasingly difficult to maintain or enhance productivity in metal-cutting production without complete automation. Companies will gain a competitive edge if they pay greater attention to the customer's perspective during these ongoing labour constraints and contemplate comprehensive machining solutions. The pressure in metal-cutting production is gradually intensifying due to a decreasing number of qualified individuals in the labour market. The labour situation is likely to deteriorate as the current skilled workforce begins to retire in the next five years. Furthermore, those workers still willing to work may lack the necessary skills for many essential tasks. An effective approach for transforming shops could involve their tool partner. If tool manufacturers consider the perspectives of customers and users, they possess tools and solutions that facilitate machining operations requiring fewer staff. This is particularly relevant in machining scenarios where fully automated processes are not feasible. One forward-thinking tool manufacturer is ARNO Werkzeuge from Ostfildern near Stuttgart. The family-run company possesses a wealth of expertise derived from its proximity to customers. This is reflected in various tools that prioritise complete machining wherever possible, enabling users to rely on rapid and user-friendly tool-changing systems for both fixed headstock and Swiss-type automatic lathes. The Swabian company has recently added height-adjustable holders for back working to its product range. These holders boast several impressive features not found in conventional systems. The newly introduced height-adjustable holders for machines without a Y2 axis can be finely pre-adjusted off the machine using an adjustment device, enhancing production and machine running times whilst making the process easy to learn. The easy-to-install system comprises a basic holder, spacer plate, top holder, and coolant supply attachment. The basic holder is precision clamped and secured by a simple dovetail guide, featuring smooth surfaces to prevent chip accumulation. ARNO Werkzeuge's new holders preserve the centre height setting when the tool holder is replaced, guaranteeing repeat accuracy and saving considerable time. Tool-changing scenarios always present challenges that can cost time and create sources of error. For trained lathe operators, these are everyday tasks. However, semi-skilled workers may lack the skills required for today's highly developed turning processes. Tool manufacturers who consider these scenarios now will have a competitive edge. When tool changes can be entirely eliminated, tasks naturally become easier. ARNO Werkzeuge has developed fixed holders with tools for machines featuring a Y2 axis, where the adjustable axis determines the centre height. These holders are designed in collaboration with machine manufacturers to ensure optimal dimensions whilst offering high stability. The company's patented AWL tool holder system can accommodate between two and eight tools, depending on the machine design, enabling a wide range of turning operations without human intervention. The AWL direct mount has an integrated coolant supply with two separate cooling channels supplying coolant to the cut point at high pressures of up to 150 bar. If tool changes are necessary, the AWL direct mount is supported by the AFC quick-change tooling system. Removing or fitting two-part tools requires only a few straightforward operations. Interchangeable tool holders can be fitted and removed swiftly, with only the front section needing detachment to attach the new insert. In view of the skilled labour shortage now and in the future, tool manufacturers need to rethink their approach. ARNO Werkzeuge, whose products are easy to use, adjust, change and handle, exemplifies achieving this transformation.
In an industry where precision and timely delivery are paramount, Guhring UK stands out as a manufacturing powerhouse. The company's Birmingham facility exemplifies a vertically integrated approach to cutting tool production that sets new standards for service, quality, and responsiveness in the precision cutting tool sector. “We're very proud of the facility,” explains Chris Bush, National Sales Manager of Guhring UK. “We've got Guhring-made machines to make our Guhring tools – this ensures quality, consistency and complete process control.” This single-site integration encompasses the entire manufacturing ecosystem, from raw materials to finished products. This stretches from production to coatings and regrinding services. The Birmingham facility houses not only standard manufacturing operations but also specialised tool production and coating capabilities that significantly extend tool life. “We've got our own grinding machines. We've got our own coating facility,” Chris elaborates. “So once the customer has used our tools, they can come back here for regrinding. They're ground on the same machines that they're originally made on, coated with the same coating that they started with.” The facility's vertical integration model provides substantial benefits to customers throughout the product lifecycle. “You get the same performance from a regrind as you do from a new tool,” Chris notes, highlighting a key differentiator in Guhring's service proposition. When asked whether this comprehensive approach is standard in the industry, Chris is clear about their position: “We're unique in that. The size of the factory and the fact that we have everything you need, all in one place.” Unmatched Inventory and Rapid Availability Perhaps most impressive is Guhring UK's commitment to product availability. “We hold so much stock here, we have £5m worth of stock on the shelf,” Chris points out. “I do think it's essential that we keep all this stock here within the UK,” Chris emphasises. “We have 45,000 standard line items, and we've just released a new catalogue, another big book, bringing everything together in one book. We have extensive rows of stock readily available for next-day delivery or same-day collection.” This inventory strategy is specifically designed to address the unpredictable nature of manufacturing operations. “People can't plan for mishaps and breakages,” explains Chris. “That's why we maintain a broad and readily available stock range. If someone needs something urgently, we can guarantee next-day delivery or even same-day collection.” This responsiveness is especially valuable in production environments where downtime incurs significant costs. By maintaining such a comprehensive local inventory, Guhring effectively serves as a strategic partner in its customers' operational continuity. Engineering Expertise in the Field Supporting this impressive manufacturing and inventory capability is Guhring UK's dedicated field engineering team. “Within the UK, we've got just under 100 people working for Guhring UK,” Chris shares. “Of those, 22 are field engineers operating across the entire UK and Ireland.” These engineers act as technical consultants, delivering expert support directly at customer sites. “This allows them to visit customers and engineering firms, where they optimise cutting data, reduce cycle times, and ensure the right tools are selected for the right applications,” Chris explains. “Ultimately, their role is to help make our customers more efficient and more profitable.” Coating Technology as Differentiator A standout aspect of Guhring's technical capability is its in-house coating department. “It's all about time,” Chris emphasises. “That's why we offer 10 different coatings here, and it's all application-specific. So, depending on the application, we'll have the right coating that goes on the tool for that process.” These specialised coatings provide significant performance enhancements: “With the coating, we can offer four times the tool life, from a bright tool to a coated one. And it's all under one roof.” By keeping coating operations in-house instead of outsourcing to third-party providers, Guhring ensures complete quality control throughout the manufacturing process. This integration also significantly reduces lead times, as tools do not have to leave the facility for coating. Agility in a Changing Market The manufacturing landscape continually evolves with new materials, tighter tolerances, and increasing production demands. When asked how Guhring addresses these changing market requirements, Chris points to the company's technical foundation: “Thanks to the facility we have and the expertise within our team, we're equipped to handle any demand that comes our way.” This confidence stems from Guhring's comprehensive approach that Chris succinctly summarises: “From the standards to the specials to the regrinds. Any application that comes our way, we've got the technology to handle it.” Industry Engagement Guhring UK maintains an open-door policy for customers interested in experiencing their operations firsthand. “We have an open door policy, so any customers who want to come along and see it firsthand are more than welcome,” Chris invites. This transparency reflects the company's confidence in its operations and its willingness to demonstrate manufacturing capabilities directly to interested parties. It also underscores Guhring's collaborative approach to customer relationships, viewing technical partnerships as essential to mutual success. In an era where global supply chains often separate manufacturing from end-users by thousands of miles and weeks of lead time, Guhring UK's Birmingham facility provides a compelling alternative. By combining extensive inventory, comprehensive manufacturing capabilities, specialised coating technology, and field engineering expertise in one location, the company offers a level of responsiveness and technical support that sets it apart. For manufacturing operations across the UK and Ireland, this vertically integrated approach results in reduced downtime, optimised productivity, and a tooling partner with the technical ability to meet virtually any cutting tool requirement.
The future of manufacturing is increasingly digital, collaborative, and intelligent. This was the clear message at Hexagon's recent ‘The Future of Shop Floor' event, held in partnership with Mills CNC at their Technology Campus. The event demonstrated how artificial intelligence, cloud-based platforms, and data-driven insights transform traditional manufacturing operations, resulting in measurable improvements in productivity and profitability. Opening the event by introducing Nexus, the company's cloud-based platform designed to tackle the collaboration crisis in manufacturing, Jason Walker, Hexagon's VP of General Manufacturing, stated: “An independent Forrester report we commissioned, surveyed around 500 manufacturers from small, medium, and large-sized organisations worldwide and 97% across all those different kinds of organisations, agreed that collaboration is the key challenge that manufacturers face.” Nexus addresses this challenge through comprehensive connectivity. “Nexus is fundamentally about connectivity. It's about joining all these different tools together within a specific function, across different functions, departments, sites, and organisations,” Walker explained. “Nexus connects to third-party tools as well, even if they are competitors of Hexagon, it builds workflows to encourage collaboration between engineers.” The platform's design philosophy emphasises integration rather than disruption. “Nexus is designed to meet you where you are. If you've got a process, a tool, or a particular place where you store your data today, Nexus won't disrupt any of that. Just join the dots to encourage and enable collaborations,” Walker emphasised. The Pro Plan Revolution Stephen Graham, Executive Vice President and General Manager for Nexus at Hexagon, revealed Pro Plan AI's impressive performance metrics during its pilot phase. For readers unfamiliar with Hexagon's Pro Plan AI suite, see the January 2025 issue of MTD magazine. “We've got ten customers engaged in a formal piloting programme at the moment, and the feedback has been stunning,” Graham announced. “Even at this early Beta Test stage, we can demonstrate something like a 70 to 75% improvement in productivity. A task that may have taken a couple of days could take just a few minutes using this powerful tool.” Pro Plan AI's approach differs fundamentally from that of existing automation tools. “There are tools out there attempting to automate CAM programming, but they're either trying to identify features in a CAD model using a rules-based system, or we've seen people trying to use generative AI,” Graham explained. “Our machine learning approach is looking through the history of programs, figuring out how you program, and replicating that based on the new geometry.” The tool's knowledge capture capabilities will address critical workforce challenges. “Pro Plan AI captures tribal knowledge. When it's first installed, it learns how users program CNC machines. It will program in the style of what it sees in the organisation's history,” Graham noted. Discussing one of the early test customers, Graham adds: “This feature proved particularly valuable in a North American pilot. The company has a relatively new programmer in his early 20s who joined the company two or three months ago. Once he started working with Pro Plan AI, he suddenly contributed programmes directly to the shop floor that were on par with anything from any of the guys who have been there programming for 20 or 30 years. This not only speeds up programming times, but also demonstrates how it is closing the ‘skills gap'.” Pro Plan AI also enables new business capabilities. “You can programme a machine in a few seconds, then for a given part, you can programme every single machine on the shop floor. You can program every machine on the shop floor for every combination of tools; you can then use that to interact with your production planning systems. You can also use it to create much more accurate quotations before starting a job in the first place,” Graham explained. The improvement in quoting accuracy addresses a fundamental business challenge. “One of the big ones we heard from customers is regarding quoting. Quite a lot of guesswork goes into quoting, because nobody's got the time to do the proper engineering work to find out how long it takes. With Pro Plan AI, even if it's not 100% accurate, you get a pretty good idea of how long it will be on a particular machine,” Graham revealed. Transforming Quote-to-Cash Processes Hexagon recognises that efficient and accurate quoting is essential for business success—and this is one reason why ‘Paperless Parts' has been added to the portfolio. A strategic partnership that delivers measurable business transformation for manufacturers, Jason Walker provided an extensive analysis: “Paperless Parts is Boston-based, and they are primarily in the US for now, although we are just in the process of helping them expand internationally.” The platform addresses critical inefficiencies in manufacturing's front-end processes through comprehensive automation of the quoting workflow. The quoting challenge directly impacts manufacturers' competitiveness. “I have asked a couple of customers exactly how long it took to get a quote out of the door before you implemented Paperless Parts. And on average, they would say about a week. So, you get an RFQ on Monday, you might only get to it by the end of the week,” Walker detailed. “The problem is that another manufacturer is getting their quote back quicker. They're probably going to win the work, because most of the OEMs just want to fulfil their order.” Paperless Parts delivers dramatic improvements in turnaround times that directly impact business outcomes. “With Paperless Parts, most manufacturers are doing turnaround within 24, sometimes 48 hours. So that's the difference,” Walker noted. The business impact extends far beyond speed enhancements: “One customer that is already reducing quote time from a week to 24 hours claims to be already winning 25% more work.” The platform's functionality includes comprehensive quote management capabilities that eliminate traditional bottlenecks. “It's an interesting space because it focuses solely on quoting, but the platform also allows for internal collaboration at a large company, which you might need when compiling a quote. You might need the engineer's input on ‘Can we manufacture this?' So the platform itself enables that real-time collaboration,” Walker explained. This collaborative approach ensures that technical feasibility is assessed during the quoting process rather than after the work is won. Automation features remove the burdens of manual data entry that have traditionally hindered quote generation. “It configures everything for you and automates the quoting setup process; it syncs back with your ERP system. Many customers will be using Excel spreadsheets or their ERP, but mostly the ERP's quoting functionality is like an Excel spreadsheet. You still have to put everything in manually. So that's where Paperless Parts is automating much of that,” Walker detailed. The integration capabilities extend throughout the manufacturing workflow. “Engineers have all that information, from the design to the integrations with our CAM software and then into Paperless Parts,” Walker explained. This smooth data flow eliminates multiple manual handoffs that traditionally delay quote generation and introduce errors. “Not only is it allowing businesses to get quotes out quicker, but it's reducing the burden. A lot of the time, it's the owner or the manager who's doing the quotes, because it's such a crucial process. You don't want to be under-quoting. This is buying them their time back,” Walker observed. This liberation of time enables leadership to focus on strategic business development rather than administrative tasks. The European expansion is proceeding with pilot customers demonstrating similar transformative results. “We've been in partnership since the beginning of last year, but we focused primarily on the US last year. There will be a European launch later in the year. At the moment, we're finding a few pilot customers,” Walker confirmed. “Early European feedback mirrors US success, it's completely transformative to the way that they were doing things before.” Innovation and Strategic Partnership Tony Dale, CEO of Mills CNC, offered insights into the strategic partnership with Hexagon as well as the company's forthcoming product innovations. Tony Dale says: “Our strengths are that we are an independently owned business, which makes us agile and allows us to respond to customers' requests.” The company's inventory management reflects its customer-focused approach. “We've got about 80 machines here now, but we've normally got around 200 machines in stock. So, the availability of machines is key for customers these days; nobody wants to wait. So that agility and stock holding enables us to support customers when they need that technology for that new contract,” Dale explained. “The relationship with Hexagon is effective. It enables us to provide a solution to the end user, not only supplying the machine tool but also programming it, reverse engineering it, and inspecting components, all of which contribute to our automation for end-to-end production,” Dale explained. Looking ahead, Mills has significant product launches planned. “Key focuses for us this year are launching two brand new models. We'll be holding an event later in October. We've got the DNX 2100 entry-level multi-tasking machine, and it's quite a big launch for us because we're seeing how customers want to leave tools set up on the machines to reduce setup and changeover times,” Dale announced. The DNX 2100 addresses specific market evolution. “If you can quickly change your jaws and programme, with your tools already set up in that carousel, this is faster than traditional block tools on a turret. We already do 5-axis mill/turn machines, but this is more entry level for customers upgrading from a traditional turret lathe to get into the realms of multitasking,” Dale explained. Dale linked the new machine to broader industry trends that Hexagon is also tackling: “With the skill shortages of engineers these days, we're finding that this is a growing part of our business offering.” The second major launch involves an evolution of existing technology. “We also have the second generation of the DVF 5000, which will launch simultaneously. It is a high-speed, high-accuracy 5-axis machine,” Dale noted. We will publish the second instalment of this event in the September issue of MTD Magazine. It will highlight the new Datanomics production monitoring suite and provide an update on the success of Hexagon's Benchmarking tool, a year after we first discussed the tool at MACH 2024.
Reitz Natursteintechnik KG plans, designs and manufactures highly precise machine components from granite. To ensure efficient processing, Vericut is employed, offering the advantages of reliable production and a reduced workload. The origins of Reitz date back to 1946, when Herrmann Reitz began extracting raw stone from his own quarry in Asslar. With the arrival of his son Friedel, gravestones were produced from 1958 until the introduction of the first granite surface plates that changed the business model, leading to the establishment of E. Reitz Natursteintechnik e.K. in 1986. Today, Christopher Reitz, the fourth generation and current Managing Director says: “Today's machine components combine the million-year-old material stone with cutting-edge technology. For 35 years, we've been manufacturing components from granite and offering system assembly and custom solutions and complete systems.” The company currently employs approximately 140 people with clients in the semiconductor, optics, general mechanical engineering, metrology, printing, and medical sectors. Competitive Edge with Granite “We've been experts in processing natural hard stone for over 60 years—a tradition we're proud of,” says Reitz. In mechanical engineering, particularly in machine tool construction, achieving optimum precision and performance is crucial. The machine bed is pivotal. “Due to its properties, granite offers clear advantages that neither steel nor mineral casting can match: stability, temperature resistance, vibration damping, and accuracy make granite the ideal material for machines,” explains Reitz. It's no surprise, therefore, that granite is commonly utilised in measuring and test stands, as well as coordinate measuring machines, for components such as surface plates, tables, and machine frames. In-House Built Gantry Milling Machines “Our granite comes mostly from South Africa, Spain, France, and Austria. It's either delivered in pre-cut slabs or as raw blocks we cut in-house. The workpieces vary in size, from 250 by 250mm up to 13m. The largest we ever made was 13 by 1.5 by 1m and weighed about 65 tons,” adds Reitz. To accurately process such blocks, Reitz relies predominantly on machines developed and constructed in-house: four gantry-type milling machines and two 5-axis gantry machines, all controlled by Siemens 840D. To ensure safe, fast, and precise granite machining, the company uses Vericut simulation software. “Granite is a natural product, so the surface is never flat. To prevent tool collisions during processing, we developed a process with Vericut that virtually eliminates this risk,” explains Reitz. Stephan Meurisse, Marketing Manager at Vericut, Deutschland, adds: “Downtime, damaged tools, costly collisions, unusable parts, long setup times, wasted materials—all of that costs time and money. Vericut helps our customers avoid these time and cost traps.” “Vericut eliminates the need for manual setup, saves valuable operator time, and protects our machines,” says René Maschlanka, responsible for sales and project management at Reitz. Intelligent Process Flow Granite blocks up to 13m long are typically delivered with +3 to 5mm oversize. They are then machined to a flatness of 20 to 5µm. Since granite is very hard (Mohs hardness 6–8), only 0.1mm of material can be removed per cut. After a visual inspection, the operator selects a measurement point pattern, generating two automatic measurement programmes in the CAM system. The first determines the block's position, and the second maps its surface—both via probing cycles,” says Maschlanka. Each probing cycle uses valuable machine time, so it is performed as infrequently as possible, yet as frequently as necessary. The resulting programs are converted into NC code and simulated in Vericut. Once verified, the programs are run on the machine. “The returned measurement points describe the actual surface condition, and from that data, a machining programme for a precise cuboid is automatically derived, then simulated in Vericut before execution,” explains Meurisse. The completed cuboid is then drilled for guide rails, drives, spindles, sensors, and attachments. Once the stainless steel thread inserts are glued in, the component is sent to the climate-controlled precision lab for final machining. “Naturally, these final programs are also validated with Vericut,” Maschlanka emphasises. “We use a special CAM system for granite processing. We built the interface to Vericut ourselves. It lets us precisely capture the position and shape of the workpiece and simulate automated steps without manual setup,” says Maschlanka. The simulation assists in detecting unnecessary movements, clamping errors, and incorrect tool usage before they occur. Some machining processes at Reitz can take over 40 hours. Previously, the operator had to stand by the entire time. Now, they simulate on a PC, press start, and only check in occasionally. “Now our programmers and operators are far more relaxed—they know their programs will run safely, with no crashes. The integrated Vericut Reviewer shows us when that approach makes sense,” says Reitz. Vericut Reviewer allows users to interact with the simulation file on any Windows PC or tablet. It helps build trust in new processes. “Operators, shop floor staff, or engineers can review simulations and confirm the project is correct before running it on the machine. Our staff love the Reviewer. It shows the full machining sequence, highlights critical steps, and helps with prep, like planning supports, tools, and clamping,” says Meurisse. Thanks to Vericut, tool breakage and collisions due to programming errors are a thing of the past at Reitz Natursteintechnik KG. “Vericut is a huge help and a great tool. It's easy to use, gives programmers confidence, avoids costly collisions, and keeps our operators at ease,” summarises Christopher Reitz.
Starrag provides a full range of manufacturing solutions, utilising its own in-house components as well as specialised tools. The high-quality Starrag machines developed and manufactured in Rorschacherberg, Switzerland, are impressive. However, the machines represent just one facet of a diverse portfolio that encompasses technology, software, clamping concepts, and carbide tools, which are also manufactured in-house and are often vital to success. Starrag's headquarters in Rorschacherberg specialises in creating high-performance machining centres for aircraft and turbine manufacturing. Nonetheless, the company offers a broader range of solutions. Years of accumulated expertise from various projects is evident in the numerous components developed internally: from carbide tools and RCS CAM software for blades to clamping technology, fixture construction, automation solutions, and host computer technologies. “This ‘full package' sets us apart from other suppliers,” says Sofian Regaz, Starrag Sales Manager for Aerospace & Turbine Technology. “We don't see ourselves purely as a machine manufacturer, but as a solution provider for production processes in the aerospace and turbine sector. This ranges from standalone machines to flexible manufacturing systems, which customers can obtain from us as a one-stop shop.” Gaining a competitive edge from tools tailored to the process Sofian Regaz is primarily responsible for product management and sales of Starrag tools. “Here in Rorschacherberg, we have spent many years developing and grinding carbide milling cutters for aircraft and turbine components made from difficult-to-machine materials such as titanium, Inconel or high-alloy steels.” Though Starrag offers a small range of standard tools, over 90% of the company's tools are custom-made products. These tools are tailored to specific machining processes that fully embrace the component, the machine, the material, and other considerations. “It makes a huge difference whether I adapt my NC program to a catalogue milling cutter or design the tool in terms of the cutting edge length, corner radius, flank angle and coating. This enables us to deliver the optimum machining process. Our customers enjoy great success with this,” says Sofian Regaz. Always available to serve customer needs Starrag sells most of its machines as part of a manufacturing solution for a specific component or component family, so the corresponding specialist tools are usually supplied with them. This incorporates an explanation of why the tools are designed in a particular way and the expertise on which they are based. The Product Manager adds: “The customer needs to know how their tools differ from catalogue tools and the impact these differences have. They also need to understand that the advantages of our tools cannot be found with other suppliers.” This expertise is no coincidence. Starrag maintains a very close, partnership-based relationship with its customers and supports them throughout the production process and beyond the warranty period. “This means that if, for example, a component is due to be changed and the machine needs to be set up for a new process, we are still by our customer's side to offer new customised tools as necessary,” assures Regaz. Starrag has a distinct advantage over traditional tool manufacturers. Tools are both developed and ground at the Rorschacherberg plant, which also houses the Aerospace and Turbine Competence Centre (ATCC). The 2,000m2 centre is equipped with all the latest 5-axis machining centres from the Starrag NB, LX, and STC series. Sofian Regaz explains: “We use these machines for a wide range of our own trials and trials for our customers, as well as for developing and optimising processes and, of course, for our analyses and tool tests. We even take on small series production on behalf of customers.” For the tool team, this means they can reproduce the customer's processes 1:1 on original machines and optimise the tools before delivery. Time and again, customers confirm that this saves numerous transport routes and, in turn, a significant amount of time and money. “If corrections to the tool are still necessary, we can react and adopt changes very quickly because we have our own grinding shop,” says Sofian Regaz. “We achieve incredibly quick response times, sometimes just in half a day.” Tool expertise for better machining results The ATCC is an important meeting place where Starrag technologists, machine operators, automation specialists, tool specialists, and customers come together. Starrag offers comprehensive support in programming the machines, managing processes, and optimising subsequent processes. For the tool team, this is a valuable source of expertise. “This is where we find out how the market is evolving, how materials are changing, what the blanks of the future will look like and what requirements components will have to meet. This allows us to get ahead of the game with our tool developments and offer our customers solutions early on.” Starrag is also well-positioned worldwide in tool servicing. Starrag has partnered with Oerlikon Balzers to save customers time and money by providing on-site regrinding and recoating services for Starrag in America and Asia. This is an important factor for Sofian Regaz: “We offer a similar service in-house as well, but customers can save themselves the long journeys from overseas by using our partner offer.” “Customer feedback on our tools is consistently positive,” mentions Sofian Regaz. He received a special confirmation of success from Honeywell Aerospace Ireland, where Starrag had the chance to work as a tool problem solver. The starting basis was that tool wear was very high when machining a titanium turbine blade. No more than ten components could be machined with the existing milling cutter. That's when the engine manufacturer invited important tool manufacturers to get a handle on the problem. The best supplier managed to increase the service life to 20 components. And Starrag? “Our special tools produce 40 components,” reports Sofian Regaz. “Honeywell considered this worthy of not only a contract, but also an award. In June 2024, we were awarded the ‘Kaizen of the Month' prize.” Success leads to growth The tool business has experienced tremendous growth in recent years. This success is not solely due to stories like the Honeywell contract. The expanded product range has also played a significant role in this. While Starrag used to produce only end mills, torus mills, and conical ball nose mills, today the company also grinds cylindrical and barrel ball nose mills, lollipop mills, barrel cutters, and chamfer milling cutters. Additionally, there is a range of high-feed, plunge, and various form milling cutters that can be applied to turbine blade roots. To generate further growth, Starrag will offer special tools for machining aluminium alongside tools for more challenging materials. Sofian Regaz's team is also strengthening its business development: “Our process expertise in aircraft and turbine construction is so extensive that we can also enjoy great success with our tools on third-party machines. And we are already in talks with other Starrag sites. In the future, we want to utilise their machining centres and their expertise to produce special tools for other industries.”
The grinding specialist Kellenberger, part of the Hardinge Group, has developed a groundbreaking innovation to simplify the automation of grinding workpieces of varying lengths for a tool manufacturer. For a considerable time, users have been interested not only in machines but also in machining solutions. Regarding these solutions, the machine manufacturer is responsible for the entire process, covering all upstream and downstream operations. The continual advancement of automation in production processes also presents challenges to the flexibility of machine tools. This innovation can be explored through UK specialists DF Precision Machinery. At the Kellenberger base in Goldach, Switzerland, the emphasis is on customer-specific system solutions. There, highly integrated cylindrical grinding systems for large-scale production are fitted with automatic loading, measuring devices, and other supplementary operations as required. Each year, a diverse range of turnkey solutions are delivered to customers, including automotive manufacturers and various suppliers. At the Kellenberger production site in Goldach, the ‘Customer-Specific Special Construction' department develops solutions that are especially challenging and not yet available on the market. A well-known tool manufacturer was seeking a solution for the automated grinding of workpieces such as drills and tool holders. The challenge in machining lies in the fact that the parts have varying lengths. This necessitates that the clamping force be adjusted manually for the required length compensation during grinding. Automated machining is therefore not feasible in this context. The designers in Goldach met the challenge and rose above the competition. They developed a positioning axis (Z2 axis) that ensures automatic length compensation by a robot or gantry loader during the fully automatic loading. The Z2-axis is mounted on the Z-axis and moves accordingly. The automatic zero-point shift is implemented using a longitudinal pushbutton (KEL-Pos). Dressing is not permitted on the Z2-axis. The grinding dressers are mounted on the Z-axis. Workpieces with up to 250mm diameters and length compensation ranging from 50 to 300mm can be machined. Non-circular parts can also be ground and can be centred fully automatically. In summary, the machine features a 250mm hub with a minimum centre height of 250mm and an axial force ranging from 50 to 1200n. The load capacity for live spindle grinding is 200Nm for a maximum load of up to 150kg. When using a synchronous tailstock (available as an optional feature), no chuck is needed due to the friction drive. An in-process measuring control covers a diameter range of 25mm. Manual retooling is no longer required. The Z2 axis was developed for the universal internal and external cylindrical grinding machines of the K100 and K1000 series with Fanuc control. The obvious question is: can the Z2 axis be retrofitted onto such machines? Patrick Gähler, Design Engineer at Kellenberger, answered: “Retrofitting is impossible because the function of the Z2 axis must be incorporated in the design of the machine beforehand.” In the showroom at Kellenberger in St. Gallen, interested customers will have the opportunity to see a KELLENBERGER K100 with Z2 axis, on which tests can also be carried out.
Nuneaton-based Birds Precision Engineering has recently invested in a Sodick AG 600L wire erosion machine from Sodi-Tech UK, marking a significant advance in the company's capabilities and service offerings. This strategic investment represents the latest chapter in the evolution of a business that has been growing steadily since its inception over three decades ago. The story of subcontract CNC machine shop Birds Precision Engineering began in 1991 when Chris Bird established B&C Engineering in Nuneaton. What started as a sole trader operation quickly expanded, necessitating a move to larger premises. As demand grew, the business relocated and transformed into the name Birds Precision Engineering Ltd. Chris's son, Tom Bird, joined the company and immersed himself in all aspects of the operation, eventually becoming the Managing Director in 2023. Bringing Wire EDM In-House The latest advancement came earlier this year with the acquisition of a Sodick AG 600L wire erosion machine from Warwick-based Sodi-Tech. This investment was driven by practical business considerations, as Tom Bird explains: “We are predominantly a subcontract CNC machine shop, and we focus mainly on the special-purpose machine tool industry. We invested in the wire eroder because, in the tooling industry, there are a lot of complex components with tight tolerances.” Before this investment, Birds Precision had outsourced wire EDM work to local companies, which created bottlenecks in their production schedules. “We were subbing a lot of the work out to a couple of companies in the local area, but it created bottlenecks with our schedules, so we decided to bring it in-house to control it a little bit better,” Tom explains. This decision to bring wire EDM capabilities in-house has proven to be transformative, enabling the company to have complete control over its production process, from start to finish, whilst eradicating subcontract EDM costs. The Sodick Advantage The Sodick AG 600L is a high-precision, linear motor-driven die-sink EDM machine renowned for its accuracy, speed, and superior finishing capabilities. For Birds Precision, this machine has been a game changer, offering several key benefits. The AG 600L utilises advanced linear motor technology to achieve remarkable precision, with accuracy on all axes (X, Y, Z, U, W) of +/-0.001mm. This level of precision is crucial for Birds Precision, as Tom notes: “Customers are always after accuracy. The components that we're machining are getting tighter and tighter on tolerances every time we see the drawings. It's a major factor, and this machine helps to set us apart as we always guarantee to hit those tolerances for our customers.” Enhanced Production Efficiency The Sodick AG 600L machine features a linear drive system that ensures swift axis movement and immediate response, optimising spark gaps and enhancing cutting performance. The AG 600L can produce fine finishes, including satin and mirror finishes, thereby expanding Birds Precision's service offerings. “It's a great machine, and it's one that, once it's set up and running, you can just leave to run. You can go and carry on with the other jobs that need doing,” Tom explains. “So for me, being in and out of the office, I can set it up and then go and do my office work.” Tom's enthusiasm for the machine's capabilities is evident: “When you see the precision this machine delivers consistently, it's a game-changer. What used to be our most challenging work is now just another day. That's the difference quality equipment makes.” This efficiency has helped Birds Precision meet delivery dates more consistently and has opened up possibilities for expanding into new sectors within the industry. The new EDM technology enables Birds Precision to achieve extremely tight tolerances across a wide range of materials, including hardened tool steels. “For us, our tolerance demands from customers are probably in the 15 to 20 micron realm, and this machine doesn't even think about it; it hits tolerance every time. We've not had a part come off that hasn't been right yet,” Tom states proudly. This capability allows Birds Precision to produce complex components for various industries, including aerospace, medical, special-purpose machine tools, and nuclear sectors. What makes this investment particularly noteworthy is that Birds Precision opted for a refurbished Sodick machine instead of a new one. This decision was driven by practical considerations, as Tom explains: “For us, not being as big as some of the other companies out there, we don't have as big a budget. This machine has opened the door to us having access to an in-house wire eroder because it's refurbished. It was significantly cheaper than a brand new one, yet for the accuracy and what we're after, it's brilliant.” Contrary to what some might assume, the refurbished machine from Sodi-Tech is far from merely a cosmetically refreshed unit. Sodi-Tech restores each refurbished machine to factory standards through a meticulous full specification check. “All the parts of the refurb are genuine Sodi-Tech parts, and they were all kept at a facility in Warwick, so it was a quick turnaround on the refurb,” Tom notes. The quality of the refurbishment was so high that Tom admits, “I haven't told any of my customers that it's a refurb. I've told them all that it's brand new, because it looks brand new.” Superior Service and Support Beyond the machine, Birds Precision has been impressed with the service provided by Sodi-Tech. Their reputation influenced the decision to choose Sodi-Tech, as Tom states: “The reason we chose Sodi-Tech was their brand, their reputation in the industry for EDM machining and customer service, which I can't fault. It's been brilliant.” The training was particularly valuable, featuring trainers who ‘knew exactly what they were doing' and understood Birds Precision's need to get the machine operational quickly. “They trained us on the parts that we were cutting. So, the afternoon they left, we were already cutting parts that needed to go out in the next couple of days,” Tom recalls. This practical approach to training, combined with the 12-month warranty on the refurbished machine, has given Birds Precision complete confidence in their investment. Looking Toward the Future For Birds Precision Engineering, the investment in the Sodick AG 600L wire erosion machine represents more than just an addition to their plant list. It's a strategic enhancement of their capabilities that positions them for future growth. “Right now, it's made sure that we can keep hitting times and delivery dates, but going forward, it will open up more doors for us into different sectors within the industry,” Tom says. When asked about the impact on his business, Tom doesn't hesitate: “This machine doesn't just cut metal—it cuts through barriers. We're now competing for work we couldn't even quote on before. In this industry, you're only as good as your tools, and with this Sodick machine, we're better than we've ever been.” As Birds Precision continues to build on its three-decade legacy of growth and precision engineering, this latest investment reinforces the company's commitment to delivering high-quality, precise components to its customers, maintaining the reputation for excellence that has defined the business since Chris Bird first opened the doors in 1991.
Founded in 1998 as a spin-off from the prestigious gunmaker Westley Richards, Westley Engineering has evolved significantly beyond its origins. While only 5% of its output now relates to gun components, the company has established itself as a trusted supplier of machined components and assemblies to various sectors, including aerospace, automotive, rail, white goods, and renewable energy. Aerospace is its largest market, representing 45% of total production by value. A notable aerospace contract involves manufacturing rotor clips used in aircraft disc brakes. Crafted from aerospace-grade steel and Inconel, these components are utilised in both civil and military aerospace programmes. Demand for these clips has significantly increased in recent years. Three years ago, Westley Engineering enhanced the accuracy of the manufacturing process by transitioning from piercing holes in the clip on press tools to drilling them on a 40-taper VMC. While this change improved precision, it also significantly increased cycle times and rendered the process more labour-intensive. So in late 2023, the company installed a Brother Speedio S700Xd1 4-axis, 30-taper machining centre, followed by a second in April 2025. Supplied by Whitehouse Machine Tools, the exclusive UK and Ireland distributor for the Japanese manufacturer, these high-speed machines have now replaced the VMC for production of the clips. John Harland, Managing Director of Westley Engineering, said: “The arrival of the first Brother machine was a game-changer. Its exceptional speed, especially the 0.7-second tool changes, means each Speedio can machine clips 35 to 40% faster than with our previous setup.” “The former VMC ran around the clock on weekdays and through the weekend. The new Speedios not only handle the entire production volume more efficiently, but also offer extra capacity for future growth.” In partnership with Whitehouse Machine Tools, Westley Engineering implemented an automated, single-operation process on each Speedio. The new production route features custom-built fixtures with nine inclined bars, each capable of holding about 36 clips. This high-density arrangement enables over 300 parts to be machined per cycle, significantly more than the flat fixtures used previously. Cycle times have been reduced to between two and three minutes per clip, depending on the variant. For example, the Inconel version requires additional milling on the outer arms, whereas the steel variants do not. Typical batch size ranges from 5,000 to 10,000 units. Before deployment, the process was validated at Whitehouse Machine Tools' Kenilworth technical centre. Its applications engineers wrote the machine programs, assisted with fixture setup and provided on-site training, all offered as part of the supplier's lifetime service and support. A coolant-actuated gripper, housed in one of the Speedio's 28 turret positions, picks up each clip from the inclined bars. After verifying the workpiece position using sensors, the gripper transfers the part to a Schunk hydraulic vice mounted on a rotary axis. The component is then machined – drilled, countersunk and in some cases milled – before being dropped into a container for post-processing. All clips undergo 100% inspection, including after heat treatment, followed by fettling as needed to correct any distortion. Mr Harland noted: “Scrap has dropped to under 1%, down from near 4% with the old process. And thanks to the energy efficiency of the Brother machines, we've cut power consumption by an estimated 60%.”
Blade Tooling, based in Pershore, has recently taken control of its wire-cutting EDM operations by investing in the Excetek V400G CNC wire EDM machine, supplied by Warwick Machine Tools. This decision was prompted by capacity shortfall that resulted in reliance on outsourcing for wire EDM services. Established over four decades ago, Blade Tooling began as a family-owned business specialising in lost wax pattern dies for the investment casting industry. After financial difficulties in 2011, it was acquired by Gardner Aerospace, supporting aerospace manufacturers including Rolls-Royce, Pratt & Whitney and Siemens. However, in 2017, Gardner Aerospace's acquisition by a Chinese company created challenges. Company Director Ian Cerrone explains: “Because of what we do to support cast turbine blade production, a lot of customers walked away. They did not want their intellectual property potentially shared with China. The perceived risk was there, and our order book suffered.” Sales dropped from £6m to £3m by 2022. Following negotiations, Blade Tooling became part of GIL Investments in March 2024. “Previous customers have come back and we have signed nine new NDAs in the last 12 months. We are now UK-owned, and former concerns have been removed,” says Cerrone. With new ownership came investment. “We were spending a lot on subcontract wire eroding. I said to the new owner, ‘For what we're spending, we could buy our own machine.' The answer was, ‘Well, why haven't you then?' It was quite refreshing,” Cerrone reflects. Blade Tooling relies heavily on CNC wire erosion for core tooling, essential for creating sacrificial ceramic cores that form intricate airflow paths within cast turbine blades. The hardened tools require wire erosion to create holes for pins, apertures, slots, and slides. “We had to send work to subcontract wirers because we didn't have capacity,” Cerrone recalls. After researching Excetek machines and noting positive reviews, he contacted nearby Warwick Machine Tools in Droitwich. A demonstration at their showroom proved the Excetek V400G was perfect for Blade Tooling's requirements. With 400 by 300mm travel and ability to accommodate workpieces up to 500kg, the machine offers versatility in a compact design. The standout feature is its auto wire feed. “All reviews stated the auto wire feed was unbelievable. The machine never stops, it just keeps feeding. Our other machine is forever stopping overnight,” says Cerrone. The new machine has given Blade Tooling control over production schedules. Previously, subcontracting left them reliant on others. “We've had jobs scrapped due to delays. If the promised delivery by Monday arrived Friday, those four lost days would have put us behind on tight lead times.” Now, with doubled capacity, they control their timeline. Looking ahead, the company is expanding from 35 to 45 staff and aiming to return to £6m turnover. Cerrone concludes: “What we make relies on high-end engineering. Every person here has pride in what they do, and everything is bespoke. Our people rely on the equipment we invest in, and we are very pleased to have installed the Excetek V400G.”
In the precision manufacturing industry, where tolerances are measured in microns and efficiency determines competitiveness, Factory 33 has established itself as a notable success story. Since its founding in 2016, this family-run engineering company has expanded from a modest 165sq/m facility with just two CNC machines to a sophisticated 500sq/m operation serving high-demand sectors including Formula 1, aerospace, medical, and nuclear industries. Central to this remarkable growth trajectory has been the strategic implementation of Hexagon's EdgeCAM CAD/CAM software, which has evolved alongside the company for over 18 years. When Factory 33 first acquired its initial Hurco machines, the need for a sophisticated CAM system became immediately apparent. “It was within the first week of operations that we realised we needed a CAM system,” recalls Marcin Krzywina, Director at Factory 33. His previous experience with EdgeCAM influenced this critical technology decision, but equally important was the software's modular architecture. “EdgeCAM is a modular package, allowing for incremental additions like 3 and 4-axis milling to full 5-axis simultaneous machining,” Marcin explains. This modularity proved ideal for a growing business, enabling Factory 33 to start with essential functionality and expand its software capabilities in parallel with its physical operations and machine inventory. The financial structure of the implementation also played a crucial role in Factory 33's early development. “As a startup, I appreciated the financial support from Hexagon, including a good price and the option to pay in instalments,” Marcin shares. “The early stages of the business were financially tight, but the support from Hexagon was a significant boost and a valuable partnership.” Driving Production Excellence EdgeCAM's technical sophistication has proven exceptionally well-suited to Factory 33's diverse machining needs. Zoltan Tomoga, a Hexagon Product Manager, highlights the software's advanced toolpath strategies as a particular strength: “We've invested in five extra strategies over the last few years, starting with 5X simultaneous deburring.” These specialised 5-axis strategies have continuously expanded, with Zoltan noting that: “Last year, we released two new 5-axis simultaneous cycles for roughing and finishing.” The ongoing development ensures Factory 33 remains at the cutting edge of machining technology, with upcoming releases focusing on ‘enhancing free access cycles' and introducing a new free access strategy called Race Line Finishing Cycle, designed specifically for cast and die ceiling faces to ensure the quickest and smoothest tool paths.” Automation: The Cornerstone of Operational Efficiency Perhaps the most significant impact on Factory 33's operations comes from EdgeCAM's comprehensive automation capabilities. “The way we've got it configured is that it's fully automated,” Marcin emphasises. This automation extends to multiple aspects of the manufacturing process. “The datums, even for our components, are generated automatically from the software, so we don't have to set anything. G10 takes care of rewriting G54 within the program. The beauty of a CAM system like EdgeCAM is that we can take any of our existing, already programmed parts, either a 3 or 5-axis part, we can literally swap the post, and off you go.” This level of automation significantly reduces programming and setup time, allowing skilled staff to focus on higher-value activities rather than routine tasks. It also enhances production flexibility, allowing Factory 33 to optimise resource allocation based on machine availability and capability. Advanced Manufacturing Workflows Factory 33 has implemented several sophisticated workflows that maximise EdgeCAM's potential. One such workflow involves tool management, with Hexagon's Zoltan describing: “The process involves downloading 3D models from tooling providers, inserting them into the tool store, and generating NC code for CNC machines.” For complex setups, including pallet loaders, Marcin believes that keeping the fixture manager up to date simplifies programming. The process involves selecting the tombstone and fixture, as well as running a full collision check and tool path trimming. The Tombstone Manager feature has proven particularly valuable as Factory 33's production complexity increased. “The Tombstone Manager in EdgeCAM enables running multiple parts on a single tombstone, enhancing versatility and efficiency,” Marcin notes. Zoltan adds that this feature allows users to ‘scale up from 3-axis machines to four or 5-axis machines.” Factory 33's proximity to Hexagon has fostered a uniquely collaborative relationship that benefits both organisations. “Marcin is located nearby and has been testing EdgeCAM features. He has been interested in advanced features like the Tombstone Manager and 5-axis programming,” Zoltan explains. This real-world testing environment allows Hexagon to refine EdgeCAM based on practical manufacturing challenges, giving Factory 33 early access to emerging capabilities. “The collaboration has allowed for continuous testing and improvement of EdgeCAM features,” Zoltan adds, highlighting how this relationship drives innovation in the software. Future Directions Despite Factory 33's sophisticated use of EdgeCAM, Zoltan suggests that some powerful features remain underutilised across the broader user base. “Customers should use the Waveform cycle more, especially with new chip thickness and material removal rate improvements,” he advises. Looking ahead, EdgeCAM continues to evolve with new releases approximately once per year, ensuring that Factory 33's investment in EdgeCAM delivers new capabilities and efficiencies. The technical capabilities of EdgeCAM translate directly into business advantages for Factory 33. “The ease of use in EdgeCAM contributes to efficient machine operation, allowing Factory 33 to offer competitive pricing and meet customer demands,” Marcin explains. The comprehensive collision detection capabilities minimise costly errors and machine downtime, protecting expensive equipment and tight production schedules. This versatility enhances production flexibility, allowing Factory 33 to optimise resource allocation. “The versatility of EdgeCAM allows for different tool paths, ensuring that Factory 33 can program parts in various ways,” Marcin adds. “The ease of finding the right toolbox within the software makes the programming process straightforward.” Factory 33's journey with Hexagon's EdgeCAM shows how the right CAD/CAM solution can become a cornerstone of manufacturing excellence. “Factory 33 has grown, and EdgeCAM has grown with them,” observes Zoltan, noting how Marcin has added modular packages to the system to expand their capabilities over time. EdgeCAM did not merely enable this evolution—it accelerated it. The software's scalable architecture allowed Factory 33 to grow its capabilities alongside its business, incorporating new modules and features as its manufacturing challenges became more complex. For manufacturers contemplating their own CAD/CAM strategy, Factory 33's experience provides valuable insights. Their success was attributed to their modular approach to software acquisition, focus on automation to minimise routine tasks, and collaborative relationship with the software provider. As Marcin concludes: “The ease of integration and automation within EdgeCAM contributes to efficient machine operation and quick part programming,” demonstrating that the right technical foundation can transform challenges into opportunities.
In the precision-driven world of non-destructive testing (NDT) manufacturing, selecting the right tooling and workholding solutions is crucial for ensuring product quality. NDT Equipment Ltd, a Northamptonshire specialist in manufacturing NDT calibration blocks and test pieces, has earned its reputation by delivering high-precision components with tolerances as tight as ±0.005mm. At the heart of their production capabilities is a strategic partnership with CERATIZIT, whose cutting-edge tooling solutions have been essential to NDT Equipment's manufacturing excellence. NDT Equipment Ltd specialises in producing ultrasonic calibration blocks and reference pieces that comply with international standards such as ISO 2400:2012, ISO:7963:2010, and ISO:16946:2017. These precision components are vital for non-destructive testing applications in various industries, including oil and gas, nuclear, aerospace, and automotive. Non-destructive testing is a critical quality control methodology used to evaluate material integrity without causing damage. From ensuring that bridge components withstand structural forces to verifying that aircraft parts meet stringent safety requirements, NDT techniques provide necessary validation that can prevent catastrophic failures. Even in the food industry, NDT methods help identify potential metallic or glass contaminants during processing. The calibration blocks manufactured by NDT Equipment Ltd serve as reference standards for NDT equipment, ensuring accurate and reliable testing results. These components boast precise dimensions, surface finishes, and material properties that must meet exacting specifications, making the manufacturing process particularly challenging. To address these challenges, NDT Equipment Ltd, based in Long Buckby, maintains a modern CNC machining facility equipped with 3 to 5-axis machining, CNC surface grinding, EDM machining, and CMM inspection with technology from brands like Doosan, XYZ, and a Matsuura MX-330 with a 10-pallet loading system. This advanced equipment enables the company to manage everything from prototypes to medium and large batch production across various materials, from standard mild steel to specialised alloys like Inconel. CERATIZIT Partnership: A Cornerstone of Quality A key factor in NDT Equipment's ability to uphold quality standards is its partnership with CERATIZIT for tooling and workholding solutions. The company relies heavily on CERATIZIT products throughout its manufacturing processes, and its production team has highlighted several specific benefits. NDT Equipment utilises CERATIZIT vices and workholding systems on their machining centres, significantly streamlining setup procedures. The company specifically alludes to the benefits of the zero-point clamping system with centralised plates, which allows for quick and precise attachment of vices without requiring constant datum setting or alignment. Director at NDT Equipment Ltd, Daniel Lenton, remarks: “We have a three-pot Centro system from CERATIZIT that makes it easy to attach vices without the need for constant datums, alignment, or setup. The system ensures the parts lock in place and align perfectly. This standardisation guarantees consistency across different machines and simplifies job transitions from one machine to another, reducing setup times and potential errors.” “The precision alignment capabilities of the CERATIZIT workholding solutions also support our collision checking requirements, ensuring that our CAM programming accurately reflects the physical setup on the machine. This minimises the risk of costly crashes and maintains consistency in our manufacturing processes.” Comprehensive Tooling Ecosystem In addition to benefiting from CERATIZIT's zero-point workholding technology, NDT Equipment has standardised nearly all of its cutting tools around CERATIZIT products. The extensive range of tooling solutions meets the diverse machining needs for the various materials and geometries involved in manufacturing NDT calibration blocks. Exceptional Supply Chain Support One of the most significant advantages of partnering with CERATIZIT is the robust supply chain support. NDT Equipment has implemented a CERATIZIT TOM vending machine system in its facility, allowing immediate access to commonly used tools. This just-in-time inventory system ensures that production is never interrupted due to tooling shortages. Referring to this, Daniel adds: “With CERATIZIT, the supply chain is so good that we have one of their vending machines on site. If we need a tool, we can access it right away. When it comes to exotic materials and we don't have the right tool in the vending machine, we know we can get it the very next day. CERATIZIT has even delivered from Sheffield on the same day for us. That's where you're only as good as your supply chain, and their supply chain is so reliable that we're never really without.” This reliability enables NDT Equipment to commit to demanding delivery schedules while maintaining its high-quality standards. “We use all the CERATIZIT turning inserts and holders; their EcoCut series is excellent. I love their EcoCut. You don't need to drill parts at all – you can send in an EcoCut multifunction turning and drilling tool and continue boring the hole out. All our tooling, except for one or two select items, is supplied by CERATIZIT - all of their tooling fits our needs.” NDT Equipment's commitment to quality is reinforced by its ISO 9001:2015 quality assurance system. Every product manufactured by the company is delivered with full traceability and certification documentation, providing customers with confidence in the conformity and performance of the NDT calibration blocks. The precision and consistency delivered by CERATIZIT tooling solutions are essential for enabling NDT Equipment to achieve the tight tolerances and surface finishes required for their products. The partnership between NDT Equipment Ltd and CERATIZIT exemplifies how advanced tooling solutions can empower precision manufacturers to deliver exceptional quality while maintaining operational efficiency. For NDT Equipment, CERATIZIT's comprehensive tooling ecosystem, superior workholding solutions, and responsive supply chain support have become integral to their manufacturing success.
In today's business environment, understanding and leveraging government loan schemes can be a game-changer for many firms. Recent data from Close Brothers Asset Finance's independent research sheds light on how businesses perceive and use these schemes, including the Recovery Loan Scheme (RLS) and the Growth Guarantee Scheme (GGS). l 53% of SMEs know how to use government loan programmes l 48% find the application process challenging l 1 in 3 businesses would use these loans to purchase assets or improve cash Awareness and understanding A significant portion of businesses are aware of these government loan programs. According to the data, 58% of respondents have heard about the RLS and GGS. However, understanding how these schemes can be applied to their businesses is slightly lower, with 53% indicating they know how to use them. Application process When it comes to the application process, 58% of businesses understand how to apply for these loans, but despite this, nearly half of the respondents (48%) find the application process challenging. Utilisation of loans Businesses have diverse plans for utilising government-backed loans. The most common uses include purchasing assets (17%), improving cash flow (16%), and investing in sustainable initiatives such as solar panels and wind power (13%). Other notable uses include training existing staff (12%) and hiring more staff (11%). British Business Bank loan schemes Growth Guarantee Scheme (GGS): Supports UK smaller businesses with loans up to £2 million. It offers term loans, overdrafts, asset finance, invoice finance, and asset-based lending and it provides a 70% government-backed guarantee. Recovery Loan Scheme (RLS): Provided loans up to £2 million for UK businesses to support investment and growth. This included term loans, overdrafts, asset finance, and invoice finance. Coronavirus Business Interruption Loan Scheme (CBILS): Provided up to £5 million in financial support to UK businesses affected by COVID-19. It included term loans, overdrafts, invoice finance, and asset finance. The CBILS offered a government-backed guarantee to lenders, encouraging more lending. Bounce Back Loan Scheme (BBLS): Provided loans between £2,000 and £50,000 to UK small and medium-sized businesses affected by COVID-19. BBLS offered a 100% government guarantee, a fixed 2.5% interest rate, and no repayments for the first year. For more information please visit:
Lifestyle-related illnesses, an ageing population and personalised health are some of the medical industry's growth drivers. Manufacturers are using digital technology, from digital dental labs to polymorphic moulds, to win orders and battle tough trading conditions. Will Stirling reports. Over 5.8 million people in the UK are living with diabetes, the highest number on record. The prevalence of type 2 diabetes has nearly doubled in the last 15 years, linked to lifestyle factors such as obesity and high-sugar diets. People are living longer and require mobility and care technology for extended periods. This exemplifies a growing and concerning burden on the NHS, while also presenting a significant business opportunity. The manufacture of hard medical products – surgical instruments, tooling, prosthetics, orthotics, and devices like wheelchairs and beds – encompasses a broad range, particularly when including consumable devices such as single-use plastics. ‘MedTech' typically refers to medical products with embedded digital technology, which includes diagnostic and monitoring devices. However, as more smart medical technology is developed, the division between machined or moulded parts and ‘digital tech' is becoming increasingly blurred. The UK MedTech industry has an annual turnover of £27.6 billion, placing it just behind the aerospace sector (about £30bn). The UK exports £10.1 billion worth of MedTech products annually (2023), but it still faces a trade deficit of £5.4 billion as imports exceed exports. High tariffs on UK-manufactured goods traded with the US increase pressure on this deficit, but there may be a twist. UK medical devices are subject to a flat 10% tariff, which is significantly lower than the high tariffs imposed on Chinese, Asian, Canadian, and Mexican imports, potentially benefiting some UK device exports. The NHS spends up to £18bn annually on medical equipment, consumables, and MedTech—everything from syringes to MRI scanners, a vast domestic market for UK designers and manufacturers to access. So, it's little surprise that it's rich with engineering and business innovation. MedTech is being affected by the same trends as other manufacturing segments: digital technology, sustainability, cost reduction pressure, new materials, and new or fast-developing manufacturing technologies. 3D printing and polymorphic moulding are used increasingly in device manufacturing, such as in Prosthetics and Orthotics, aka ‘PO', and specialist CAD/CAM software is utilised for digital dental manufacturing. The PO industry is worth £274m in 2024. Growth in prosthetics is fueled partly by amputations related to type 2 diabetes, and in orthotics by child mobility and disability needs. About 260 businesses operate in the PO sector, which surprisingly has 24% higher productivity compared to the entire healthcare sector (Source: BHTA, Healthtech's economic impact in the UK). Light the Fyous Orthotics are externally applied devices used to influence the body's function. They can be applied across the body but are most used to support the feet and lower legs. Foot orthotics are custom-made supports for the patient. Here, conventional mould tools used to make a plastic mould are uneconomic—short-run batches don't cover the tool cost. Fyous, the Sheffield-based polymorphic moulding technology provider, uses a proprietary pin tool with 28,000 pins to create a customised, ‘shapeshifting' mould in around 20 minutes. It recently partnered with Peacocks Medical Group, the UK's largest independent orthotics company, to use the polymorphic technology for its products. “This collaboration shows how polymorphic moulding can help the production of lasts (foot orthotics), cutting waste and costs, and improving efficiency,” said Joshua Shires, CEO and Co-Founder of Fyous. “Early adopters like Peacocks will gain a competitive edge as the industry moves towards more sustainable, digital-first manufacturing.” Fyous is now developing its pin technology to address the diabetic foot care market, where the NHS spends nearly £1bn a year on diabetic care. Several British MedTech companies are attracting big investments. In April, Cambridge-based robotics company CMR Surgical closed a US$200m funding round with a mix of equity and debt capital from investors Trinity Capital. The funds will be used to expand CMR's flagship Versius Surgical Robotic System to more hospitals globally, with a focus on the US market, and to support the launch of the enhanced Versius Plus. In 2021, CMR's private funding pushed above £1bn, valuing the company at $3bn. “We are now at a pivotal stage, poised to capitalise on significant opportunities for market expansion, including in the U.S, while penetrating deeper into expanding markets,” says CEO Massimiliano Colella. Cutting into the booming digital dental market Digital technology has allowed the production of dental implants and restorations to change rapidly. Today, many digital manufacturing labs can provide uber-accurate dental implants, crowns, and tooth sets in multiple materials in quick delivery times from 3D models of teeth supplied by dentists. These labs need the best milling tools to machine these implants accurately. Nine months ago, dental lab Optadent contacted high-precision tooling company Quickgrind to supply a two-flute, ball nose tool with 5mm extra reach. Optadent was compromising its CNC machining strategies; Managing Director Anthony Wainwright felt this could be improved by moving from standard tools from dental consumable distributors, to using a bespoke manufactured tool. Quickgrind's Total Solutions Engineering Strategy, a custom-made tooling service, was a perfect match. Material versatility is key in dental implants, and these tools are designed to machine the main specialist dental materials – chrome cobalt, titanium, zirconium oxide, PMMA, PEEK and wax. This engagement showed Quickgrind a relatively new and booming global, digital business – an industry within an industry. “Since spotting the opportunity we have worked closely with digital machining dental lab owners & technicians, machine tool manufacturers, machine tool distributors, CAD/CAM developers, CAD/CAM resellers, CNC application engineers and academics, to build our knowledge and understand how the market is growing and what may limit the speed of growth,” says Technical Support Manager Mark Aspinall. You can read the full story on page 52 and 53. Hold your nerve and keep innovating Amies is a 96-year-old, family-owned injection moulded component and assembly manufacturer. Over the last 20 years, the company has steadily built its medical business so that it now exceeds 50% of turnover across a diverse customer base in medical devices and IVD products. “Over our long history, we have learned that the best strategy is to maintain a solid and reliable technical base, such as the fleet of modern Arburg IMM machines we operate, while keeping fully aware of new technologies and materials as they develop, with a view to early adoption,” says Managing Director Simon Stewart-Smith. As regards innovation trends, Amies is increasing its use of in-house additive manufacturing in the development phases of medical projects and even most recently, some early pre-series production runs of complete assemblies. There is a lot of interest in eco-materials, too. “We are delighted to be engaged in some exciting, top-secret projects around a promising bioplastic that are progressing well,” Simon adds. “We are all operating in a challenging environment now, with many challenges coming from changes imposed by governments both home and abroad, but there is every reason to be optimistic that by remaining agile and focused, we can remain strong and continue to steadily grow.” Tariffs and turbulence put the brakes on medical's potential Like other sectors, medical devices face troubling conditions, not only US tariffs causing mayhem in supply chains. “The MedTech and HealthTech sectors currently face an unprecedented array of challenges; employers' NI increases, trade tariffs, regulatory uncertainty, post-Brexit trading status with the EU, NHS reform, the need for social care reform, the list goes on!” says David Stockdale, CEO of the British Healthcare Trades Association. “With so many moving parts and burdens placed on these sectors, it is an incredibly challenging market to be in. That said, there are opportunities, as innovations come into the market, coupled with an ageing population, there is growth potential here – it is just hard to see amid all the turmoil. It is important that the government better understands the sectors, who to support and to work with them at this time to help them flourish.”
Croom Precision Medical has selected Renishaw as its partner for additive manufacturing (AM) and metrology. It will use Renishaw technology throughout the production and validation of its ISO: 13485 certified medical devices. The company has found that using Renishaw's AM technology enables them to incorporate complex features into their implant designs at a commercially viable cost. They also note that Renishaw's integrated AM software, combined with its metrology solutions, helps them maintain traceability throughout their manufacturing process, which is vital in a heavily regulated environment. Background Croom Precision Medical (CPM) is at the forefront of Ireland's thriving medical device industry. Established in 1984, CPM has supplied Class I, II, and III medical devices to the orthopaedic market for over 35 years. Since these devices ultimately impact people's lives, it is crucial to implement rigorous quality procedures to ensure their safety and effectiveness during and after implantation. “We strive to achieve consistency and reliability in our manufactured products. CPM envisions becoming a centre of excellence for additive manufacturing in Ireland,” explains Patrick Byrnes, Research and Development Manager at CPM. CPM operates an integrated management system (IMS) that encompasses ISO: 9001, ISO: 13485, and ISO: 14001 accreditation. To demonstrate compliance with these standards, CPM must ensure transparency and traceability at every stage of the manufacturing process. Medical implant designs are rapidly advancing. Manufacturers are increasingly integrating novel and complex structures into these designs to enhance performance and longevity. However, creating such structures with traditional manufacturing techniques can be challenging and may not always be economically feasible. To evaluate the quality of parts, CPM conducts a series of offline tests to assess the implants' chemical, mechanical, and morphological properties. While these tests are essential for measuring the mechanical and chemical consistency of the implants, they can be time-consuming and can raise the overall cost per part. CPM's goal is to transform production so that more monitoring occurs during manufacturing. “We're looking for a red or green light, indicating whether the part is good or bad. Currently, we perform extensive offline testing, aiming to minimise it to reduce our cost of goods. We have made substantial progress in that direction over the past couple of years; there's still some work to be done, but we believe we are ahead of many of our competitors in the area of in-process monitoring,” Byrnes noted. Solution Emerging from the aerospace sector, Renishaw has a proven history of providing solutions that enhance manufacturing efficiency and part safety in highly regulated environments. CPM is applying Renishaw's technology in the medical sector for the same purpose. CPM has invested in a RenAM 500M additive manufacturing system, which it uses to 3D print medical devices in titanium. Renishaw's AM technology can create complex structures in a single manufacturing operation. For instance, CPM has begun to evaluate the use of gyroid lattices on acetabular cups, a design feature that was previously not economically feasible before their investment in AM. The resulting implants have undergone rigorous quality testing, and CPM reports notably good density and Young's Modulus values. In addition to the advanced manufacturing capabilities of AM, Byrnes emphasises that inline process monitoring is what truly sets apart Renishaw's technology and provides CPM with a competitive advantage: “The Renishaw software equips us with all the necessary information to ensure the quality of our parts, from build reports to post-processing, enabling us to trace our parts from beginning to end.” To promote quality and consistency, CPM has also selected Renishaw as its partner for precision metrology equipment, employing Renishaw technology at various stages of their testing and part validation. The team has long recognised Renishaw's reputation for producing reliable, robust metrology equipment: “When you visit multinational companies and see all the Renishaw products on the shop floor, they have a reputation for being repeatable, reliable, and capable of consistently operating in harsh environments,” commented Byrnes. CPM exemplifies how Renishaw can provide a comprehensive solution with technology that supports the manufacturing of technically ambitious parts and quality verification. Results CPM reports an increased market share, directly attributed to its investment in AM technology. “We have captured new market share in international markets, specifically in East Asia and North America, which were previously unattainable for us. Only in the last two years have these markets become accessible. We chose Renishaw as a development partner, not just as a supplier, envisioning the next few years as a strategic partnership to grow our additive manufacturing base here in Ireland.” Healthcare stands out as one of the leading industries for AM development. Although significant progress has already been made, ample room for growth still exists. CPM views Renishaw as a strategic partner in advancing AM technology. Byrnes adds, “Approaching AM for us has been a journey; it's an entirely different way of thinking. It's a more laboratory-like environment, a more cognitive approach to the process as opposed to conventional engineering.” In the coming years, CPM will continue to leverage the knowledge gained from its rigorous development programs and collaborate closely with customers and regulatory bodies to advance additive manufacturing technology and support enhancements in healthcare.
s a globally recognised manufacturer of leaf chains, FB Chain products are used in the automotive, material handling, and industrial machining sectors. The Letchworth Garden City company has earned a reputation for producing durable high-performance chains that support critical operations in demanding environments. To further this commitment, the company employs equipment from Mitutoyo. The product range includes leaf chains, roller chains, anchor bolts, sprockets, and customised chain solutions. The company's leaf chain kits include pre-measured components like chains, bolts, and attachments. FB Chain's dedication is supported by a continuous partnership with Mitutoyo, which has been vital in maintaining the highest quality control. With production volumes rising and the demand for tighter tolerances increasing, the need for faster and more automated measurement processes became essential. The company sought a solution that would enhance measurement accuracy while ensuring components were within the required tolerances. FB Chain approached Mitutoyo for their Roundtracer Flash, an advanced, non-contact measurement solution. This optical measurement system is perfect for inspecting the intricate surface profiles and geometries of the produced anchor bolts and pins. The Mitutoyo Roundtracer Flash enables FB Chain to measure dimensional accuracy and geometric consistency down to microns. Additionally, the Roundtracer Flash provides precise process control for demanding customers. The strong partnership between FB Chain and Mitutoyo was crucial in implementing the Roundtracer Flash system. Chris Cook, the Operations and Manufacturing Manager at FB Chain, visited Mitutoyo's Coventry site, where he received invaluable experience and support from Mitutoyo, collaborating closely to customise the measurement processes and integrate the Roundtracer Flash into the existing production line. Discussing this, Chris Cook stated: “Bigger customers require more accurate results, and we knew Mitutoyo could cover the range we were looking for. We sought a machine that would be easy to implement and provide static and dynamic measurements for our anchor bolts, blocks, and pins.” With a Mitutoyo hardness tester, small tools, and gauges already in use at the facility, Chris and his team continued the Mitutoyo synergy while searching for a shop floor measuring machine. Aiming to operate 24/7, FB Chain has set an ambitious production target of 168 hours per week. It is eager to determine if this is achievable when considering measurement and loading/unloading times. With more accurate and consistent measurements from the Roundtracer Flash, FB Chain can assess tool life limits, contributing to the 168-hour production target with increased unmanned working hours. With demand rising, FB Chain processes 25 to 30 tonnes of steel monthly. With 97% of manufacturing conducted in-house, their automated machining is being maximised to meet customer demands, necessitating the deployment of a high-priority, non-contact measuring machine. Initially, the Roundtracer Flash will be manually loaded, but as production increases, FB Chain intends to integrate another robot arm. After installing the Roundtracer Flash, Chris remarked: “The machine is user-friendly, interacts well, and has enhanced measurement efficiency. We already had trust in Mitutoyo, but observing the performance of the Roundtracer Flash and its extensive capabilities has further validated our continued reliance on Mitutoyo products.” With some initial guidance, both operators and inspectors can effectively use the machine. The speed of the Roundtracer Flash improves inspector efficiency by 97.5%, reducing a 10-minute inspection to just 15 seconds. Furthermore, the number of measurements has increased, enabling comprehensive dimensional checks during every batch. Not only is it capable of measuring cylinders, round parts, and turned components, but the machine has also been further programmed to assess milled flat surfaces and hole diameters/alignments. The Roundtracer Flash revealed that previous measurement methods using hand tools did not meet the requirements of specific customers, demonstrating that eliminating human error from the process has enhanced the inspection process.
Dedienne Santé, a French medical device manufacturer specialising in hip prostheses, has significantly improved its quality control process by implementing three advanced Hexagon CMMs. These technologies have enhanced measurement accuracy and reduced inspection times by 20%, setting new standards in medical device manufacturing. Founded in 1986 and based in Mauguio, France, Dedienne Santé is a leading SME specialising in surgical products, particularly dual-mobility hip replacements. As a manufacturer of high-precision prostheses, the company must adhere to strict industry standards, where any deviation can lead to serious consequences. Ensuring complete conformity at every stage of production is essential. Improving quality control with precision technology To enhance the quality control process for its hip prostheses, Dedienne Santé aimed to automate the dimensional measurement of critical components such as the cup (half-sphere part), liner, femoral head and stem. These parts must be measured precisely during production and final inspection to ensure conformity with strict medical standards. Previously, these measurements were conducted manually, which required significant time and effort. Dedienne Santé collaborated with Hexagon to address this challenge and provide reliable, accurate, and swift measurement solutions. To meet Dedienne Santé's needs, Hexagon deployed one GLOBAL Scan+ CMM and two retrofitted CMMs. These machines are equipped with highly accurate HP-S-X1 scanning probes and rotating probe heads, which are ideal for measuring roundness and sphericity. The systems also feature PC-DMIS metrology software that simplifies the measurement process, along with an Eco Mode that automatically shuts down the system when not in use, promoting energy savings. The user-friendly software, combined with automated and visual execution methods, enables operators to assess part conformity with just a few clicks. “We chose Hexagon CMMs for their ability to measure dimensions and circularities down to a hundredth of a millimetre. The scanning sensor is essential for checking our prostheses, where high precision is crucial,” says Alexis Lecomte, Quality Control Manager at Dedienne Santé. Significant gains in productivity and precision The implementation of Hexagon's solutions has brought multiple benefits to Dedienne Santé. It has increased precision as the CMMs meet the high-precision demands of the medical sector, ensuring each part conforms to stringent dimensional standards. The automated measurement process has resulted in a 20% reduction in inspection times, allowing operators to focus on other value-added tasks. For example, operators can run the inspection program and return to machining the parts, optimising the workflow. The intuitive PC-DMIS software simplifies the inspection process, enabling operators to perform quick self-checking and automated in-process inspection and final control, improving ease of use. “Hexagon's solutions have significantly improved our productivity. For instance, inspecting a hip replacement cup now takes 20% less time, and we can perform inspections without constant supervision,” adds Lecomte. Dedienne Santé values Hexagon's precision, speed, and simplicity, as well as the ongoing support they receive. They also appreciate how Hexagon helps maintain high-tech manufacturing capabilities at their French Mauguio facility, ensuring they meet evolving production requirements. “We must partner with suppliers who can help us maintain fast, productive manufacturing in France. Hexagon plays a key role in supporting our operations and ensuring we stay competitive in the global market,” says Ludovic Toledo, CEO of Dedienne Santé. Dedienne Santé's Commitment to Sustainability Dedienne Santé is also committed to sustainable development and reducing its carbon footprint, as evidenced by its Coq Vert label, which recognises its efforts to minimise greenhouse gas emissions throughout manufacturing. With Hexagon's solutions, Dedienne Santé can further its commitment to sustainability while maintaining top-tier manufacturing quality. “We're proud to have earned the French Tech label and the Coq Vert label, which reflect our ongoing dedication to innovation and sustainability. Hexagon's support is crucial in helping us meet these high standards,” concludes Toledo.
Cutting and Wear Resistant Developments Ltd, a leading manufacturer of specialised downhole tools for the oil and gas industry, has undergone a transformative shift in its production capabilities after investing in an Ibarmia machine from Dugard. The company, led by Managing Director Matthew Cooper, has followed a successful growth trajectory over the past 12 years, and the introduction of this advanced CNC machine has played a pivotal role in supporting its expansion. Cutting and Wear's unique selling proposition lies in its ability to manufacture tools with a hard-facing aspect and integrate innovative machining processes to deliver comprehensive solutions for its customers. Prior to the arrival of the Ibarmia ZVH 45 L3000 machine, the company encountered challenges related to the complexity of its tools, lead time constraints, and the efficiency of its manufacturing methods. However, the implementation of the new machine has revolutionised their operations. “In the 12 years I've been here, I've seen many changes, both in the company and the industry, but pleasingly, we've adhered to a successful growth plan, leading us to where we are today—continuing that growth and progressing in the right direction with new machine investments,” explains Matthew. The Ibarmia machine, equipped with a high-performance spindle capable of reaching speeds of up to 12,000rpm, has enabled Cutting and Wear to reduce lead times and machining times significantly. Mark Taylor, a CNC Programmer at Cutting and Wear Ltd., highlights a remarkable example: “We had one tool that previously took us 11 hours to mill; on the new machine, it was reduced to just two hours.” That's a massive improvement for us.” One of the standout features of the Ibarmia machine is its advanced probing capabilities. By integrating probing into the machine's programming cycle, Cutting and Wear have eliminated the need for manual programming, further streamlining the manufacturing process. As Mark explains: “We can execute everything on the machine as it's built into the programme, so there's no need to remove it from the machine for inspection, and that's a time saver as well.” The Ibarmia ZVH 45 L3000 machine from Dugard is a 5-axis travelling column machine with an X, Y and Z axis travel of 3m by 1.2m by 800mm with a B-axis head range of +/-105 degrees. Supplied with an SK40 head as standard or HSK A-63 as an option, the ZVH 45 has a powerful 45kW spindle with 200Nm of torque. Provided with a FANUC or Heidenhain TNC control, the ZVH 45 L3000 is available with a multitude of options to maximise productivity for the end user. The machine's state-of-the-art graphics function has also significantly enhanced the programming experience. Mark notes that approximately 90% of the programming is now done offline, with the remaining 10% proven on the machine. “The graphics have been tremendously improved on these machines. A lot of the programming, I'd say 90%, is done through offline programming, and then we have to prove it out here, but with the graphics function on this machine, it just makes everything so much easier and reduces errors,” he says. The advanced simultaneous 5-axis machining capabilities of the Ibarmia machine have been a game-changer for Cutting and Wear. This technology allows the machine to perform complex, multi-dimensional operations with a single setup, significantly reducing the need for manual intervention and enhancing overall efficiency. “It was a learning curve because it has a simultaneous head. We do have machines quite similar to it, but this one is a lot quicker,” acknowledges Mark, highlighting the initial challenges faced by the team in adapting to new technology. The introduction of the Ibarmia machine has profoundly influenced the mindsets of Cutting and Wear's machinists. Matthew explains: “The machines have assisted in that. Not only have they changed our manufacturing methods, but they've also shifted the mindset of the machinists. They've completely embraced the new technology, flipping their approach to the manufacture of downhole tools. The Ibarmia machine's advanced features—including its high-speed spindle, integrated probing, and state-of-the-art graphics—have allowed Cutting and Wear to achieve notable improvements in accuracy, speed, and programming efficiency.” These enhancements have directly contributed to the company's ability to meet the growing demands of the oil and gas industry. In addition to its technical capabilities, the strong partnership between Cutting and Wear and Dugard has been instrumental in the success of this investment. Matthew emphasises: “Dugard came in, worked with us very closely, understood the tools we wanted to produce, and from then on, simply matched us with the appropriate machines. So it's a well-suited relationship, and the machines are doing precisely as Dugard said they would.” The positive impact of the Ibarmia machine on Cutting and Wear's manufacturing mindset, along with the resulting efficiency gains, has positioned the company for continued success in the years ahead. As Matthew concludes: “It's massively changed. As I mentioned, we were on this growth path, and with that, we aimed to adopt more modern machining techniques; the machines have helped facilitate that.”
In the fast-paced world of precision manufacturing, staying ahead of the curve is crucial for maintaining a competitive edge. For Richard Haim, the owner of RPH Manufacturing Ltd, this realisation came early in his career, leading him to make a strategic investment in Hurco machine tools. RPH, a company based in Bournemouth, has been a stalwart in the industry, delivering over 45,000 parts annually to its diverse customer base. At the heart of this impressive output lies Richard's unwavering commitment to leveraging the latest manufacturing technologies, with Hurco machines. Richard's journey with Hurco began in 1999 when he acquired his first Hurco machine tool. Attracted by the brand's reputation, he saw an opportunity to enhance his company's capabilities. “I like Hurco because many of Hurco's customers are Formula One teams. I am very interested in Formula One, so what better endorsement than purchasing a Hurco machine tool?” Richard explains. One standout feature that has made Hurco machines invaluable for RPH is the seamless integration of the control system. Rather than programming directly on the machine, Richard uses Hurco's desktop software, which allows him to create and refine programmes. “I've got Hurco desktop software installed in my programming hub, and I program from there, then I import the programme into the control. I do very subtle editing, so as soon as it leaves the programming hub, it's ready to go in the control.” The versatility of Hurco has also been a significant factor in RPH's success. Richard has invested in a range of Hurco models, including the VM10, VM20, and VM30, each offering unique capabilities for various manufacturing tasks. “I may have one operation on a VM30, and then I put a reverse operation on a VM10,” he explains, highlighting the benefits of having access to different machine sizes. One of the key advantages of Hurco's control system is its ability to facilitate seamless programme transfers between machines. This has been particularly beneficial for RPH, as the company often needs to move parts between different machines. “I can network all the machines by importing the programme into whatever machine I wish to use,” Richard explains. “Sometimes, I use one part on the same machine, and then I'll move it around. With all that tooling, the Hurco machines are familiar and will recognise that tooling.” Another crucial aspect is the control system's graphics capabilities. “The first thing to consider when programming anything new is your stock geometry. You must have that perfect,” Richard explains. “Then, when you're doing your animation, you can flip and ensure that you've got the machine correctly positioned around the stock geometry.” The ability to dry-run programmes on the Hurco control system has also been a game-changer for RPH, particularly for fixture-based work. “I place a 50mm block on top of the work surface, and then I run the entire programme with a 50mm Z offset,” Richard explains. “This allows me to ensure that I won't hit any clamps or bolts during the machining process.” As Richard looks to the future, his commitment to Hurco remains steadfast. “My mission is that I've been in business for 44 years now. Fifty years will be my milestone. That's 2031. I will still be running Hurco CNC machines.” Richard's investment in Hurco machine tools has been a strategic decision that has yielded results for RPH. From the seamless integration of the control system to the versatility of the machine lineup and advanced graphics capabilities, Hurco's technology has empowered RPH to maintain its competitive edge and consistently deliver high-quality parts to its customers. As Richard looks to the future, his unwavering commitment to Hurco underscores the value these machines have brought to his business and his confidence in the brand's ability to support his continued success.
The global economic environment of 2024 presented unprecedented challenges for industrial manufacturers, yet Studer emerged not only as a survivor but also as a strategic innovator. At this year's press conference, Studer once again delivered an insightful overview of the company's performance and innovations. Always a highlight in the calendar for the trade media, the 2025 event was hosted online as opposed to a trip to the picturesque Steffisburg municipality of Switzerland – but the insights were no less impressive. By Rhys Williams Outgoing CEO Jens Blaher set the tone for the annual press conference with a candid and compelling narrative of organisational resilience. “During the recently concluded 2024 financial year, we effectively navigated the deteriorating economic and geopolitical landscape,” he explained, his words resonating with a deep understanding of the complex challenges facing modern industrial enterprises. Studer's approach to these challenges was fundamentally different from that of many competitors. Rather than retreating or dramatically scaling back, the company embraced a strategy of diversification and targeted growth. Blaher emphasised this point by highlighting how the company's multifaceted approach allowed it to grow in select markets, transforming potential obstacles into opportunities for expansion and innovation. The company's performance was nuanced and strategically calibrated. While incoming orders were slightly below the previous year, they precisely aligned with Studer's carefully planned expectations. Geographically, the company maintained a robust presence, with Asia remaining its largest sales region and North America showing significant growth. Approximately 50% of incoming orders were generated outside Europe, underscoring the company's global reach. A remarkable highlight was the 43% increase in new customer acquisition, with strength in key sectors, including automotive and the respective supply chain industries, as well as tool and die manufacturing, the machine tool industry and aerospace manufacturing. The New favoritCNC At the heart of Studer's 2024 innovations was the advanced favoritCNC universal cylindrical grinding machine, representing a significant leap in grinding technology. The machine integrates the latest FANUC 0i-TFP control system with a sophisticated engineering approach that demonstrates the company's commitment to precision and user accessibility. Technical specifications reveal a meticulously designed piece of equipment. The machine offers flexible wheelhead configurations, including a fixed wheelhead with manual positioning at 0°, 15°, and 30° and a universal wheelhead with a 2.5° Hirth coupling for seamless internal and external grinding capabilities. Its foundation is constructed from Granitan® S103 mineral casting, a proprietary material that provides exceptional thermal stability and vibration damping. The machine's physical capabilities are equally impressive. It can accommodate centre distances of 650mm or 1m, handle workpiece weights between 80 and 120kg, and accept grinding wheels up to 500mm in diameter. Perhaps most innovative is the machine's intuitive StuderPictogramming and StuderGRIND grinding software, which provide modern digital solutions that allow even complex grinding processes to be set up and controlled intuitively. Commenting on the machine, Sandro Bottazzo, the new CEO at Studer, said: “With numerous new features, optimisations, and automation capabilities, the favoritCNC is a future-oriented, economical solution for the external and internal cylindrical grinding of small to medium-sized workpieces in individual and series production. Both for high-quality contract manufacturing and in-house production and with the conventional mode, the new favoritCNC is an optimal solution for a wide range of different grinding applications.” Pushing the Boundaries of Precision Beyond the favoritCNC, Studer introduced several groundbreaking technological innovations that underscore its position at the forefront of precision engineering. The Universal W-axis represents a quantum leap in grinding technology, integrating directly onto the Z-slide to enable automatic machining of different workpiece lengths without operator intervention. The axis's most revolutionary feature is its direct force measurement capability, which allows for a force-controlled clamping process that delivers maximum precision and repeatability. Aerospace Industry: A Proving Ground for Innovation The aerospace industry serves as a critical proving ground for Studer's technological capabilities. Modern aviation demands extraordinary precision, with components requiring micron-level accuracy and the ability to withstand extreme conditions. Studer's machines play a crucial role, with the S31 and S33 CNC universal cylindrical grinding machines capable of grinding landing gear components to microns. Martin Hofmann, Studer's Sales Director for North America and aerospace specialist, emphasises that the company's focus remains on supporting human expertise. Hofmann explains that the entire industry is currently experiencing an increasing trend towards better materials, optimised aerodynamics, sensor technology and data analysis for more efficient engines. “We are therefore supporting our customers with innovative production technologies to be even more successful.” The SmartJet® coolant concept demonstrates STUDER's commitment to sustainable manufacturing. This advanced system reduces coolant consumption by up to 40% and energy utilisation by 50% compared to conventional methods. Its expanded application range includes sophisticated optimisations for thread grinding and innovative plug-in coolant nozzles designed for various grinding wheel profiles. Another breakthrough is the WireDress® dressing process, explicitly developed for metal-bonded CBN and diamond grinding wheels. In 2024, Studer extended this non-contact dressing system to internal grinding wheel applications. Hofmann also sees the future-proof C.O.R.E. hardware and software architecture and intelligent Studer software with comprehensive digital capabilities as a significant advantage of the new generation of Studer cylindrical grinding machines. This includes intuitive operation, process and data visualisation as well as standardised or customised automation systems. “Our focus is always on people; technology should support them,” he explains. Operational Excellence and Sustainability Studer's 2024 strategy extended beyond technological innovation to encompass operational efficiency and sustainability. The company implemented comprehensive improvements, including the consolidation of spindle assembly locations, advanced testing and diagnostic systems, and a complete renewal of internal electrical pre-assembly. Sustainability initiatives were equally impressive. The company converted extensively to LED lighting, replaced operational systems with energy-efficient devices, and designed a new logistics facility aimed at reducing energy consumption. Ongoing digitalisation projects across operations further demonstrate Studer's commitment to efficiency and environmental responsibility. A Commitment to Excellence Studer's 2024 journey represents a masterful blend of technological innovation, market adaptability, and strategic foresight. By investing in advanced technologies, expanding customer care, and maintaining a forward-looking digital strategy, the company has not just weathered global challenges but positioned itself for continued growth in the precision engineering market. As Jens Bleher aptly summarised: “Know-how and commitment are the future of a technology company”—a philosophy that continues to drive Studer's remarkable journey of innovation and excellence: novation and excellence.
Aleading OEM specialising in the design and production of equipment for oil heating and diesel tank applications, as well as being a subcontract engineering firm, Atkinson Equipment has dramatically reduced lead-times following investment in a Brother Speedio U500Xd1 5-axis machining centre equipped with Tezmaksan CubeBox automation from Whitehouse Machine Tools. Adam Walford, Engineering Group Sales Manager at Atkinson Equipment explained: “The automation solution from Whitehouse has increased our productivity dramatically. We have typically halved lead-times from 12 weeks down to six for complex subcontract parts and reduced them even further when making components for our own products, say from a month down to one week.” “Since automating the milling side of the business, we have also seen a reduction in the bottleneck we previously had when parts arrive from our turning section for prismatic machining. Our ability to get product out of the door to our customers is through the roof. It is helping us to win new business in the subcontract area, as well as to grow our OEM division.” Based in Westbury, Wiltshire, Atkinson Equipment is required to manufacture large volumes of parts for its own refuelling and liquid transfer products, which it has been doing for over 50 years. It also needs to produce a high mix of smaller volumes for the subcontracting division, which has been running for half that time, but which is growing rapidly. This dual role places significant demands on its manufacturing capabilities and was pivotal in the investment in the automated Brother-Tezmaksan cell. The relationship with Whitehouse Machine Tools began in 2019 with the purchase of a Brother 5-axis CNC machining centre, a Speedio S700X1 equipped with a Lehmann rotary-swivelling compound table. This initial investment allowed the company to machine complex parts on multiple faces in a single set-up, significantly improving efficiency. Having experienced the benefits, Atkinson Equipment went on to buy a Brother Speedio M200Xd1 trunnion-type 5-axis machining centre in 2023, initially to manufacture a complex aerospace part. At first, the idea was to automate the existing S700X1 on site with the Tezmaksan CubeBox, but this would have necessitated an upgrade to the Lehmann equipment to provide pneumatic supply for automatic clamping of parts. However, a visit to the Whitehouse showroom in Kenilworth revealed the potential of automating a Brother U500Xd1 5-axis machining centre instead, as this was the configuration being demonstrated. Mr Walford explained, “Looking at the cost differential between just the Tezmaksan compared with the automation plus the U500Xd1, it made sense to go for the automated set-up complete with the new 5-axis machine. We needed extra capacity anyway, so it made absolute sense for us, especially as it was more affordable than we anticipated.” The Brother U500Xd1's large working volume for the compact footprint, 28-tool ATC capacity and integrated rotary joint for pneumatically actuating the fixtures proved ideal for the Westbury firm's production needs. Whitehouse provided comprehensive support during the set-up process, assisting with tray template design for holding raw material and finished components, as well as the end-of-arm tooling with double grippers for handling them. The automated cell's sensors create a safe working environment, without the need for traditional guarding. Mr Walford concluded: “It was quite daunting at first taking on a completely new piece of technology like this, but we were confident with the support that we would get from Whitehouse and their ability to guide us through the process to where we are now.” “The relationship with this machine supplier is key. We're very happy with their service and support, it's really brilliant, and it gives us confidence to keep buying from them.”
Key Precision is a subcontract manufacturer specialising in precision turned and milled components. Founded 21 years ago, the Cannock-based company focuses on driving efficiency throughout the business. Managing Director Greg Jackson identified cutting fluid performance as an issue needing attention—the solution was OEMETA's ESTRAMET S95 coolant. Greg says: “We have an impressive array of machines from sliding and fixed head turning to vertical machining centres.” The plant list boasts prestigious brands like Citizen, Hanwha, HAAS, DMG MORI, and Doosan. Ryan Aviles from OEMETA explains: “Our relationship with Key Precision has been in place for years. Initially, we identified areas for improvement, and they invited us to trial.” OEMETA's engagement began with a consultative process where technical representatives evaluated the shop floor and collected samples for analysis. By taking fluid samples and sending them to OEMETA Germany for over 50 different tests, the process remains non-disruptive to production. The six-step process includes sample capture, performance analysis, result review, trial, product transfer and partnership. From this analysis, OEMETA yields a 95% success rate in delivering performance-enhancing solutions. Following a consultation, OEMETA identified ESTRAMET S95 as the most viable solution. Compatible with steel, stainless and high-alloy steels, aluminium, and aerospace-grade alloys, ESTRAMET S95 serves the entire spectrum of applications, from drilling and milling to grinding. Ryan adds: “On our first consultations we take samples, send them to Germany for analysis, and discuss results with the customer. Once we have sample results, we examine opportunities in detail. From our testing, we can benchmark against existing products and forecast benefits with confidence—before our product reaches their shop floor.” Seismic Benefits from OEMETA With testing covering lubricity, corrosion, stability, foaming, water quality, safety, and environmental impact, Key Precision experienced efficiency gains ranging from 35% to 150% across various operations. Greg continues: “We've seen tool life improvements from 70% up to 150%. Every operation has shown a minimum improvement of 35%. For long-running jobs, U-drills saw a 77% increase. Parting-off efficiency increased by 35% and turning operations by 300%.” The extended tool performance has allowed the company to recoup its annual OEMETA fluid costs in the first month. Machine and component cleanliness and quality have also improved. Based on synthetic ester oils, the translucent ESTRAMET S95 is free from mineral oil, boron, formaldehyde, fungicide, and active sulphur. This makes it a bio-sustainable, operator-friendly fluid. As a highly stable fluid, it has increased tool life from 20% to 50% on most machines, generating significant cost savings. The implementation strategy incorporated a comprehensive approach, including bi-weekly site visits, laboratory testing, and compatibility assessments. OEMETA's service model includes monthly coolant maintenance checks far beyond standard industry practices, with concentration verification, pH monitoring, microbiology testing, and tank evaluations. Ryan explains: “We regularly revisit the site every two weeks to collect samples. With the results, we update customers on performance. Once KPIs are achieved, we start the roll-out process, taking samples from all machines to ensure compatibility with existing coolants.” The success has prompted Key Precision to implement OEMETA across all water-based machining. Plans are also in place for oil-based solutions on sliding heads. Ryan adds: “We've run tests on the sliding head machines and will deliver similar savings with our GTL (Gas To Liquid) product.” Greg concludes: “The trial results speak for themselves. We're committed to rolling out OEMETA fluids across our full range of machines. The results have been fantastic, and we look forward to more efficiencies and savings from working with OEMETA.”
In the dynamic world of machining, efficiency and precision are paramount. Most of the machining allowance is removed during rough cuts. Therefore, increasing productivity at this stage is crucial for reducing the machining costs of the entire manufacturing process. Even with improved capabilities in precise forging, die-casting, injection moulding, and other workpiece production methods that allow for obtaining a workpiece very close to the part's final shape, a high metal removal rate during rough cutting continues to be an important factor in reducing total costs. ISCAR has consistently pushed the boundaries to provide solutions that meet the ever-evolving demands of manufacturing. One of ISCAR's standout innovations is the Fast Feed line of tools designed to enhance productivity while maintaining exceptional precision. Fast Feed tools by ISCAR are designed to operate at high feed rates, significantly reducing machining time and increasing productivity. The concept hinges on the principle of shallow depth of cut combined with high feed, allowing for rapid material removal without compromising surface finish or tool life. This approach is particularly beneficial in roughing operations, where the primary goal is to remove as much material as possible in the shortest time. ISCAR's Fast Feed tools are engineered with advanced geometries that optimise chip evacuation and reduce cutting forces. This results in less wear and tear on both the tool and the machine, extending their lifespan. The Fast Feed tools are suitable for a wide range of materials, including steels, stainless steels, cast irons, high-temperature superalloys (HTSA), and titanium. This versatility makes the tools an attractive option for industries such as aerospace, automotive, and mould and die, where diverse materials are often encountered. By allowing for higher feed rates, Fast Feed tools significantly reduce machining time. This efficiency results in cost savings and increased throughput, which are essential in high-volume production environments. While primarily focused on roughing, ISCAR's Fast Feed tools are also designed to achieve suitable surface finishes, minimising the need for secondary operations and further enhancing productivity. The combination of advanced cutting tool materials, wear-resistant coatings, and optimised geometries ensure that Fast Feed tools have a long tool life, even under the demanding conditions of high-speed machining. Fast Feed tools are making significant impacts across various industries. In aerospace, where difficult-to-cut materials like titanium and HTSA are common, these tools help address the challenges of machining tough materials. In the automotive sector, they enable manufacturers to meet the fast-paced production demands while maintaining high quality. The mould and die industry also benefits from reduced machining times and improved surface finishes, which are crucial for producing complex shapes with high precision. ISCAR offers a comprehensive selection of advanced cutting tools, including fast-feed turning and grooving tools. These tools are designed to enhance productivity, efficiency, and precision in various machining operations. Fast Feed Turning Tools (Fig.1) l High Feed Rates: These tools enable increased feed rates, thereby reducing machining cycle times. l Durable Materials: Constructed from high-quality materials to withstand high-speed machining conditions. l Precision Cutting: Engineered for accuracy, ensuring precise cuts with minimal tool wear. l Versatility: Suitable for a variety of materials and applications, offering great flexibility. Fast Feed Grooving and Parting Tools (Fig.2) l High-Speed Performance: Designed to perform at high speeds, improving the overall efficiency of grooving operations. l Reduced Cycle Times: High feed capabilities allow for quicker material removal, reducing overall cycle times. l Enhanced Tool Life: Made from durable materials that extend the life of the tool, even under demanding conditions. l Consistent Quality: Ensures consistent performance and high-quality results in various grooving applications. ISCAR also provides an extensive range of fast feed milling tools designed to significantly increase efficiency and productivity. These tools are specifically engineered to deliver high material removal rates and reduce cycle times in various milling operations. Fast feed (FF) milling cutters are a key factor in high feed milling (HFM) techniques. The cutter geometry, designed for efficient chip thinning, must ensure the correct distribution of the cutting force. There are two principal geometrical approaches. The first design requires the cutting edge of an FF milling cutter to be an arc of a circle. Another concept is based on using one or two straight edges that are chords of the arc. In both cases, the small cutting edge angle (usually 9-17°) meets the requirements of chip thinning and decreasing the total bending load on a tool. Ensuring the geometry of solid carbide fast feed endmills and replaceable milling heads demands the specific shape of a cutting edge, while in indexable milling, it may be provided by the appropriate location of an insert of even a simple profile. Although the introduction of innovative grades and advances in chip forming rake faces have improved progress in FF milling cutters, the essential element, the geometry, remains constant. If the cutting edge of an FF milling cutter is the arc of a circle (or the chords that approximate the arc), the cutting edge angle of the cutter is not a constant value but varies depending on the axial depth of cut from 0 to the mentioned 9-17°. In milling, the chip thickness is a function of the tool's cutting edge angle. Under the same conditions, the smaller the cutting edge angle, the thinner the chip. Therefore, the programmed feed should be increased correspondingly to produce chips of the required thickness. Features of ISCAR Fast Feed Milling Tools (fig.3) l High Feed Rates: These tools are designed to operate at high feed rates, allowing for faster machining processes and reduced cycle times. l Durable Structure: Made from high-quality materials that ensure durability and long tool life, even under demanding conditions. l Precision and Stability: It is engineered to provide precise and stable cuts, minimise tool wear, and improve the quality of the finished product. l Versatile Applications: It is suitable for a wide range of materials and applications and offers great flexibility in use. l Innovative Design: It incorporates advanced geometries and coatings to enhance performance and chip evacuation, reduce heat generation, and increase tool life. Popular Product Families l HELI-6-FEED: Known for its double-sided indexable inserts, offering high feed rates and excellent performance in various milling applications. l NEOFEED: Specifically designed for high feed milling, these tools carry cost-beneficial double-sided square inserts with 8 indexable cutting edges, providing outstanding material removal rates. l MULTI-MASTER: This modular system with interchangeable heads allows for quick and easy tool changes, enhancing productivity and reducing downtime. ISCAR's Fast Feed tools exemplify the company's commitment to providing innovative solutions that address the real-world challenges faced by manufacturers. ISCAR's Fast Feed tools are a testament to the company's forward-thinking approach and dedication to enhancing machining efficiency. As industries continue to demand faster, more precise, and cost-effective solutions, ISCAR's innovations in fast feed technology are set to play a pivotal role in shaping the future of manufacturing.
When it comes to the medical field, precision and reliability are crucial for producing high-quality biocompatible components. Kennametal's TopSwiss™ line of tooling excels at meeting stringent requirements and close tolerances. This platform supports the development of cutting-edge medical technology, helping to improve the lives of those who rely on the latest medical innovations. TopSwiss tooling features sharp cutting edges and aggressive geometries that create low cutting forces and excellent chip evacuation, ensuring longer tool life and superior surface finishes. The TopSwiss™ MBS (Micro Boring Solid) system is especially distinguished for its precision in machining extremely complex and small components. “In regard to the TopSwiss MBS, especially for medical-grade applications, the tooling must be precise and reliable to manufacture components like bone screws, tulip heads, dental implants, and surgical instruments,” said Scott DeVinney, Senior Global Product Manager, Medical and Small Part Machining. “They have to meet the most stringent requirements for safety and compatibility with human tissue.” Innovative Solutions Finding the best results for customers is always a priority when designing the latest technology. When a prominent medical company is faced with the challenge of pinch-turning long instruments made of 17-4PH stainless steel, there is a struggle with tool life and chip control. To resolve this, the Kennametal team creatively adjusted parameters. They processed these instruments on Swiss-type turning machines using a standard TopSwiss ISO turning insert with advanced finishing wiper technology and a new coated cermet grade (KTP25S), designed specifically for Swiss-type turning. This resulted in excellent chip control and surface finish, and it increased tool life by 900%, from 50 to 500 pieces. Additionally, a TopSwiss ISO turning insert with the new Light Finishing Swiss (LFS) geometry and grade KCP20S was used to enhance surface quality and chip control for a company needing a solution for turning PH stainless steel instruments. The TopSwiss tooling not only improved surface quality but also offered nearly 50% cost savings over the customer's existing solution. Advanced Coatings and Tool Holders The TopSwiss™ MBS platform contains micro boring inserts specifically designed for machining medical components. These inserts feature a specialised KCSM25S coating for a smooth, polished surface that reduces chip adhesion and improves component quality. The inserts also have a unique lead and relief angle that can withstand high tool pressure. Additionally, coolant is delivered directly through the tool to the cutting edge, reducing heat and improving chip control. For optimal performance, the inserts can be paired with HP (High Performance) tool holders, which offer high precision and repeatability to the centerline of ±5 microns. Versatility and Customisation Kennametal's TopSwiss™ platform stands out for its versatility in handling a wide range of applications, with nearly 1,000 inserts available. This extensive selection allows for precise customisation to meet specific machining needs, whether it's boring, profiling, back boring, grooving, threading or multi-directional turning. Low Feed and Speed Applications Highly effective in low feed and speed applications due to their superior chip evacuation, the TopSwiss™ ISO inserts ensure smooth operation by efficiently removing chips and preventing build-up. They provide excellent surface finishes and extended tool life, thanks to their precision and sharpness. With nose radii ranging from 0 (sharp) to 0.80mm and close tolerances (+0/-0.05mm), these inserts offer precise cutting capabilities. Material-Specific Inserts The ISO platform offers specialised inserts in both carbide and cermet grades. These inserts come in fine finishing, light finishing, parallel positive, and finishing wiper geometries. Carbide inserts can be used on steels, stainless steels, high-temperature alloys, and non-ferrous materials with grades such as KCS25S, KCM25S, KCP20S, and KN10S. Cermet inserts are designed for carbon steels, alloy steels, and stainless steels with the grade KTP25S. The Importance of TopSwiss Cermet Wiper Cermet is highly effective for machining applications that require high surface quality, dimensional stability, and tight tolerances. It is particularly suitable for high-speed finishing. Offering significant improvements in surface finish and productivity, the TopSwiss Cermet wiper insert features a secondary radius (rw) that follows the primary corner radius (r), effectively reducing the scallop height (Ra) and greatly enhancing surface roughness. Key Advantages of Cermet Wiper Inserts Due to the larger size of the secondary radius, wiper inserts can achieve higher feed rates while still maintaining or even improving surface roughness. This results in increased productivity without compromising quality. Wiper inserts are most effective when used to activate features that enable the secondary radius to follow the corner radius. This includes straight lines, small angles, and chamfers. However, they are less effective on steep angles or chamfers, where the geometry does not allow the secondary radius to follow the corner radius. “When you're using wiper inserts, it's all about the details. Think about the lead angle and the specific feature you're machining,” said DeVinney. “These details can make or break the effectiveness of the inserts. You must take the time to plan and set up carefully to achieve the best results.” To avoid workpiece damage, it's crucial to select the appropriate material and machining speed and use coolant to prevent overheating. This can be achieved by adjusting cutting speeds, feed rates, and the depth of cut, ensuring proper coolant flow, and selecting the right cutting tools. Kennametal's Swiss-type turning platform is the perfect solution to enhance efficiency and provides a cost-effective, versatile solution applicable to various materials. Kennametal's TopSwiss™ platform stands out as a premier solution for precision turning. With its advanced tooling features, innovative solutions, specialised coatings, and material-specific inserts, TopSwiss™ ensures precise machining capabilities, particularly in the medical field.
The dental industry has witnessed explosive growth over the last decade. Dentistry has become a lucrative field, with an ageing population retaining their teeth for longer, an increase in sugary foods on supermarket shelves, and a socially media-influenced population pursuing cosmetic enhancements. Over the last ten years, NHS treatments have incrementally increased by 1 to 2% per annum, private dental care by 5 to 7%, and cosmetic dentistry has boomed by as much as 35%. All these factors exert pressure on the supply chain, and it's here that Quickgrind is making an impact. By definition, high-street dentists, laboratories, and the supply chain supporting the sector are medical experts, not engineers. Engineering expertise becomes essential as more dentists perform scans, utilise 3D printing, and engage in micromachining at-source or through local laboratories. This is why Anthony Wainwright of Optadent contacted Quickgrind last year. The company uses a range of small cutting tools and it required a 2-flute ball nose with an extra 5mm of reach. Optadent was compromising its machining strategies, and Anthony believed that processes could be improved with the right solution. Purchasing standard tools via a dental consumable distributor, Optadent, was confident that a better solution was available. Commenting on the initial meeting with Optadent, Quickgrind's Technical Support Manager Mark Aspinall says: “Discussing the dental CNC milling industry with Anthony, it was clear that Quickgrind's Total Solutions Engineering Strategy (TSE) fitted perfectly with Optadent's desire to improve processes. This initial meeting sparked Quickgrind's desire to further investigate the digital dental market to reduce their total costs while optimising efficiency, productivity, and sustainability.” Understanding the market Quickgrind has collaborated with digital machining dental lab owners, technicians, machine tool manufacturers, distributors, CAD/CAM developers, CAD/CAM resellers, CNC application engineers, and academics. Discussing this research, Mark adds: “We have observed firsthand how and where the market is growing, the frustrations the dentistry industry faces regarding its manufacturing practices, and how these challenges impact the speed of market growth, future technologies, and materials. At Quickgrind, we have listened to the industry and support the sector through our advanced cutting technologies.” Over the past 12 months, Quickgrind has seen the automation and digital workflow within the industry. This encompasses everything from models and materials to CAM programming of toolpaths, loading, tool databases and breakage detection. “The level of automation is impressive, and the manufacturing supply chain in other industries could learn a lot from it. The automation in dental milling laboratories enables them to program and rapidly produce complex dental components to specific quality standards, with minimal manual input. Therefore, cutting tool performance is even more critical for machine uptimes,” Mark says. “Dental labs process a wide variety of materials, ranging from wax to titanium, and comprehending the terminology of the dental world is essential to meet clients' requirements. CNC milling strategies, tool databases and ‘standard' cutting tools are typically provided as a package from the distributor of the small and often bespoke machine tools. In many UK laboratories, expertise in cutting tools and machining strategies is often limited to what has been provided by the machine tool distributor.” “While very complex components are machined, the full potential of the CAD/CAM software and the machine's capabilities is not being utilised to maximise productivity. In this area, our experts are assisting with machining strategies, cutting parameters, and, of course, tools to extend tool life, optimise machine uptime while enhancing the quality of components and implants.” Quickgrind recognises that the dental industry has been plagued by low-cost and low-quality cutting tools sold by dental consumables and machine tool distributors at inflated prices. Rather than exploiting this industry, Quickgrind's approach is to collaborate with customers and support them through its Infinite Possibilities program. The Tewkesbury manufacturer has published a cutting tool brochure for the dental industry, with full support available for manufacturers. In the past 12 months, Quickgrind has worked closely with manufacturers such as Optadent Solutions, Element Digital Solutions, PRO4 DENTAL, Beaumont Ceramics, Radiant Dental Laboratory, and countless others, including Bristol CADCAM and Hexagon. Commenting on the relationship with Quickgrind, Antony Wainwright, Company Owner at Optadent Solutions, says: “We were getting frustrated with cutting tool issues when milling titanium and chrome cobalt dental restorations. Typical issues were tool breakage, poor tool life and inadequate reach. By partnering with Quickgrind, we now have a cutting tool supplier whose products have helped us achieve a 40% improvement on tool life, reduced production costs and more stable milling processes.” “By utilising Quickgrind's Infinite Possibilities® process, we have created our own tooling suite for which we can tailor our milling strategies. This has reduced cycle times significantly with no detrimental effect on quality. Quickgrind has helped us optimise our CNC milling strategies using the latest cutting tool technologies to improve quality, cycle times, and costs. This willingness to collaborate sets them apart from other cutting tool suppliers in the dental market.” Adding to this testimonial, Dan Barber, Company Owner at Element Digital, says: “Quickgrind doesn't just want to sell us milling tools; they want to work with us to understand our machining requirements, workpiece materials, and quality expectations and to ensure their tools provide improved performance. We have seen huge improvements in tool life and consumable costs using their Zodiac, Gladiator, and Ribcutter ranges across all materials from pre-sintered zirconia to titanium and chrome cobalt.” We are now interested in applying Quickgrind's Infinite Possibilities® methodology for producing non-standard tooling to maximise the capabilities of our CAM systems and CNC milling machines, thereby reducing our cycle times and improving our overall efficiency. With end mill ranges from the Zodiac, Rib Cutter, and Typhoon to the Orbis, Spectre, and Lynx, along with the infinite possibilities of bespoke solutions, Quickgrind has an engineer and a solution to support the demands of this specialised industry sector. Quickgrind's Mark Aspinall concludes: “Dental laboratory owners are open and willing to collaborate with a desire to learn and utilise their machining capabilities. There are lots of best practices that should be shared between industrial machining and dental labs that would benefit both sectors. The level of automation I have seen in dental milling has genuinely blown me away, and dental labs could benefit more from cutting tool and milling knowledge to utilise the machine capabilities they have. This will help reduce cycle times, improve tool life, minimise downtime, increase capacity, and reduce operational costs.”
In the world of medical manufacturing, where precision is paramount, the production process is key. From crafting bone screws to fabricating complex hip replacements, there's a high demand for accuracy, reliability, and efficiency. Annika Langéen, Vice President of Offer Management and R&D expert in metal cutting tools at Sandvik Coromant, explains how small part machining supports precise medical device manufacturing. The medical device industry encompasses various products designed to diagnose, monitor, and treat medical conditions. From diagnostic equipment to implantable devices, the industry caters to the needs of healthcare professionals and patients worldwide. Today, according to the World Health Organisation (WHO), there are an estimated two million different medical devices, categorised into more than 7,000 device groups. Manufacturing components for medical devices presents challenges that demand advanced machining solutions. End users rely on these devices being manufactured to the highest quality, as products that do not meet quality standards can cause massive disruptions. Machining challenges From a machining perspective, the size and complexity of components require micron-level precision, so any manufacturing process must offer accurate end products. The materials used for a wide range of medical device components—typically titanium, stainless steel, and special alloys are selected due to their resistance to corrosion and wear. However, machining must address issues around tool wear, heat generation, and surface finish. There's also the issue of productivity. Generally, there is an imbalance between the cost of development and what the market is willing to pay for in any industry. To bridge that gap, manufacturers must continuously increase efficiency and productivity. Sandvik Coromant estimates that manufacturers waste between 10% and 30% of material in their machining processes, with a typical machining efficiency of below 50%, which includes the design, planning, and cutting phases. To overcome this, Sandvik Coromant focus on reducing non-cutting time to ensure maximum productivity. Tools are designed to be highly flexible and modular and make use of high-pressure coolant to maximise uptime. To illustrate Sandvik Coromant's medical device tool and machine success, let's take the example of bone screw manufacturing. Bone screws may be used alone in reconstruction or reparative surgery or with other hardware devices, such as plates, to fix them to the bones. With such a wide array of applications, bone screws are typically long and thin and manufactured for different body parts. They're generally produced in quantities of between 30 and 1,000 using thread whirling. Here, a cutting tool is mounted on a rotating spindle, which is fed into the workpiece while it rotates. The cutting tool typically has multiple inserts. During thread whirling, the workpiece rotates on its axis while also being moved longitudinally along its axis. Meanwhile, the cutting tool rotates around the workpiece. Sandvik machining solutions for sliding head machines use the CoroMill® 325 whirling system, a dedicated whirling unit, and a high-pressure coolant pump with a filter. The CoroMill® 325 is designed specifically for medical device manufacturing, producing special thread forms at high tolerances. The machine completes single-pass machining from stock diameter to reduce the cycle time by minutes and is easily set up to minimise downtime. All Sandvik Coromant thread whirling inserts are available in GC1105 — the first-choice medical grade. Sandvik Coromant also offers an extensive range of advanced tooling and machining solutions for many additional devices, including hip joints, pedicle screws, and bone plates. Precision machining is essential as medical device manufacturing continues to evolve and become more competitive, driven by advancements in materials, design, and manufacturing technologies.
Longbridge-based DaceCrown Ltd has established itself as a leading supplier of precision components to the bottling and packaging industry. However, after 25 years of operation, a new generation of engineering talent has taken over and plans to elevate the company to new heights. “Over the years, the company built a strong reputation among global brewing, beverage, and pharmaceutical brands for tackling the toughest packaging and handling challenges,” says Tom White, Co-owner at DaceCrown Ltd. Tom, whose background is in applications engineering and technical sales, purchased DaceCrown in 2023 with his business partner and Operations Director, Jake Harley-Arliss. In less than a year, they transformed DaceCrown from a fully manual workshop into a facility with three HAAS machine tools: a VF-9 large-capacity VMC, a VF-2 VMC, and an ST10 high-performance turning centre. “The previous owners primarily used manual lathes for production, a highly skilled but increasingly scarce method. Recognising the need to futureproof the business and expand the customer base, we made a strategic decision to transition to more modern production methods,” Tom explains. “This change in approach very quickly opened the door to winning more jobs for high-value components with complex machining requirements, such as sharper tips, better corner radii and finer screw threads. You couldn't do that work at scale on manual machines.” However, as business grew, the DaceCrown team soon realised that the tooling on their HAAS machines was still potentially holding them back from reaching their true potential. To help align the company's tooling with its growth ambitions, DaceCrown turned to MSC Industrial Supply Co. UK. MSC application engineers visited DaceCrown over several weeks to immerse themselves in the business and gain firsthand experience of the tooling challenges facing Tom and his team. The trials coincided with the testing stage of MSC's newly launched MSC EDGE range of multipurpose solid carbide holemaking and milling tools. In turn, DaceCrown served as a vital field test site, providing important performance data to MSC throughout the testing process. During the trial, a variety of materials and toolpaths were tested. Following its completion, DaceCrown was supplied with a set of 4, 8, and 12mm MSC EDGE endmills, which have enabled the team to handle a wide range of materials and applications without having to change tooling regularly. “It was an instant game changer. We went from a 1 minute 50 second cycle time down to 10 seconds. It was a case of plug and play; put the tool in, set the speeds and feeds, and press go. We've used them on stainless steel, mild steel, structural steel, and aluminium. We can do pocket milling, milling into holes that were drilled too small, and we've also done some profiling work,” Tom adds. “The best thing is, we can keep them in the tool magazine, which reduces our set-up times. And, even though we are running at higher speeds and feeds, we've found the MSC EDGE tooling to be very durable, so we don't have to replace it as often as we used to with our previous supplier. This means we can not only complete jobs faster and turn around work for our customers quicker but also keep our own tooling costs down.” “We've always strived to deliver the best possible quality for our customers. The parts we supply touch the end product last, so if we make a mistake, then the whole line can go down. Quality is everything for us and our customers; therefore, if it's not right, it's not leaving our facility,” Tom concludes, reassuring the audience about the company's commitment to quality.
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.
© 2020-2025 Ivy Podcast Discovery LLC
