This is the audio version of the MTD magazine which is a magazine focused on metal cutting and manufacturing technologies.
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.
Edging closer to its 50th anniversary, the Progressive Technology Group has enjoyed a meteoric rise over the last decade. Founded in 1977, the relocation to larger premises in 2013 was one of the many catalysts for the Newbury company's decade-long growth. Opening multiple new divisions and branching into new markets, the company now employs more than 250 staff. Among its accolades are many prestigious awards from AMG Petronas and Rolls-Royce, to name a few. However, this pedigree cannot be bought; it is embedded in the company's culture, with Progressive Technology opening its Apprentice Academy in 2015. In this bedrock for developing the talent of tomorrow, Tooling Intelligence Ltd has just donated a SmartDrawer® vending solution. The impressive Apprentice Academy at Progressive Technology enlisted 18 apprentices as part of its 2024 cohort, and this production line of talent nurturing has contributed significantly to the business's ongoing success. Aiming to mirror the high-tech manufacturing facilities, the Apprentice Academy has a complete range of technologies, from simple two and 3-axis manual machines to high-end 3 to 5-axis multi-functional machine tools. Three full-time trainers and a classroom with PCs support academic and computer-based training. Part of this progression from apprentice to a skilled engineer in an advanced manufacturing facility includes using high-end cutting tools and the associated inventory management systems. With technical partner Industrial Tooling Corporation (ITC), Tooling Intelligence installed its first vending solution at the ISO:9001 and AS:9100 subcontract outfit in 2014. The success of this first SmartDrawer® system led to a second installation in 2016 and a third in September 2024. The versatile SmartDrawer® system from Tooling Intelligence is a drawer system that is completely configurable to the end user's requirements. Using smart technology, the SmartDrawer® can dispense single or multiple items with reliable, accurate, and monitored inventory control, giving the end user complete visibility and control of its supply chain. The benefits of the SmartDrawer® were evident at Progressive Technology, and this is why the company rapidly adopted additional systems when shop floor inventory management required them. The SmartDrawer®, which comprises individually locked compartments controlled by a user-friendly touchscreen interface, provides ‘self-serve' access to consumables, equipment, and cutting tools. This has enabled Progressive Technology to manage, monitor, and control its cutting tool consumption with greater visibility while automatically re-ordering stock to ensure the right tool is always available. With a complete audit trail, the SmartDrawer® provides visibility regarding which employee uses which specific item and where and when it is used. With apprentices destined to enter the advanced production facilities in the future, understanding the inventory management process at the West Berkshire company is essential. This is why Tooling Intelligence has made such a generous contribution. The December 2024 arrival of the SmartDrawer® in the Apprentice Academy was installation number four, with the fifth SmartDrawer® being installed simultaneously on the shop floor of the 24/7 manufacturing site. As part of Tooling Intelligence's donation, ITC has supported the installation with a selection of regularly used cutting tools for the Apprentice Academy. Included are a complete selection of solid carbide and indexable milling and turning tools. The apprentices now have access to the consumables they require as and when they need them from a single source system. Commenting upon the installation, Tooling Intelligence's Managing Director, Richard Swaffield, says: “We are delighted to support such a valuable customer in their growth journey over the last 10 years. An industry-leading subcontract manufacturer's repeat business for over a decade is a testament to how our SmartDrawer® system delivers an inventory management system that is bespoke to the demands of each customer. Since investing in its first SmartDrawer®, Progressive Technology has witnessed cost savings, improved inventory management and control, and complete visibility over what products are used and when. This level of insight is essential for the future of any modern manufacturing business. This is why we have donated a SmartDrawer® to the Apprentice Academy at Progressive – the talent of tomorrow needs a complete understanding of the benefits of effective inventory management as well as the implications of not managing your supply chain.”
The Brough Superior, a classic British motorcycle designed by George Brough in 1919 and manufactured in Nottingham, was of such high quality that it was dubbed the Rolls-Royce of motorcycles. One famous customer, T.E. Lawrence (Lawrence of Arabia), owned eight and died in 1935 from injuries sustained when he crashed number seven. The design was beautiful and practical, and a sidecar was often added. Although the factory closed after the Second World War, enthusiasts have ensured the name survives. In 2004, around 1,000 original Brough Superior motorcycles still existed. The brand is regularly seen in period movies and television series, as well as in classic bike shows, hill climbs, and motor races. In 2014 the Brough Superior brand was purchased by a Jersey-registered corporation, which engaged Thierry Henriette to create a Brough Superior factory in St Jean, Southern France, near the aerospace capital of Toulouse. The factory produces luxury motorcycles at the pinnacle of exclusivity and distinction. Although production is in France, the British design spirit has been maintained through a joint venture with Aston Martin to create the AMB 001 Pro, a limited-edition, high-performance motorcycle. To support the R&D process, bringing in-house the manufacture of some complex prismatic components was necessary. A Hurco VMX42SRTi 5-axis VMC was chosen due to its ability to achieve the accuracy and surface finish required. It can also accept 3D models directly into the proprietary WinMax control, renowned for its suitability for high-mix, low-volume production. Additionally, and most importantly, it enabled the manufacturer to go even further in customising motorcycles for its discerning clientele, offering different machining finishes and engraving possibilities and assuring the impeccable quality of parts. The VMC also supports CNC machining of a new, dual-cylinder, 997cc engine for the AMB 001 Pro, a high-performance, turbocharged, track-only motorcycle born from a collaboration between Aston Martin and Brough Superior. It draws inspiration from Aston Martin's Valkyrie AMR Pro hypercar, which has a power-to-weight ratio comparable to a Formula One car. Manufactured from solid aluminium billet, the engine is lighter, stiffer and more powerful than in previous Brough Superior bikes. In addition to powering the AMB 001 Pro, it has been engineered to fit perfectly into contemporary versions of the classic Lawrence and Dagger motorcycles. Most metal removal and finishing are completed in a single set-up on the Hurco VMX42SRTi.
Difficult-to-cut materials are defined as engineering materials with significantly lower machinability than typical. These materials are often referred to in shoptalk as ‘hard-to-machine,' ‘tough-to-cut,' or even ‘nasty.' It is important to note that high hardness is not the only characteristic that makes these materials challenging to machine; several other factors contribute to their machining difficulties. Every industrial branch, in one way or another, must deal with such materials. However, the leading consumer of these materials is the aerospace industry. It is in this sector—whether in the production of turbine engines, landing gear components, or primary airframe elements—that difficult-to-cut materials have found their most significant application. In the aerospace industry, the key characteristics of required materials are strength-to-weight ratio, robustness, fatigue life, and resistance to corrosion and hot temperatures. It turns out that materials meeting these characteristics are difficult to machine, posing a serious challenge for production. When speaking about such materials, the following information should be considered: l High-alloy high-strength steel, l Titanium alloys, l Hot temperature superalloys, l Composites. High-strength steels are used in elements subjected to extreme mechanical load, such as landing gear. They are also the primary material for various fasteners. Titanium alloys, with their excellent strength-to-density ratio, high corrosion-proof, and creep resistance, have become the preferred material for producing the main parts of a jet engine's cold section. These alloys also provide a suitable alternative to steel and stainless steel for weight savings. Hot-temperature superalloys (HTSA), which can maintain their strength in high-temperature environments, are common in the components of a jet engine's hot section. Composites offer impressive specific strength, helping to decrease an aircraft's weight and opening new prospects for aerodynamic fairing. In military aviation, composites contribute to improved aircraft's stealth characteristics. However, machining these materials presents numerous challenges for several reasons. The main challenges are as follows: l High material strength results in significant cutting forces that increase the mechanical load on the cutting tool. l Intensive heat generation and low thermal conductivity of the material (for example, when machining titanium alloys) cause poor heat transfer. This leads to a growing thermal load on the tool and increases the risk of build-up on a cutting edge. l Work hardening of materials (specifically HTSA) increases the strength and hardness of the workpiece surface during cutting, making machining difficult. l The high abrasion factor (when machining composites) intensifies the galling of the tool's active area. Additionally, other specific material features affect machinability. For example, the ‘springiness' of titanium alloys contributes to vibration, worsening machining accuracy and surface finish. The inner structure of composites is associated with material delamination during machining. All the mentioned aspects accelerate tool wear and diminish tool life. The trends in the aerospace industry distinctly point to the increased usage of difficult-to-cut materials. This is manifested by introducing new alloys with higher strength and heat-resistance characteristics, the broad application of composites, and the utilisation of hybrid-structure (metal-composite) materials. To meet these challenges, the metalworking industry introduces new cutting strategies based on the impressive capabilities of modern CNC machines and CAM systems. However, the cutting tool is the final link in the entire machining chain, which directly contacts the material and removes its layer during operation. This link is the most ‘conservative' part of the chain, and its development is slow, often hindering the full utilisation of advanced machines' capabilities. To overcome the existing difficulties, it is necessary to reduce machining data, which leads to low productivity and increased machining costs. Understandably, every step forward, even a small one, in the tool field can significantly improve machining ‘nasty' materials. Therefore, the metalworking industry welcomes the latest advances in cutting tools, hoping they will radically change the situation. What are the main requirements for tools intended for efficient machining of tough-to-cut aerospace materials? In brief, they need to be hard, durable, and precise to enable productive machining while ensuring predictable and stable prolonged tool life and the required accuracy level. However, meeting these understandable and reasonable demands requires significant efforts, and even small progress in this direction faces challenges. Every new advance involves serious R&D work and extensive testing. Hence, tool development focuses on the following areas: Cutting material grades. Tool design. A tool's digital component. The emphasis in cutting materials is on improving hardness, wear resistance, and high-temperature strength. This is achieved by introducing new coatings, particularly those based on nanotechnology, and expanding the use of extra-hard cutting materials like cubic boron nitride (CBN) and ceramics. In tool design, enhancements optimise macro and micro-geometries, such as the cutting edge design and cutting edge preparation, to improve cutting capabilities. Computer modelling, combined with computational dynamics and the impressive possibilities of additive manufacturing (AM), provides new opportunities for shaping flutes, chip gullets, and internal coolant channels. This contributes to better chip evacuation and coolant supply, improving tool performance. A key area is increasing the vibration resistance of the tool through advanced cutting geometry, enhancing the rigidity of the tool structure, and using vibration-damping toolholders. The tool's digital component includes the digital twin and various software products, which allow for virtual assembly, machining simulation, cutting data selection, tool life estimation, and necessary calculations such as machining power and cutting forces. ISCAR expects that this component will be compatible with data exchange standards to meet the requirements of Smart manufacturing. The noted trends are evident in the new developments from ISCAR, one of the leaders in tool manufacturing, presented within the framework of the latest LOGIQUICK campaign. The company has introduced two new carbide grades with PVD coating: IC1017, which ISCAR created for turning Ni-based HTSA, and IC716, which is intended for high-performance indexable milling titanium alloys. The range of chatter-dampening solid carbide endmills has been expanded with contemporary designs made from the bronze-coloured IC608 carbide grade, which is the first choice for the ISO S group of applications (cutting superalloys and titanium). Another carbide grade, IC5600, has been developed by ISCAR's prolific R&D Materials Sciences engineers for milling steel (ISO P group). The combination of the grade's submicron substrate, CVD coating, and post-coating treatment aims to enhance resistance to abrasive wear and thermal loading, increasing cutting speed, particularly when machining high-strength steel. CERAMILL, a new family of endmills with indexable single-sided round inserts (Fig. 1), is interesting from two points of view. First, the family utilises an ingenious mechanism for high-rigidity insert clamping. This mechanism allows for an increased number of teeth compared to a typical design of similar tools in the same diameter. Additionally, it enables simple indexing and insert replacement without removing the endmill from the toolholder. Second, the inserts are produced from ceramic grades specially engineered for machining HTSA. ISCAR has expanded its range of anti-vibration products based on the innovative built-in damping mechanism, which features a heavy mass supported by a rubber spring element containing oil for enhanced dampening. The turning line now includes vibration-absorbing boring bars for machining depths of 12 and 14 times the shank diameter (Fig. 2). Additionally, the milling line has incorporated anti-vibration shanks with MULTI-MASTER adaptation. The QUICK-X-FLUTE is a family of extended flute shell mills developed to achieve high metal removal rates (MRR) in rough milling of challenging materials such as HTSA and titanium (ISO S), austenitic and duplex stainless steel (ISO M), and steel (ISO P). These ‘porcupines' utilise cost-effective, double-sided square inserts with 8 indexable cutting edges. A key aspect of the mill design is the optimised flute geometry (Fig. 3), which balances mill rigidity and the necessity for adequate chip flow when cutting at high MRR. The QUICK-X-FLUTE mills also feature an inner coolant supply option. Using high-pressure pinpointed coolant with replaceable nozzles and face frontal outlets ensures a direct supply of coolant to the cutting zone. This enhances the cooling and lubrication action, contributing to optimal chip control. Effective coolant supply has become a primary emphasis in contemporary tool designs. In the PICCO line of miniature turning tools, ISCAR has introduced new inserts with internal coolant channels (Fig. 4). In hole making; the company has unveiled new 3-flute solid carbide drills for machining flat-bottom holes featuring three coolant outlets. The latest additions to tool holding include holders with coolant channels along the shank bore. Additionally, in ISCAR's classical HELIMILL indexable milling family, the company's R&D engineers have upgraded the design to maximise flow rate with minimal pressure drop using computerised fluid dynamic (CFD) software. Improvements have also been made to NEOITA, an integral part of the company's digital tool component. NEOITA, an expert system that recommends optimal tooling solutions and forecasts tool life for a specific application, now includes new features. One of these is the AI-powered information search, specifically designed to retrieve detailed data on workpiece materials, including their metallurgical composition and typical uses. Enhanced performance in machining difficult-to-cut aerospace materials is a complex challenge. Tool manufacturers continually strive to provide more advanced and productive solutions to address this. While no radical breakthroughs have been observed, recent developments indicate steady evolutionary progress in this area.
Building on the success of their award-winning 3D-printed stator bore tool for electric vehicle machining, Kennametal has developed an innovative 3D-printed transmission housing tool for Voith that cuts weight by approximately 45% and reduces machining time by approximately 50%. As transportation components become increasingly more sophisticated and the requirements more stringent, manufacturers need complex tooling solutions to machine those components. That poses a challenge as the weight of such tooling can become too heavy for efficient operation on machining centres, tool changers and tool magazines. Machine operators may also have difficulty managing the tool. A recent collaboration by Kennametal, an industrial technology leader, and Voith, a leading supplier of drive technologies, shows how 3D printing offers a pathway to novel, lighter-weight tooling solutions that overcome these challenges while improving productivity and efficiency. The Challenge: Machine multiple, tight tolerance, large diameter bores with existing machining centres Voith wanted an innovative solution to optimise its machining processes for transmission housings further. To achieve the required tolerances, the company needed a multi-stage tool capable of machining multiple bores in one operation. The tool also needed to have two effective cutting edges on the main diameters to achieve the specified cycle time. Finally, the tool had to weigh less than 12kg to meet the requirements for tool changing and tilting moment on the toolchain. “Finish machining a large aluminium housing with multiple bores up to 350mm and IT7 tolerance grade is a demanding application,” said Werner Penkert, Manager of Product Engineering. “To machine these large bores with such tight tolerances, we need very rigid tools, which typically means they are heavy weight. When manufactured using conventional methods, a typical tooling solution for this type of application could weigh as much as 25kg, which is too heavy for the existing machines or for an operator working with the tool.” Intrigued by how Kennametal leveraged 3D printing to produce a lighter-weight stator bore tool for electric vehicle machining, the Voith team turned to the industrial technology leader to collaborate on a solution. “Kennametal's innovative approach with 3D printing excited and inspired us to take this path together,” says Friedrich Oberländer, Director of Production Technology at Voith. The solution As with the stator bore tool, Kennametal leveraged its expertise in metal additive manufacturing—plus the concept of generative design to meet the demanding requirements of Voith's transmission tool. With conventional subtractive manufacturing, weight is reduced by removing excess material. However, with 3D printing, manufacturers can start with nothing and put material only where it is needed, resulting in lighter-weight, more complex geometries not possible via conventional manufacturing processes. To fully leverage additive manufacturing's design freedom, Kennametal used generative design, an iterative process that optimises the design of 3D-printed parts to meet an application-specific set of constraints. The generative design process often results in complex, organic shapes reminiscent of natural structures. In the case of the Voith tool, generative design directly addressed machining forces on the tool, enabling Kennametal to design a solution optimised for stability, stiffness, balancing and coolant supply—with a weight of just 11.5kg. Kennametal applied its expertise in additive manufacturing and machining to produce the tool. The tool pockets are precision machined and designed to be used in combination with Kennametal's proven RIQ inserts technology. “Additive is one tool in our toolbox, but we also applied our deep expertise in precision machining to develop a novel solution that efficiently addresses the challenges of boring deep holes in conjunction with multiple large diameters,” Penkert. The design of Kennametal's 3D-printed transmission housing tool mimics the organic shapes found in nature, delivering reduced weight and a 50% reduction in machining time for the customer, Voith. The Results: 50% reduction in machining time Working in close collaboration with Voith, Kennametal manufactured a prototype tool and put it to the test in its demonstration centre in Fürth, Germany—part of a global network of test and demonstration centres where the company works with customers to design, iterate and validate machining solutions. This solution was particularly challenging in achieving both manufacturing and part quality requirements. Design simulation, additive manufacturing, and practical tests in the demonstration centre allowed the team to validate the machining results. Voith then conducted the first tests on-site, followed by longer-term tests for series production. Further customer requirements were implemented, and the tool was jointly perfected and finalised. “The Kennametal tool delivered outstanding quality and performance from the first use, achieving a 50% reduction in machining time while still meeting accuracy and surface finish requirements. Additionally, the reduced weight limits the load on the magazine, tool changer and spindle—effectively reducing maintenance costs,” said Oberländer. “Our collaboration with Kennametal clearly shows the enormous innovation potential of additive manufacturing when applied in such a cooperative partnership.” Kennametal Additive Manufacturing (AM) offers a game-changing solution by utilising high-performance materials and parts that are produced faster and with the design flexibility of 3D printing. Kennametal brings nearly a century of materials and manufacturing expertise to every layer of the AM process—from raw material to finished part. This helps customers unlock the full value of 3D pr
The electrification transition and inflexible EV production quotas are taking a heavy toll on the automotive industry, but buses and commercial vehicles posted their best years since 2008. Will Stirling reports. MTD magazine is unwaveringly positive in its coverage of manufacturing news, but facts are facts: automotive manufacturing is on a downward slide. Combining cars and commercial vehicles (CVs), the UK produced 905,233 units in 2024, -11.8% from 2023, and slipping below the psychologically important one million units mark. Electric vehicles now comprise over one-fifth of all new car registrations, but the EV market contracted by 2.5% to 139,345 units. The bright spots are in the commercial vehicle (CV) and bus markets. Production in the UK rose 4% to 125,649 units, and both buses and CVs have had their best years since 2008. Carmakers face a multitude of challenges to produce both ICE (combustion engine) and EV cars in high volume. Higher energy and material costs, shortage of skilled people and potential tariffs on exports to the US, but the two most significant factors affecting the production of cars are the costly transition to electric and globally softer demand. The government has set onerous targets for the proportion of EVs that car companies make in Britain, from 22% last year to 28% this year – a tall order that experts believe won't happen – and 80% by 2030, after which the ICE car ban kicks in. The problem is that these targets are running ahead of demand. “The targets were set when demand forecasts were much higher; we know there'll be a significant shortfall,” says Professor David Bailey, an automotive business expert at the University of Birmingham. “Car firms are going to struggle to shift that volume of cars without very significant discounting, and therefore losses.” He adds: “Our two biggest producers, Nissan and Jaguar Land Rover, will struggle to meet that kind of stretched targets as they get bigger, so they will potentially be fined, and they may well have to buy credits from Chinese all-EV makers who can hit the target. So what a perverse policy that is – that you're subsidising the Chinese and fining domestic manufacturers.” Electric vehicle production and net zero targets have not been intelligently assessed. The government intends to phase out new petrol and diesel cars by 2030, and although the car industry was invited to consult on this in December 2024, many think the target is too early to hit. “The 2030 ban on ICE policy was plucked out of thin air to try to differentiate the UK from the European Union while signalling to investors that the UK is serious about decarbonisation to encourage investment in the UK. But it hasn't worked – because Brexit has made the UK less competitive and attractive, because of high energy costs, and it hasn't worked because we don't have a proper industrial strategy to support that transition,” David says. The government is now consulting on the industrial strategy, but it should have been firmly embedded in 2025 to help hit the 2030 ICE ban effectively. Stimulate demand; cost of electrification bites Demand for electric vehicles needs to be higher. The government has proposed cheap loans for EVs, but it sounds too complicated for the average car buyer, who wants to know the price, not a complex subsidy and loan. And a VAT break on EVs has been proposed, although this is a pro-tax government. “The government's problem is that it has boxed itself in agreeing to continue the fiscal rules that the Conservatives put in place, which I think was a bad mistake all along, and that has limited their room for manoeuvre. The industry wants a fiscal incentive for EVs, which could either be an upfront discount if you buy one or a VAT reduction on purchases and charging, to stimulate demand,” Bailey says. Demand for vehicles aside, car production volumes are also lower because factories spend millions of pounds and months retooling their lines for EV manufacture, affecting their ability to produce. Internalisation of component manufacturing Some tier one and smaller suppliers to UK automotive have gone, due partly to the complications and costs of Brexit. GKN Automotive moved its Birmingham factory capacity to Poland in 2021/2022. A lot of smaller companies have been cut out of European supply chains post-Brexit, and several auto suppliers have struggled or gone out of business, unable to cope with the export and reimport bureaucracy when some components may cross the English Channel several times before being assembled here. In addition, several big carmakers are internalising the manufacture of key components as these companies aim to be more vertically integrated. “Partly, this is in reaction to the semiconductor crisis where firms were caught out,” says David Bailey. “For example, Jaguar Land Rover will be making its new electric drive train in-house, probably at the i54 plant. Previously, for internal combustion engine cars, JLR would have bought the drives from GKN Driveline, but it is internalising it. We are seeing that shift broadly as well.” A good example is Nissan's partnership with battery company AESC, which supplies directly to Sunderland. This year, Nissan is expected to open a new 360m long, 23x football pitch-sized battery gigafactory in Sunderland. When operational, it will employ over 1,000 people and deliver a sixfold increase in UK electric vehicle battery production. The plant is basically an extension of Nissan's car factory, a tier-one supplier part-owned by Nissan right next door. Pay attention, subbies: Bus bonanza Deliveries of new buses, coaches and minibuses reached a 16-year high in 2024, with 8,390 new units hitting the UK's roads (total buses produced were higher due to healthy exports). Demand rose across the three main segments: minibuses, single-deckers and double-deckers, with minibuses posting 102.5% year-on-year growth. Zero emission is the main story in buses, and the UK is still Europe's biggest zero-emission bus market, with deliveries up by more than a third in 2024. As of 2023, Ballymena-based bus manufacturer Wrightbus reported a turnover of £283.4m, a significant 71% increase from £163.3m in 2022. Despite this, profits in 2023 were negative, probably reflecting the big investment in transitioning to net zero powertrains and new tooling. Wrightbus exemplifies the switch to zero emissions. “Alongside our market-leading EV bus, 95% of all buses produced by Wrightbus in Ballymena are now zero emissions – a marked change on 2019, when 95% of all orders were for diesels,” said Jean-Marc Gales, CEO of Wrightbus, when unveiling the new Streetdeck Hydroliner Gen 2.0 hydrogen-powered bus on 20 February. Wrightbus says production will increase to 1,200 this year and then again to 1,400 in 2026 – a record in the company's proud history of bus manufacture. Dozens of suppliers from across the UK and Europe visited the Wrightbus factory in February to hear how the firm's continued growth will act as a shot in the arm for the manufacturing sector, with the expected creation of up to 1,000 new supply chain jobs in the next two years. When will car making recover? Industry body The Society of Motor Manufacturers and Traders forecasts vehicle production to fall further in 2025 (cars and light vans to 839,000 units in 2025). Still, it adds that while the EV transition is affecting production, this will be temporary. While the volumes of all electrified technology cars were down 20.4% in 2023, with more than £20 billion worth of investment announced in 2023 and a further £3.5 billion in 2024 to support the UK's transition, the decline will be temporary; the SMMT stated in February. Car and light van output will increase to circa 930,000 units by 2027, it says. However, potential tariffs from the US are a real threat (second biggest UK car export market), and the lingering cost of living crisis affects EV sales. “Charging at home overnight is cheap but can be 10 times the cost at some public charging points. Plus there is 20 percent VAT at a charging point, but just five percent at home – so the one third of people who have no ability to charge at home will struggle with the transition,” says David Bailey. And while the Dept for Transport has said it is on track to install the target 300,000 charging points by 2030, many people have range and charging speed anxiety, so much more PR is needed to persuade a cash-strapped, conservative public to go electric.
Opening its doors with just four toolmakers 50 years ago, Smithstown Light Engineering Ltd is now a business with three manufacturing sites and over 165 employees. Working with the world's leading medical device and orthopaedic companies, Smithstown extensively uses OPEN MIND Technologies‘ hyperMILL CAD/CAM suite to streamline its throughput and maximise efficiency. Initially a toolmaking business supplying plastic injection moulds to the electronics industry, the Shannon-based business transitioned to medical manufacturing in 1990—and it hasn't looked back since. With two sites in Shannon spanning 80,000sq/ft and a third 15,000sq/ft facility in Poland, 75% of the company's technology is less than 5 years old. Certified to ISO: 9001, ISO:13485 and ISO:14001, Smithstown has a bank of Citizen sliding head turning centres, in-house heat treatment, Rollomatic, Jung and Jones & Shipman grinding centres, DMG MORI and Mikron machining centres, Trumpf 3D additive manufacturing and Makino EDM technology. Working with renowned clients such as Stryker, Boston Scientific, Zimmer Biomet, and Cook Medical, to name a few, the company provides a turnkey service from concept and design through prototyping, machining, and validation of medical components and orthopaedic implants. With over 14 million components manufactured annually, the Irish manufacturer adopts stringent quality measures that are a necessity for ultra-precision medical device parts used in life-saving surgery. Alluding to his role within the company and a background in Smithstown Engineering, Gerard Henn from Smithstown Light Engineering says: “I've been here now nearly three years in the role of CEO, and I support the principal director of the business in the running of the operation. Smithtown started in 1974, so we are now 50 years in existence. Our principal area of expertise is precision machining to impeccable quality levels with customer service. We really pride ourselves in supporting the customer in all their difficulties and all their successes.” Manufacturing high precision parts to stringent standards, Gerard alludes to why the County Clare company opted for hyperMILL from OPEN MIND Technologies: “There are so many different options in the marketplace, but OPEN MIND made it much easier for us to work forward with hyperMILL. The explanation of the facets, the features, and how we could optimise our machining strategies and cutting paths – it has everything. That worked in our favour. The relationship with OPEN MIND and its hyperMILL system came together and created a partnership with us.” When Gerard joined the company, one of his aims was to upskill the staff, which was a critical necessity considering the shortage of skilled engineers. Alluding to this, Gerard adds: “OPEN MIND were very enthusiastic and got behind us. They understood what we were trying to achieve, and it's been a positive relationship all the way through. We'd recommend OPEN MIND to any companies out there who are interested in upskilling their internal workforce – the partnership has been extremely positive.“ Looking closer at the types of work the company is involved in, Gerard continues: “We operate in the medical space, and we support the orthopaedic and medical device companies in Ireland and also globally. We also do instrumentation for procedures, so it's very much a medical-focused enterprise.” Occupying a large floor area and two facilities, the company is continually evolving. Gerard adds: “So, we have over 200 employees and two sites here in Shannon. The second site is just literally 1 kilometre down the road, so you find us trekking up and down quite a bit, but you see the same technologies and approach in both buildings. We have a third facility in Rzeszów, Poland, a business that's been operating for 3 to 4 years. We also recently announced a major expansion there.“ “What we find in any process development is you're going through an iterative process. You're optimising the machining and cutting process, checking dimensions back to the machine to the virtual CAD station, and bringing all that together. So, I think the fact that OPEN MIND has supported us so much means we have a great understanding of hyperMILL. The upskilling is well in parallel and enables us to bring all the strands together to succeed. By success, I mean that we can deliver parts to specification earlier. That is because that's what everyone wants. Customers want parts in their hands, and having that collaboration of everyone allows us to achieve that.”
Michael Phillips, joint owner with partner Wayne Robins of contract machining firm Atomic Precision, describes their recently purchased, Japanese-built Brother Speedio U500Xd1 as ‘a Swiss army knife of 5-axis machining centres.' His comment is due to the 30-taper machine's high quality, versatile functionality, compactness, and ability to complete an extensive range of jobs quickly and efficiently. Brother machines are sold and serviced in the UK and Ireland by Whitehouse Machine Tools, Kenilworth. Founded in East Hendred, Oxfordshire, in 2020 by the two time-served mechanical engineering apprentices, who both previously worked in the machine shop at nearby Rutherford Appleton Laboratory's space development facility, Atomic Precision specialises unsurprisingly in manufacturing components and assemblies for the space and scientific research sectors. Over the next four years, a succession of 40-taper VMCs from another supplier arrived on the shop floor: three 3-axis models and two 5-axis machines. During that time, the subcontractor enjoyed an impressive growth rate of 50% yearly. It was clear to the two partners, who work alone that the ongoing rate of growth was unsustainable without progression on the shop floor to more efficient machine tools and perhaps also automation to gain substantial periods of unattended production. They operate a single-day shift, and working longer hours is not part of their game plan. As a first step to raising productivity, Whitehouse Machine Tools installed and commissioned the high-speed Brother U500Xd1 in September 2024. The partners learned of the machine at the Southern Manufacturing exhibition in Farnborough in early 2023. The order was placed after early hesitation regarding the smaller spindle interface, which later proved to be a non-issue and benchmarking a couple of other 30-taper machines on the market. Mr Phillips commented: “The area taken up on our shop floor by the U500Xd1 is half of the space that one of our 40-taper 5-axis machines occupies, yet the 30-taper VMC produces larger parts. Not only that, but the Speedio finishes an identical component in two-thirds of the time, as the non-cutting elements of cycles are incredibly short, so tools are in-cut for typically 90% of the time during a cycle.” “The linear axes accelerate at 2.2 g up to 56m/min, and chip-to-chip time is 1.3 seconds. Rotary positioning by the trunnion and table is similarly fast, and parts come off complete, resulting in rapid floor-to-floor times.” The machine installed in East Hendred is a well-specified version of the Speedio model, with a 16,000rpm 15kW spindle, 28-position tool turret, high-pressure coolant, and Blum tool and part probing. Axis strokes are 500 by 400 by 300mm, but multi-face machining of components up to 500mm in diameter by 270mm high and weighing up to 100kg is possible owing to the layout of the machining area. As well as producing parts up to the maximum working envelope, the Speedio also machines tiny components requiring complex features cut with a 0.2 mm diameter end mill, hence the decision to opt for the highest speed spindle Brother offers. Towers are extensively used for fixturing multiple smaller parts to extend the walk-away time from the machine if individual cycle times are short. Batch size is usually up to 10-off, although often single prototypes are machined. However, in November 2024, Atomic Precision received a huge order from a new customer for 400-off aluminium brackets requiring a 3+2 machining strategy, using the rotary axes to position the part. The subcontractor could not have accepted the contract if it had been unable to use the elevated speed of the Brother machine. A 5-axis, 40-taper VMC would have been too slow to meet the three-week lead time, so the subcontractor would have had to turn down the work. If more jobs involving quantities of several hundred starts coming in, automating the Brother and other VMCs on-site will go ahead imminently. The factory processes various materials, including aluminium, stainless steel, brass, copper, tungsten, and tantalum. Mr Phillips advises that it is possible to hold ± 10 micron dimensional tolerance ‘comfortably' on the Speedio, even without climate control in the factory.
Engines were already being built at the site in Zafra in 1875, where DEUTZ today has its main factory for processing engine components. Around 500 employees in modern manufacturing facilities produce engine blocks, cylinder blocks, connecting rods, and gears for the Group's assembly lines in Cologne and Ulm. DEUTZ's new 3.9-litre diesel engine is mostly used in agricultural and construction machines. It is designed for long service life as an industrial engine and will be built until at least 2035. Series production will start in the coming year after the current prototype phase. Available in a power range from 55 to 160kW, this engine represents an important future project for Deutz with 50,000 units to be produced per year. It is the same size as its 3.6-litre predecessor, so it can be installed in the same vehicles, providing very efficient performance. “Our engines are typically deployed in off-highway applications like agricultural and construction machines, which are in constant use and move heavy loads. We'll continue to need an internal combustion engine to move those machines. For now, it will be in the form we use today: the diesel engine. Synthetic fuels or hydrogen can considerably prolong their deployment,” explains Alejandro Castilla De La Hoya, Zafra Plant Manager. He points out that the income from this area finances DEUTZ's investments in the green segment, which is dedicated to the transformation of mobility. The 3.9-litre diesel engine is already set to run on gas or hydrogen in the future. “Based on today's design, this diesel engine can become a green engine in the long run,” says Manuel Rodríguez López, Industrialisation Manager. This is possible thanks to small modifications, particularly to the cylinder head. However, the engine remains mostly the same. MAPAL is already collaborating on DEUTZ's first hydrogen engine – a huge 7.8 litres. Two weeks from design freeze to offer “Our clients' development periods for new parts are becoming shorter and shorter,” explains Thomas Spang, Global Head of Tool Management at MAPAL. This represents a growing challenge for tool manufacturers or complete suppliers like MAPAL. This is true if plans change at the last minute while the deadline for the tool design remains the same. For the engine block of the new 3.9-litre diesel engine, MAPAL only had two weeks after the design freeze to complete a final offer. An ardent team of experts in Aalen completed this ambitious task on time. Well-tuned workflows and many years of experience with the client's production methods proved advantageous for the team. MAPAL has been conducting tool management for DEUTZ in Spain for 18 years and several projects have been completed together over the years. MAPAL already engineered the machining of the engine blocks for the predecessor 3.6-litre diesel engine, which meant they could draw on practical experience and didn't have to start from scratch. For example, the tool experts already knew which machines the engine manufacturer had from previous projects. DEUTZ has equipped its assembly line in Zafra with new 5-axis machines over recent years so that they can easily switch to new products. When DEUTZ sent their request, the Tool Management department, in collaboration with the Technology Expert Team (TET) in Aalen, first gave some thought to the production process. “To be quick here, we don't concern ourselves with detail at this early stage, but instead pull together reference tools and concepts from previously completed projects,” explains Harald Traub from TET. As a project engineer, he is responsible for planning the entire process. “In this way, we can specify an approximate budget and the rough scope of the tool package for the client.” One hundred different tools for an engine block After this rough planning, the concrete tool design followed in the second week. In the end, MAPAL's offer for the series production of the motor block included almost 100 different tools. Many custom tools achieve short machining times and, thus, high economic efficiency. Aside from these, standard tools are used mainly for milling. A few close-to-standard tools were also used to produce prototypes quickly. Series production can then begin with the optimal set of tools. As part of their original delivery, MAPAL supplied consumable tools as well as the required tool holders and adapters to DEUTZ. All other consumables will be handled by the tool management on-site. From now on, the client no longer pays per tool but per completed part—i.e., the cost per part is billed. The unit costs at first correspond to the price determined during engineering. Certain ratios have been agreed upon for the following years. The client receives an increasing rebate percentage and pays a bit less per unit every year. For this business model to work out, MAPAL has to implement continual improvements to save costs. This is done with new tool technologies and corresponding optimisation. The costs per part are fixed over the contract term, after which a reassessment occurs. Such contracts run over four to five years and offer the client planning security. “With our engineering expertise, we support DEUTZ beyond the tool-setting area and cultivate a close partnership,” Spang highlights. After helping to build the prototype, it is the tool management's turn to shine on-site during series production. DEUTZ uses approximately 1,300 different tools in total. Thousands of tools are available from stock and must be managed in Zafra. To keep inventory optimal, MAPAL uses its warehouse management systems and digital solutions with the cloud-based software c-Com for tool management. The Digital Tool Management 4.0 doesn't only handle procurement processes, which are initiated semi-automatically; it also acts as a reporting tool to analyse cost drivers and stocks. Industrialisation Manager Manuel Rodríguez López praises the good collaboration with MAPAL regarding tool management: “Over the course of our cooperation, we have developed extensive technological concepts, which go far beyond mere logistics. Besides achieving cost reductions, tool setting is particularly important for us. The MAPAL employees working on-site have much know-how and ensure that production has exactly the tool they need at the right time.” MAPAL's tool manager on site is David Castaño. MAPAL also employs tool setters permanently in Zafra. They make sure that a dozen different parts are produced without a hitch. “It is very beneficial to have David here on-site with us,” emphasises Manuel Padilla Fernández, Manufacturing Engineering Manager at DEUTZ. “We can talk about any opportunities for optimisation directly at the machine. We don't consider David Castaño an external service provider but a part of our team. It's a very strong cooperation.” Developing together to solve problems If required, new tool solutions can be developed in Aalen via the local MAPAL team. That was the case in Zafra when it became necessary to optimise the tools for machining the bore in the crankshaft and camshaft. A new machining concept from MAPAL with the HPR400 reamer was implemented in cooperation with DEUTZ. David Castaño is convinced of its advantages: “The tool life of the previous tool was 350 units, and resetting was required every 100 units. With the HPR400, we achieve a tool life of 1,000 parts without resetting. The resulting machining quality is exceptionally go
Mills CNC has recently supplied Ayrshire Precision, a subcontract specialist based in Ayrshire, with two new SYNERGi systems. The systems, both derivations and highly customised versions of Mills' standard SYNERGi ‘SPRINT' solutions, were installed at Ayrshire Precision's 14,000sq/ft site. In 2023, the first system was retrofitted to a Puma 2600SY lathe, and six months later, the second was retrofitted to a Puma 2100SY. SYNERGi Sprint automation systems are compact, flexible, and cost-effective. Mills' dedicated automation experts can integrate them with DN Solutions' lathes, machining centres, and mill-turn machines to create high-productivity automated manufacturing cells. The essential elements of a SYNERGi Sprint system comprise an industrial FANUC robot with varying payloads and reaches, a two- or three-jaw pneumatic gripper, a 900 by 900mm part loading/unloading grid plate, and industrial safety guarding positioned around the system. Mills can also supply customers with multi-socket inserts to optimise each system's capacity. These are sheet metal fabrications that customers can also choose to manufacture for themselves. Ayrshire Precision serves customers in the oil and gas, subsea, renewables, power generation, and aerospace sectors. It has a well-resourced machine shop and regularly invests in its people, plant and equipment, processes, and systems as part of its ongoing continuous improvement programme. Since 2012, Ayrshire Precision has invested in various Doosan machines, from two-axis and multi-tasking lathes to large-capacity, heavy-duty vertical machining centres and horizontal borers. “We rely on machine tools from Mills. They are powerful, fast and accurate and enable us to meet the highly-regulated, tight-tied up tolerances and exacting surface finishes that characterise a majority of the components we machine,” says Chris Hepburn, Ayrshire Precision's Managing Director. Ayrshire Precision's decision to invest in automation was made for several reasons. The volatility of the markets served by the company and, as a consequence, fluctuating customer demand for the company's machining services, combined with difficulty recruiting and retaining skilled labour, all contributed to Ayrshire Precision's decision to ‘think outside the box' and begin its automation journey. “It's either feast or famine in the markets where we operate. We can either be swamped or, due largely to external macro-economic factors that impact our customers' business, can experience order cancellations and/or postponements that make it difficult to match our production capabilities and resources with changing customer requirements,” explains Chris Hepburn. Rather than be at the mercy of market forces and to protect the company's long-term viability and profitability, Ayrshire Precision decided in 2020 to explore new ways to improve its flexibility, performance, and competitiveness. The company's focus was initially on its small part-turning operation, which, at that time, comprised two Puma lathes, running over two shifts and operated by four staff members. To increase the productivity of its Puma lathes, the company had previously considered integrating a bar feeder into each machine. However, the diameters of the machined drop forged parts, the batch sizes required, and the limited diameter capacity of the bar feeders prevented this approach. Ayrshire Precision discussed its requirements with several automation system suppliers, focusing on the proposed system's configuration, availability, and cost. As part of its decision-making process, Ayrshire Precision visited Mills CNC, which had previously supplied it with eight Doosan machines. After discussing its plans further with Mills' automation application specialists and seeing a couple of different SYNERGi systems in action at Mills' Technology Campus facility in Leamington, it was confirmed that two separate SYNERGi Sprint systems would better meet Ayrshire Precision's manufacturing requirements. “We liked the design and build of the SYNERGi Sprint system,” remembers Chris Hepburn. “It was simple.” “We asked Mills to put forward their plans and proposals for two SYNERGi Sprint cells – one incorporating our existing Puma 2600SY for larger parts, and the second incorporating our Puma 2100SY for smaller components.” Says Chris Hepburn: “Mills' approach was responsive and helpful. They worked with us to tailor-make the SYNERGI Sprint systems and offered useful advice. We placed the business with Mills, not just because of their technical and automation expertise, but also because they had originally supplied the two Puma lathes and knew the machines inside out. We also thought that dealing with one supplier for our machine tool and automation system requirements would be easier and would simplify communications, servicing, training, etc.” Ayrshire Precision's first manufacturing cell was installed in March 2023. The cell comprises a Puma 2600SY multi-tasking lathe and a FANUC 35kg industrial robot with dual Schunk 3-jaw grippers. Other elements include Renishaw probing systems, safety caging, and the system's HMI control driven by Mills' proprietary SYNERGi software. With individual part cycle times of approximately 10 minutes, Ayrshire Precision is now benefiting from up to an additional 16 hours of unmanned operation of its Puma 2600SY lathe. Since installation, the company has manufactured different sheet metal pocket inserts to accommodate larger parts and different batch volumes. Ayrshire Precision's second SYNERGi cell was installed in September 2023. This cell incorporates the Puma 2100SY lathe, a 20kg payload industrial robot and a 900 by 900mm table for processing smaller components. The automation process for both cells involves the robot picking up a workpiece from the grid plate in a programmed sequence and, using the lathes' auto door opening facility, loading the part into the machine's main spindle. The door closes to enable the machining of the part's front end. After all machining operations are finished, the robot picks up the next sequenced workpiece from the table and, in one continuous movement, loads it into the main spindle. Then, it removes the finished part from the sub-spindle and returns it to its designated position on the table. Says Chris Hepburn: “Every time the auto door opens, a completed part is removed from the sub-spindle and a new part is loaded into the main spindle. The process is fast, seamless and continuous. Furthermore, one staff member can operate both cells simultaneously.” With less labour intervention required, Ayrshire Precision's small part turning operation is now more efficient and profitable. Creating its two cells has also helped free up a couple of its operators, enabling them to be deployed to other machine shop areas. Chris Hepburn concludes: “The investment in our two SYNERGi cells is paying dividends. We have two inherently flexible automated cells that have not only helped us future-proof our small-turned-part operations but have also increased our overall capacity. Although there was initially some anxiety concerning our move towards automated production, the results exceeded our expectations.”
In the aerospace industry, compliance is not just a requirement, but a culture. Senior Aerospace Weston places significant importance on workplace standards—which is why it has installed more than 50 Filtermist oil mist filters. Working primarily with OEMs like Rolls-Royce, Airbus, MTU Engines, Spirit Aerosystems, and many other prestigious clients, Senior Aerospace Weston manufactures a variety of aerofoil and aerostructure components for various platforms in the commercial aviation market. Founded in 1937 and acquired by Senior plc in 2011, the Earby-based manufacturer is now part of an FTSE 250-listed group with over 6,800 employees in 12 countries. As part of a global group in the top echelons of aerospace manufacturing with 3 to 5-axis machining and grinding, CAD/CAM, assembly, NDT, surface treatment, robotic polishing, and much more – achieving standards is critical. Gary Bell from Senior Aerospace Weston says: “Here at Senior Airspace Weston, we believe in maintaining good, orderly, clean standards, housekeeping, and a good working environment. A clean working environment is essential to ensure that we produce our high-specification components.” Providing more detail on the machine shop, Gary adds, “We make a variety of aerospace components for different aircraft programmes and work with a range of materials. This is predominantly aluminium, but we also work with titanium, bronze, nimonic, inconel and steel. We have lots of different types of CNC machining centres with 3, 4, and 5-axis machines. Each machine is specified to manufacture certain types of components, and this is why we have such a wide variety.” With Filtermist extraction units, including the FX6002 and FX7002 on 58 of the company's machine tools, it is imperative that oil mist is extracted from the machines. As Gary adds: “The type of high-speed machining that we undertake produces oil mist that needs removing from the working environment. Our first thought was to look at the industry-leading standards, and Filtermist was the name that first came up. We engaged with them straight away, and they were extremely helpful in giving us some advice and support. They were able to come on-site and carry out a free survey so that they were able to specify exactly what equipment would be available to support our needs.” With machine tools from leading manufacturers such as Matsuura, DN Solutions via Mills CNC, Grob and Hermle among others on-site, Gary continues: “In total, we have 58 Filtermist extraction units. Some machines require multiple Filtermist units to be installed to ensure the volume is extracted quickly and efficiently. We have a huge variety of machines, and the Filtermist units are flexible enough to accommodate the different types, sizes and requirements of those machines. We have machines that are large in scale, so we needed something that was able to extract from all those different types of scenarios effectively.” Discussing the maintenance requirements and the ongoing relationship with Filtermist, Gary says: “The beauty of the Filtermist system is it's easily serviceable, so we can specify whether the Filtermist units are standalone or mounted to the equipment. They are easily accessible for the service engineers to come in and replace any components effectively and quickly. The Filtermist units are fitted with F monitors, which are a really easy-to-use system. The operators can see at a glance using the traffic light system whether there are any issues with the effectiveness of the extraction.” Using the globally recognised ‘traffic light' system of coloured warning lights to alert machine operators when the unit needs servicing, the F Monitor measures velocity pressure to check the airflow through the Filtermist oil mist collector is correct. The Bluetooth-enabled F Monitor 2 measures airflow and time, and the F Monitor 2+ also monitors vibration and motor temperature - making it even easier to identify when the Filtermist unit needs servicing. For existing customers, the F Monitors
Manufacturers could only drill on inclined or curved surfaces with pre-chamfering using a milling cutter in the past. Those days are now behind us and you only need one tool - the newly developed WTX Micropilot from CERATIZIT. It can even pull off 90° countersinks at the bore entry in a single operation —saving tool changes, cycle time and costs. Micro machining has rules and practices that are different to everyday machining. Simply put, what works well with standard tool dimensions does not necessarily hold true with small diameters. “To this end, we have revised our micro drilling program and developed a genuine time saver. The WTX - Micropilot is small in stature, but big in performance. Perfectly matched to our WTX - Micro micro drill from 8xD to 30xD, the pilot drill is used at drilling depths of up to 2.5xD,” says Manuel Keller, Product Manager at CERATIZIT. When faults occur in complex, micro-sized components, they quickly end up dumped in the recycling can. The truth is that a number of things can go wrong. Drills can run off, drill holes get crooked or tools break—including damage to the workpiece itself. “Efficient machining of small components presents its own set of challenges,” says Manuel Keller. “Our customers want process reliability, the shortest possible machining times and demand extremely high-quality standards. Fortunately, our WTX - Micro series is up to the task.” Thanks to its ingenious face geometry with a 160°-point angle, the tool ensures the follow-up drill can plunge in cleanly and without running. And with the special Dragonskin coating, clean chip removal and a longer tool life are guaranteed. The WTX - Micropilot is developed from the latest technologies from the substrate to the geometry to the coating. It is also perfectly designed to work together with its ‘best buddy' WTX – Micro. This drill duo can handle the most common as well as the most demanding tasks. “One special feature of the WTX – Micropilot is that it circumvents the usual mirroring required if drilling inclined and curved surfaces with an inclination of up to 50. This eliminates one processing step, saving time and tool changes. When piloting on straight surfaces, a 90° countersink at the bore entry is also possible,” reveals Manuel Keller. What all WTX micro drills have in common is their special pointing. This maximises positioning accuracy and excellent centring properties. Their lapped surfaces and the patented chip space grinding also guarantee safe and fast chip removal. Additionally, the spiral internal cooling channels of the WTX Micro drill have been optimised to ensure maximum flow of cooling lubricant, which, in turn, secures improved surface quality of the holes. Among other things, this is thanks to a power chamber, which is fitted to the micro drills from 5xD over the entire shank length, which increases the amount of coolant at the tip while maintaining uniform pressure—thus improving tool life. Made for maximum precision With its micro-tool portfolio, CERATIZIT covers most micro-machining applications with high-quality solutions. “This also applies to the WTX - Micro product range, including the new WTX - Micropilot, which makes the impossible possible. On both inclined or curved surfaces with an inclination of up to 50°, there is no need for prior mirroring. And if 90° countersinks are required at the bore entry point on straight surfaces, WTX - Micropilot can easily handle the task in a single operation, saving tool changes, time and costs—without sacrificing quality,” says Manuel Keller.
Milling is a fundamental process that shapes everything from complex aerospace components to critical automotive parts. But despite its ubiquity, successful milling hinges on some careful considerations. How can manufacturers consistently achieve high accuracy, impeccable surface finishes, and cost-effective results? Barry Cahoon, Product Solution Specialist Rotating Indexable—Europe at Sandvik Coromant, offers his advice. Achieving optimal milling results necessitates selecting cutting tools specifically engineered to meet precise machining requirements. This must consider factors such as cutting geometry, material hardness, and machining strategies. Whether the task involves high-precision shoulder milling, high-speed face milling, or complex multi-axis contouring, the tool's performance directly influences the efficiency and accuracy of the entire process. What defines successful milling? Precision is paramount for any milling operation to be considered successful. Achieving tight dimensional tolerances and geometric accuracy is essential. Surface finish is another critical factor. A smooth, clean finish is not just an aesthetic requirement but often a functional one. In industries such as aerospace, where components such as turbine blades or compressor casings must meet stringent performance standards, even slight deviations in surface quality can lead to major problems. Efficiency also comes into play. Milling processes need to maximise material removal rates while keeping machining time to a minimum, all without compromising quality. Then there's the question of tool life. Manufacturers constantly seek ways to extend tool life, reduce tool changes, minimise downtime, and ultimately cut costs. However, tool life is closely linked to chip control and cutting forces. Poor chip evacuation or excessive force can cause rapid tool wear, reducing efficiency and producing suboptimal results. Tool selection With so many variables, selecting the right tool is often the biggest challenge. Different operations — such as shoulder, face, or high-feed milling — demand tools with specific geometries and cutting capabilities. Accuracy and precision are the foundation of every milling process. From creating flat surfaces to machining 90-degree shoulders or complex contours, precision is non-negotiable. Proper tool path control, optimised cutting parameters, and stable machine dynamics are all essential to ensure that dimensional tolerances are met. Thanks to their true 90-degree shoulder capability, tools like CoroMill® MS60 deliver reliable performance, particularly for shoulder milling. Efficiency and cost-effectiveness are key considerations in any manufacturing environment. Time saved on machining processes translates directly to reduced costs, making it essential to minimise cycle times without sacrificing quality. In this regard, CoroMill® MH20, specifically designed for lightweight milling, offers excellent performance in operations where high-speed material removal is required. Its insert design reduces cutting forces, allowing for faster feed rates while maintaining tool stability, particularly in deep cavity and pocketing applications. This increases machining speed and extends tool life, reducing the need for frequent tool changes and lowering overall production costs. Chip control and cutting forces are often underestimated but profoundly impact the milling process. Efficient chip evacuation prevents heat buildup and ensures a clean cut, especially in applications involving deep cavities or pockets. Insufficient chip control can cause chips to re-cut, leading to poor surface finish and faster tool wear. Modern tool geometries are designed to optimise chip flow, reducing the risk of clogging and improving overall tool longevity. CoroMill® MF80 offers smooth chip flow and minimal cutting forces, making it highly reliable for roughing and finishing operations. Its ability to handle various materials and machining conditions enhances versatility and productivity across multiple applications. Finally, precision and reliability are non-negotiable when selecting tools for demanding materials such as ISO M and ISO S. CoroMill® MS20, Sandvik Coromant's new 90-degree shoulder milling solution, delivers exceptional edge-line security and dimensional accuracy. This ensures high productivity and consistent results, even in challenging aerospace and oil and gas applications. Successful milling hinges on a deep understanding of the interplay between tool design, material properties and machining parameters. By carefully selecting tools that are purpose-built for the task at hand — whether that's shoulder milling with high precision or high-speed face milling for rapid material removal —manufacturers can achieve their goals of improved productivity, lower costs and exceptional part quality. The balance between accuracy, efficiency, tool life and chip control ultimately defines a successful milling operation.
On the 27th and 28th of November, Hexagon Manufacturing Intelligence invited MTD magazine to the official opening of its new Experience Centre in Holland. Located at the Brainport Industries Campus in the Northwest of Eindhoven, the two-day event was an opportunity to tour the new campus and participate in insightful presentations that demonstrated how Hexagon is driving innovation and, as a result, developing successful industrial partnerships. Eindhoven is responsible for the Philishave, the automatic gearbox, the cassette tape and the compact disc. To foster this culture of innovation for future generations, the Dutch government funded the Brainport Industries Campus, which broke ground in 2017. At around 100,000sq/m, the innovation centre is virtually fully subscribed, and that is why construction of a 225,000sq/m phase two on the 17-hectare site will commence this year. With dozens of high-tech businesses collaborating at the campus, Hexagon is alongside cutting-edge companies with brands like Siemens and Meta (Facebook), just a few located at the facility. MTD magazine attended and the itinerary for the innovation extravaganza promised an exciting lineup. The event started with a welcome from Jan Klingen, Vice President EMEA North, and Eric Veurink, Brainport Industries Campus Director, and a facility tour. As expected with a Hexagon LIVE event, the breadth and depth of technology and insights were so expansive that delegates could choose the most relevant content for their business. Exemplifying this was one of the first panel discussions on the ‘Future of Mobility in Aerospace and Automotive', hosted by Hexagon Senior Director for Industry Solutions, Johannes Mann, who was joined by speakers Rob van Loon, Additive Manufacturing Manager at KMWE and Thom Grobben, the Vice President of the Technology Hub at KLM Royal Dutch Airlines. The discussion flowed through the challenges of accelerating innovation and agility in the automotive sector to deliver the next generation of smart, connected vehicles. This conversation then moved on to the aerospace industry's challenges in redefining aircraft architecture and propulsion systems to become more sustainable. Other prominent seminars discussed ‘The challenges in production and collaboration', ‘Extending asset lifecycles and improving productivity with HxGN EAM', ‘Surfing the future now' and ‘Innovation beyond silos: Transforming Manufacturing through connectivity, collaboration, and Cloud/AI'. There was a lot more on show, with panel discussions, presentations, workshops and roundtable debates encompassing every industry sector. Nowhere was this more prominent than in Morgan Maia's presentation, the Partnership Manager at Oracle Red Bull Racing. Hexagon has partnered with the F1 team since its inception. Flying in from the F1 Teams' weekend win in Las Vegas, Morgan discussed how Hexagon supports the team in streamlining performance by ensuring compliance with FIA regulations, precision manufacturing, and ensuring the team ‘gets it right first time'. More than just a soundbite, Mike Hughes, Head of Quality Assurance and Manufacturing Engineering at Oracle Red Bull Racing, qualified the support of Hexagon with a statement: “With Hexagon's help, we've managed to reduce our faults by 50% over the last two years.” Morgan's presentation alluded to how Hexagon is involved throughout the process chain, from 3D CAD modelling and CFD simulations in the virtual wind tunnel to simulation and physical wind tunnel testing. With over one million components handled throughout the season, Oracle Red Bull Racing combines exceptional hardware with efficient software and digital twins to deliver rapid inspection rates. The team has four QA departments encompassing mechanical, external, composites, and race support. They all utilise Hexagon tools, from CAM software to 3D scanners, laser trackers, portable measuring arms and CMMs. The Leica AT960 scanner is a core element of the trackside equipment that improves accuracy and holistic measurement. Its custom orientation enables measurement from different perspectives. For legality checks, Oracle Red Bull Racing uses the AS1 scanner to scan the floor, front, and rear wings to extract key points of the car for performance set-up. With the arrival of Red Bull's first road car, the RB17, and the opening of its 5,000sq/ft powertrain manufacturing site in Milton Keynes, Red Bull's number of components produced is set to expand significantly, as will its relationship with Hexagon. The F1 car continually undergoes design cycles that follow the same structured path. With up to 100 projects in-cycle at any time, around 1,000 design cycles are completed yearly. It starts with developing a 3D CAD model and the subsequent digital twin, which is the foundation block for everything that comes after. With CFD, prototypes and a whole raft of processes before the team gets to a finished car, Morgan said: “When you work on a car in the factory and then take it to the track, if there is an issue in manufacturing – it's too late to do anything about it. We must be sure the car is 100% correct before shipping it. That is why we need Hexagon: to ensure that everything leaving the factory is perfect for when it arrives at the track. We have thousands of parts that need to fit together perfectly. We work to the micron. It's precision you would see in a high-end watch – but not typically in a 5m long vehicle.” A presentation on Hexagon's Nexus suite by Stephen Graham, Executive Vice President and GM of Nexus at Hexagon, followed this. Stephen explained: “Nexus is our cloud-based manufacturing platform. We initially conceived it to solve an internal problem. We have acquired over 150 companies in more than 25 years, which has helped us build this portfolio of technologies throughout the product life-cycle. Our challenge is a large portfolio of technology solutions that were never really intended to work together. We wanted to offer our customers a solution to join the dots and bring the next level of value with the technologies all being under one roof. Nexus was conceived to solve this problem of connectivity. As soon as we took the proposition to our customers, we found they had the same problem. Over decades, they had purchased different technologies to solve different problems.” “Nexus directly solves that problem, and what we have found in the last few months is an ability to connect to different technologies from different vendors - it doesn't just have to be Hexagon products. Since starting development, we have found that businesses are structured very hierarchically, with different disciplines arranged in different silos. The whole thing is very process-driven, and as we try to push the boundaries of manufacturing, this becomes a barrier to succeeding. The need to drive collaboration horizontally across an organisation is coming to the fore as a challenge that needs to be faced.” To demonstrate this, Stephen provided a slide show showing a reverse-engineered workflow using 10 products from Hexagon that facilitate different elements of a product's lifecycle. The demonstration alluded to new cloud-native apps, technologies and solutions connected to products in the portfolio for decades, such as PC-DMIS. Nexus creates an end-to-end solution that connects the dots. Stephen added: “Once these collaborative workflows have been strung together, engineers can work collaboratively. This provides the opportunity to bring automated and AI technologies into the workflow as automated collaborators in the workflow. A great example of this is ProPlanAI, which we just launched. This large NAPA language model provides precise engineering answers for CAM engineers who may be programming CNC machines. It automatically collates data and generates a G-Code to drive machines on the shop floor. This gives engineers superpowers to drive productivity to the next level.” Hexagon claims that ProPlan AI cuts the time to program machine tools by 75%. The new AI technology enables machine shops to achieve operational excellence at scale, powered by Microsoft Azure services built into Hexagon's cloud-based Nexus connectivity platform. Available in Q1 2025, ProPlanAI will ‘learn' from the data created by a company's CAM programmers. This will enable manufacturers to automatically explore existing programming information to predict ideal outcomes tailored to a company's preferences, production capabilities, and needs. ProPlanAI will continuously learn and adapt, ensuring programs are as efficient and productive as possible. ProPlanAI can be trained with a company's institutional knowledge to ensure machines can be quickly and efficiently programmed to their quality standards. Additionally, a Hexagon Copilot provides suggested pathways to advise on best practices without leaving their CAM software. The innovation has been developed in collaboration with Microsoft, and Ygal Levy, the EMEA Manufacturing Managing Director at Microsoft, discussed the company's strategic partnership with Hexagon in greater detail during an afternoon presentation on the ‘Transformation of manufacturing through Connectivity, Collaboration and Cloud/AI'. Clare Barclay, President of Enterprise and Industry at Microsoft EMEA, said: “Microsoft's collaboration with Hexagon is driven by a shared belief that we can transform manufacturing productivity. It's rewarding for us to see how the AI capabilities provided by Azure are empowering CNC programmers with productivity-boosting automation while helping new users upskill faster. This is exactly the sort of transformation AI can bring to the industry, and we are excited to see Hexagon apply its manufacturing expertise to transform workplace productivity.” Verifying the Solution Just over a year ago, MTD magazine visited RODIN Machining. A few miles north of Amsterdam, the start-up company set out to develop an autonomous factory. Incorporating FASTEMS automation, robot-loaded Mazak machines, and integrated innovations that made the mind boggle, RODIN has been a beta-test customer, putting ProPlanAI through its paces before market introduction. Paul Mooij, Director of Digital at RODIN Machining, said: “Machine tool programming is complicated to automate and requires experience. ProPlanAI is exciting because we can leverage our human capital for greater machine utilisation. Our team can program machines in a fraction of the time by applying their valued skills in supervising ProPlanAI suggestions and finalising the programme specifics.” Paul added: “We have built an autonomous factory but are limited by the engineering input we can put into it. This boils down to a race for talent, and we all know it isn't easy to get good people. We have been working with Hexagon on the development of ProPlanAI, looking at how can we fill it with our data and train it with our models, our machines, tools and our way of working - providing a suggestion of how the model thinks our way of working should be. We can then position our engineer to supervise and undertake ‘prompt engineering'. ProPlanAI is very powerful and provides the right context for the features, model, machines, and tooling available. Using the given context, it then decides, ‘I think you should use these processes for this machining operation''.” “This has become powerful, and we are progressing rapidly to make big savings. We are leveraging our human capital to achieve more by using AI to provide suggestions. Then, our engineers decide whether to accept the suggestion and proceed or refine the process. For example, we may have a 2D PDF drawing that needs to meet specific tolerances, and ProPlanAI may not know this – and this is the experience we can add to the system. It's been a fantastic collaboration, and the system continually evolves.” Discussing the current situation, Paul told MTD magazine: “Our engineers will consider how they approach a job and create the CAM file in Esprit. We then feed our models to our developers. Over the last 18 months, we have been feeding the data to ProPlan AI, which uses our approach, machining strategies, cutting tools, machines, characteristics and experience. ProPlan AI creates suggestions for the next job and pre-populates our program, so our engineers are validating and refining the suggestions to meet our specifications. It amplifies the output of our staff.” “For example, if we have an aluminium job that needs a threaded hole with a chamfer, we would have a unique way of doing that with our machines and tools in our CAM files. Based on those patterns, the model learns our strategies and recognises the parameters for a threaded hole in aluminium, the feeds, speeds and so on.” Looking at benefits during testing, Paul adds: “It is amplifying our output and boosting our efficiency. At present, the savings are impressive. We continuously add data to our ProPlanAI suite, so the savings will cascade into ever greater efficiencies as we progress.”
Archway Engineering has invested in a drill sharpener from 1st Machine Tool Accessories, and the savings have been incredible. Danielle Toner, Production Manager at Archway, a site drilling equipment manufacturer, is overjoyed with the benefits the company has enjoyed from the new Darex XT-3000. A US-made Darex XT-3000 for repeatedly regrinding carbide and HSS drill bits to ‘as-new' condition was delivered by sole UK sales agent 1st MTA to Archway Engineering's Elland factory in July 2023. By November 2023, it had already paid for itself, as Mrs Toner had not purchased a single new carbide drill in all that time to replace broken or damaged bits. According to the work going through the factory, the saving was between £700 and £1,500 per month. Mrs Toner said: “We did not previously send drills out for resharpening, so worn bits were discarded. The cost was significant, especially for solid carbide drills. One component we regularly machine involves using a 160mm long, single-flute carbide drill, and we previously needed four of them to complete the part. If we ran out of bits, we couldn't finish the job until the next drill delivery, which delayed assembly of our products.” “Now we simply resharpen a bit four times, and we are certain that the component will be finished on time. New carbide drills cost around £165 each, so the saving is considerable and contributes to lowering the cost of production.” This example is by no means exceptional. Another job requires three new carbide drills to make two parts. In a different process, an HSS taper-shank twist drill is put through 30mm thick EN19 high-tensile steel. A TC shoe made from an S355 hot-finish stainless steel tube is drilled in up to 16 places using a split-point, single-flute carbide drill that has to be repeatedly resharpened before the component comes off completely machined. Mrs Toner explained that some bits could be resharpened a dozen times or more, depending on their length, while maintaining top quality. It takes about one minute to sharpen the point, or a little longer if necessary to grind past a chip on a cutting edge. It happens quite often due to the toughness of the materials being machined and also because of a frequent need to drill cross holes at various angles into the wall of tubular components. This tends to damage the cutting edges of a drill as it breaks through. HSS jobber drills from the assembly department are also regularly sharpened, which Mrs Toner describes as ‘a massive saving'. It requires the 220-grit diamond wheel used for sharpening carbide drills to be exchanged for a 180-grit CBN grinding wheel. The process takes about five minutes, so batches of around 20 HSS bits are set aside and resharpened simultaneously. 1st MTA demonstrated the XT-3000 in the Elland factory before Archway Engineering purchased it with an attachment to process bits up to 30mm in diameter. Left and right-hand drills can be processed, and attachments are available for sharpening step drills, countersink and spot drills, and others with a 90-degree point. Standard sizes of carbide drills used regularly by the site drilling manufacturer are 8, 10, 12 and 14mm in diameter and up to 6XD in length. However, bits from 3 to 21mm in diameter can be accommodated in normal use. It resharpens bits in a three-step process. A drill is placed in a finger chuck, and the protrusion length is set at an alignment station. Carbide fingers enter the flute to fix the rotational orientation, and the drill is tightened in that position by rotating the chuck clockwise. The grinding motor is then started, and at a second station, the drill is sharpened on both sides while clamped in the same chuck. In an optional last operation, the chuck holding the sharpened drill is presented to a third station for point splitting to shorten the chisel line and lessen the force required for drilling components. In conclusion, Mrs Toner observed: “The savings that the Darex XT-3000 brings make it an obvious investment once you realise the benefits. We wish we had done it much earlier. The sharpener paid for itself in less than six months, after which the ongoing monthly savings continue to add to the profit margin on all jobs that require drilling operations, which is most of them.” “The sales arguments that 1st MTA make are difficult to ignore. We also purchase Chick workholding products from them, which have doubled productivity on one of our machining centres, and the supplier has also provided us with a new chuck for one of our lathes.”
In the realm of cutting-edge aerospace applications, precision and performance are essential for transforming the toughest materials into high-flying components. Whether titanium alloys, nickel-based superalloys or advanced ceramics, these materials and the tools that machine them are the backbone of aerospace innovation. Kennametal's tooling solutions are designed to tackle manufacturers' challenges, helping them achieve higher precision, better surface finishes and increased productivity. Reliance on high-temperature resistant materials presents challenges. Traditional tooling doesn't stand a chance when used in this environment due to friction, deformation and other component failure. For example, engine parts made from titanium and superalloys must endure temperatures over 1,000°F. That's why high-temperature machining solutions become critical. It also means that the materials being used demand more than just tough tools; they must thrive under extreme conditions. High-Temperature Machining Goes the Distance Components powering everything from jet engines to exhaust systems are built to withstand extreme environments. Machining these components requires tools that can perform without compromising an aircraft's structural integrity. This is exactly where Kennametal excels, delivering tooling solutions that meet aerospace's toughest demands head-on. Innovative Tooling Solutions Kennametal's high-temperature machining tools are specifically engineered to tackle challenges such as high cutting forces, heat buildup, and work hardening. They use advanced coatings, precision geometries, and heat-resistant materials for efficient machining under extreme conditions. Kennametal's family of HARVI solid carbide end mills is a game-changer for machining tough aerospace materials like titanium and Inconel. HARVI™ Ultra 8X excels in airframe structural machining, while HARVI™ III is optimised for titanium applications. The HARVI I TE, with its twisted cutting edge, boosts corner stability and excels in ramping and helical interpolation. It features advanced anti-vibration and anti-friction technology. The innovative flute design with chip gashes reduces cutting forces, making chip evacuation super-efficient. Building on the success of the HARVI series, the newly launched HARVI II TE end mills feature a 5-flute design for aggressive cutting in ramping and plunging, as well as a proprietary W-flute shape for better chip evacuation and a stronger core. Overall, the HARVI tools deliver significant time and cost savings in aerospace operations, with impressive Metal Removal Rates (MMR) and tool life. Drilling composites like CFRP can effectively create fuselage, wing skins, and spoilers. Still, Kennametal's KenTIP™ FS series of drills featuring a double-angle geometry is specifically designed for composites. Additionally, Kennametal offers KenShape™ MaPACS & MaxPACS and HiPACS countersink and drill solutions. These tools are engineered to handle the challenges of drilling composites, ensuring clean cuts and minimising issues like delamination and fibre breakout. By using these advanced tools, manufacturers can achieve high-quality results while maintaining the structural integrity of their components. When it comes to precision turning, especially with tough materials, Kennametal's Beyond Evolution™ line of carbide and ceramic inserts will be effective. These inserts are built to handle the high temperatures associated with turning operations, which are common when working with hardened steels in landing gear and other components. Dealing with the hassle of frequent tool changes, especially when working on large components like wing sections, Kennametal's KM™ and KM4X™ modular quick-change tooling systems come into play. They make tool changes super quickly without losing accuracy. For tasks that need high repeatability, like wing skin assembly, it's crucial to calibrate tool holders to keep everything aligned perfectly regularly. “Aerospace manufacturers can achieve exceptional precision and productivity with our tooling solutions, ensuring every component meets our aerospace customers rigorous demands,” said Eva-Maria Weber, Manager Aerospace Business Unit CE. Overcoming Challenges in High Temp Machining In high-temp machining, precision, reliability, and speed are key and always at the forefront. Sometimes, problems arise, such as in thin-wall applications, surface finishes, and milling applications. Walking the Thin Line Thin-wall applications are often used to reduce weight without sacrificing structural integrity. Parts like fuselage skins, wing sections and other structural components rely on this technique. However, machining thin walls can be challenging due to vibration, deformation, and heat. To address these challenges, adjusting the feed rate and depth of cut can help reduce vibration before resorting to complex setups. Dampening tools at lower spindle speeds can improve stability without compromising finish quality. Kennametal's high-feed mills and coated carbide inserts can successfully machine titanium for fuselage sections, maintaining wall stability and accuracy. In relation to spar fittings, machining composite components and aluminium, which consist of thin walls, requires careful part movement and precise and rigid fixturing while managing machining around multiple pockets. Milling Applications Machining materials like titanium, Inconel, and CFRP can present obstacles due to their strength, lightweight, and resistance to high temperatures. Superalloys and hardened metals generate significant cutting forces, leading to vibration, deflection, and tool wear, especially when tight tolerances are required. Aerospace components are often complex and have 3D shapes, requiring multi-axis milling and customised tooling strategies to ensure accuracy in hard-to-reach areas. “Our advanced milling solutions are specifically designed to address unique challenges, providing efficiency and accuracy when machining high-performance materials like titanium and Inconel,” said Patrick Mesnil, District Business Manager and aerospace business leader France & Benelux. Advanced tooling coated with Diamond-Like Carbon (DLC) or PCD can improve cutting efficiency. Optimised cutting conditions, including adjusting speeds, feeds, and depths of cut, help manage heat and forces during machining. Effective cooling solutions, like high-pressure coolant, dissipate heat and prevent workpiece deformation. Multi-axis CNC machines allow for precise machining of complex 3D shapes, ensuring accuracy in hard-to-reach areas. Surface Finish When it comes to high-temp machining, achieving quality surface finishes is essential. It can be affected by factors such as tool wear, cutting speed, feed rate and the material being machined. Advanced multilayer coating technologies like TiAlN and AlTiN on their carbide tools help control the heat at the cutting edge. These coatings act as a barrier, reducing friction and heat transfer. As new aircraft standards emerge, emphasising lighter, more heat-resistant, and sustainable components, continuous innovation in tool geometries and coatings plays a critical role in advancing component development. For example, larger components, such as engine cases, require challenging process controls and careful application with tool pressure in mind. Internal and external milling operations must also consider thin walls and fine surface finish requirements when working with tough materials. Additionally, turbine disks require managing low thermal conductivity and vibration to avoid part deformation. This requires application-specific tooling to provide the required cooling capabilities and productivity. As the industry continues to explore new materials and complex geometries, advanced tooling solutions must meet emerging challenges. In high-temperature machining, where precision, reliability and speed are crucial, Kennametal's tools provide aerospace manufacturers with solutions to support the next generation of high-flying components. Designing and engineering tools that solve today's challenges and anticipate tomorrow is essential.
Milling originated in the late 18th century and quickly became one of the primary machining technologies. Nowadays, it is easier to imagine any machine shop with milling operations on the shop floor; it's an essential process in manufacturing. The increasing demands of manufacturing drive this integral part of machining technology. However, there are specific aspects that uniquely impact the advancement of milling. We are witnessing significant changes in manufacturing that will have profound consequences on the development of milling directions. These changes are driven by various factors, such as the increasing accuracy of metal forming through precision investment cutting and precision forging, the widespread adoption of 3D printing, and the growing usage of new composite and sintered materials. Furthermore, there is a need to enhance productivity in machining hard-to-cut superalloys and titanium grades, and the strong focus on electric and hybrid cars in the automotive industry contributes to these changes. In addition, advancements in multi-axis machine tools have opened new possibilities for the precise machining of complex parts and enabled the implementation of new cutting strategies to improve productivity. In modern technological processes, there is a tendency to significantly reduce the machining stock intended for milling operations while simultaneously increasing the requirements for surface finish. Therefore, the advancement in milling is driven by the need for higher productivity, precision and sustainability in milling operations. Consequently, the main developments can be characterised as follows: Fast metal removal focuses on boosting the metal removal rate (MRR) to achieve higher productivity by significantly increasing cutting speed or feed per tooth. This is achieved through techniques such as high-speed milling (HSM) and, in rough operations, high-feed milling (HFM). Precision milling provides higher accuracy in milling operations. The utilisation of multi-axis machining centres characterises multi-axis milling to enable complex milling operations. Adaptive milling aims to develop intelligent systems that can adapt to changing conditions during machining. Sustainable milling strives to reduce the environmental impact of milling operations. It involves developing eco-friendly cutting fluids, recycling and reusing materials, and using energy-efficient machine tools and milling cutters. Success in these areas relies on the synergy of several key components: machine tools, cutting tools, and CAM systems. High-speed milling necessitates machine tool technologies capable of handling exceptionally high rotational velocities and advanced cutting materials and coatings for milling tools. Simultaneously, enhancing the precision of milling operations requires milling cutters with tighter tolerances and improved control systems and linear motor drives. In the case of multi-axis milling, the breakthrough lies in effectively controlled axes movement, along with the application of appropriate cutting geometries for milling tools. On the other hand, adaptive milling incorporates innovations such as using state-of-the-art monitoring systems, high-sensitive sensors, and efficient algorithms to optimise cutting data and tool paths in real-time. Moreover, sustainability advancements require energy-efficient milling strategies that employ suitable machine tools, cutting tools, and eco-friendly coolant techniques. Indexable milling reflects the advancements that feature exchangeable cutting inserts in machining operations. a) Advanced insert materials are an ongoing process to improve the cutting materials for indexable milling inserts, including the development of advanced carbide grades, ceramics, and ultra-hard cutting materials. b) Coating technologies with continuous R&D focus on new coatings to improve wear and heat resistance while enhancing lubricity. c) Progressive cutting geometry optimises cutting geometry and chip forming topology of inserts to improve cutting action and diminish cutting forces and chip flow in milling operations. d) Effective cutting material uses an intelligent insert design to provide maximum indexable cutting edges without reducing cutting capabilities. In addition, the distinct course on smart manufacturing requires the integration of digitisation into milling operations and tools. Regarding tools, digital twins and software applications have already become a ‘must' feature of a comprehensive tool range. How can cutting tool producers rise to the challenge? Which milling tool solutions will provide the right answer to the emerging trends? Is the field of cutting tool manufacturing, often considered conservative in metalworking, capable of delivering a timely response to current demands? The recent advancements from ISCAR provide greater insights into these subjects. High-speed trochoidal milling involves following a curvilinear tool path to maintain a constant load on the cutting edge to eliminate spikes in load during material entry. This strategy is efficient for milling deep slots, pockets, and cavities. Additionally, trochoidal milling has shown excellent results when working with challenging materials such as high-temperature superalloys. The CHATTERFREE EC-E7/H7-CF is a new family of multi-flute endmills for trochoidal milling techniques. The family's geometric design includes different helix angles and variable angular pitches to improve dynamic behaviour. These endmills are available in a range of length-to-diameter ratios (Fig. 1). Machine tools allow highly productive milling of aluminium alloys at extreme spindle speeds, reaching up to 33,000rpm. To meet this challenge, ISCAR has developed 90° indexable milling cutters that accommodate large inserts for a depths of cut up to 22mm (Fig. 2). The cutters have been designed to eliminate insert radial displacement, which may occur due to the high centrifugal forces generated during very high rotational speeds. High-feed milling (HFM) has become a widely adopted method for efficiently rough machining complex and flat surfaces. ISCAR offers a comprehensive range of HFM products to meet the demands of various industrial applications. Recently, the range has been expanded with new additions. The LOGIQ-4-FEED family of HFM tools, featuring specific bone-shaped inserts (Fig. 3), now includes tools with larger inserts. These new products significantly broaden the application range, particularly in the mould and die industry's high-feed milling of large-sized cavities. Another addition is NEOFEED, a family of HFM tools with double-sided inserts, providing eight cutting edges for improved cost-effectiveness. Advancements in multi-axis machine tools and CAD/CAM systems have given rise to precise milling of complex shapes with minimal machining stock, using segment or barrel-shaped endmills. ISCAR's program for these endmills encompasses three design concepts: a solid carbide design, an exchangeable MULTI-MASTER head, and a one-insert approach (Fig. 4). When milling high-temperature superalloys, cutting ceramics can substantially increase cutting speeds, reaching 1000m/min. ISCAR's latest ceramic tools include ceramic solid endmills and indexable milling cutters with double-sided round ceramic inserts. The double-sided design aims to maximise the utilisation of ceramic material grades, such as ‘black' ceramic, whisker-reinforced ceramic, and SiAlON (a silicon-nitride-based ceramic). These selected examples serve as good illustrations of the main directions of advancement in milling tools. As new demands arise, new solutions are required, and these new challenges will fuel the search for innovative tool designs.
ARNO believes that machining is now something like Formula 1 racing: every little screw is tuned to increase performance. Thinking outside the box is essential, especially when considering cutting tools and turning. It would be helpful if users could always use the right combination of tools, inserts, and coolant supply. In Formula 1, everything is constantly scrutinised to glean maximum performance. Yet only the driver and the manufacturer who have mastered the overall package can reap the world championship crown. Despite all the optimisations and specifications, cutting tools for turning have yet to reach the end of their potential. Responsible tool manufacturers think about selling as many cutting tools as possible and include the tool holders and cooling supply into the equation. On the other hand, users should be open to tips, let consulting manufacturers approach them, and allow them to enter the production process. The potential that can be achieved in this way can provide a decisive leading edge. Be open to third-party expert tips For example, ARNO Werkzeuge has long been involved in the continued development of tool holders and coolant supply. Thanks to its customer proximity, the family-run company has a wealth of expertise from numerous applications and a wide range of holders with and without coolant supply. Users can rely on the best overall packages for small and large batches, as well as Swiss and fixed headstock lathes. “Here, too, we are not interested in maximising sales figures for high-margin products. We aim to find the best solution for our customers,” assures Sales Manager Dieter Wollensack from ARNO Werkzeuge. As an experienced technical advisor, he focuses on long-term and intensive customer relationships. He detests the promise of ‘double the service at half the price' and pie in the sky. “I sometimes say to my customers: ‘No, that's not possible' or ‘We won't do that' and risk being turned down. I've always been successful with this approach - and ultimately, so have my customers.” Advice or not, process optimisation products must be convincing in practice. For this reason, the overall package consisting of a cutting insert or indexable insert with a matching tool holder and high-performance cooling must always deliver the best customer performance. This is exactly what users should attach importance to their tool partners to understand the processes and have the right overall package for every production situation. For example, universal packages for small batches, high-tech solutions for large batches, and special products for difficult-to-machine materials. Exorbitant promises never help. Innovative when it comes to ‘cost per part' When tool manufacturers adopt this mindset, new products and solutions result. One example is the clamping holders with through-tool cooling for inserts that ARNO Werkzeuge developed in 2022. They are produced using a hybrid manufacturing process that combines additive technology with conventional CNC milling, achieving better surface quality. But why? Coolant flows directly where it's needed. Three precisely aligned channels guide the coolant to the cutting edge from above and underneath without obstructing chip evacuation. The special geometry of the cooling channel creates a nozzle effect that greatly improves cooling compared to conventional channels. The outlet openings are always perfect—they need no adjustment. And since they are much closer to the cutting zone, the coolant significantly reduces the temperature. Experienced users will recognise the benefits immediately: greater process reliability, less vibration, better surface quality and a much longer tool life. Users have sent reports about tool life that is three times longer. Of course, this is not at all suitable for small batches - but when it comes to large batch orders, it's just the right ace in the calculation where everything has to do with the cost per part. Hybrid holder: productive from additive The secret isn't rocket science, but you must figure it out first. The shanks of the hybrid holders from ARNO Werkzeuge are produced using conventional CNC milling. On the other hand, the complex head part of the holder is attached directly to the shank using a 3D printing process. “This gives us new design freedom and outstanding stability,” says Werner Meditz, Head of Technology at ARNO Werkzeuge. The geometric design of the cooling ducts can be precisely optimised so that coolant is guided through the holder to the cutting tool at maximum efficiency and reaches the cutting edge directly from above and underneath. This cools the tool flanks in a way that was previously unthinkable. At the same time, the number of attachments required at the top of the head is reduced to the absolute minimum. The chip breaks as needed and is optimally evacuated - regardless of the cutting depth. “We get a lot more coolant to where it needs to go,” Meditz assures us. The innovative hybrid holder is exactly what clever users want - and this all comes from a tool partner thinking out of the box. Not only high-tech but also ‘basic work.' But even when it's not high-end, machine shops welcome innovative turning tool manufacturers with well-thought-out products. Meeting someone who can also offer the right holders and complete systems for small batches with frequent workpiece changes is refreshing. At ARNO Werkzeuge, you will find a wide range of turning holders for external machining, where the length is easily adjustable using a scale. “The ARNO special design is extremely simple and practical when it comes to adjusting the length and coolant access,” confirms Meditz. The holder and through-tool cooling are easy to install and ensure repeatable process reliability. Their nickel-plated, high-tensile, and precisely finished nature promises top quality and long tool life. The efficient cooling system, which feeds coolant directly to the cutting edge through three channels, not only ensures long tool life but also allows higher cutting speeds with optimised chip control. The machining time savings make the cost calculation look good. Variety of boring bars for internal machining Finally, we come to internal machining. Turning tool manufacturers have already given this much thought. First and foremost, the designers at ARNO Werkzeuge have also considered the customer's situation and developed suitable boring bars for a wide range of applications. The range includes boring bars of steel and solid carbide, each with two possible coolant hole exits. Depending on the turning process, users can choose between a coolant channel from above (IKO) for through holes and a coolant channel from underneath (IKU) for blind holes. Accordingly, chips are guided forward away from the cutting edge (IKO) or behind the cutting edge and flushed out (IKU). This reduces wear. Boring bars come in right or left-hand versions with different shank diameters, a wide variety of clamping holders, and many approach angles. This variety alone shows that the manufacturer thinks from a user's point of view. Combined with suitable mini indexable inserts from ARNO Werkzeuge, components from Dmin 4.8mm can be machined effortlessly, regardless of diameter and material. This is only the standard range, not customised products. This already promises long tool life because all ARNO boring bars are nickel-plated, high tensile and precisely machined, which certainly boosts confidence. Users looking for suitable, long-life productivity-enhancing tools for all their turning operations and processes should be glad that some manufacturers have adapted their thinking to include their customers applications.
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