gtma news issue 2 2012

newstoolmaking l precision machining l metrology l tooling technologies l rpd

inside...

At the heart of...UK Manufacturing

How to save money in Auto

Emerging Technologies update

ISSUE 2 2012

Make Measurement Matter is all set to go

GTMA NEWS ISSUE 2 2012 2/10/12 15:22

Nothing compares to Equator™

Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom

T +44 (0)1453 524524 F +44 (0)1453 524901 E [email protected]

www.renishaw.com

To see Equator in action visit www.renishaw.com/gaugingapps

or scan the code

The unique new Equator™ is a versatile alternative to

traditional gauging, offering inspection of an unprecedented

variety of manufactured parts. It has been developed and

proven on the shop-floor with industry-leading gauging users

in multiple industries and applications.

Nothing compares like Equator™

Benefits which can be gained by using Equator™ include:

• Reduced gauging costs

• Robust shop floor measurement process

• Reduced production bottlenecks

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Renishaw One Gauge advert GTMA 0912 indd 1 8/21/2012 4:19:00 PM

GTMA NEWS ISSUE 2 2012 2/10/12 15:22

33

Contact GTMAIn order to receive a copy of this GTMA News please phone, fax or emailyour request to GTMA. We do not accept responsibility for omissions orerrors. Please note the views expressed in articles by contributors andadvertisements included in this edition do not necessarily represent thoseof the GTMA.

issue 2 2012

Published by: Gauge & Toolmakers AssociationThe National Metalforming Centre,47 Birmingham Road, West Bromwich, B70 6PY

Tel: 0121 601 6350 Fax: 0121 601 6378Email: [email protected] Web: www.gtma.co.uk

This publication has been produced for the GTMA by Channel Publications Ltd, 14 John Slessor Court, Camden Row, Bath BA1 5LDTel: 07800 962 473 Email: [email protected] Website: www.channelpublications.co.uk and was printed by Buxton Press.

CONTENTSGTMA President Foreword 3

News 4-5

New Members 6-7

Annual Meeting 8

News 9

AT THE HEART OF...MANUFACTURING UK 10-23

Precision Engineering - Overview 12-13What we do 13A-Z of companies 14

Case Studies 15-17

Press Tools – Overview 19-20A-Z of companies 20What we do 21

Case Studies 21-23

Emerging Technologies 24-25

AUTOMOTIVE FOCUS 26-35

MMM 2012 36-51

Showing off solutions 38-39

Exhibitors 39

Case Studies 40-51

Press Releases 52

AEROSPACE 53-55

TCT Live and more 56-57

Events and Next Issue 58

3

Proud to be yournew President

I would like to introduce myself to themembers and readers of the GTMA News– as the recently elected President ofGTMA and to say how proud I am to bein this position having served on theGTMA Board for the last 12 years.

Since our last edition in March, GTMA hasbeen continuing to conduct our poll of over2500 engineering companies to establish thesize and make up of the UK tool-making industry. Companies haveprovided solid and substantial information about their capabilities andthe industry sectors in which they are involved.

We have also hosted a series of industry-led workshops around thecountry with GTMA members to discuss the current situation, explorestrategies to take the UK tooling industry forward and consider howbusiness prospects for our industry can be improved.

GTMA understands the need for, and every chance it sees engages in,raising the profile of our industry to the manufacturers, particularly as wesee more and more companies returning manufacturing to UK shores.

This is an opportunity members should embrace, together with the needto become more competitive and responsive to change and technology.

Speaking of technology, as we go to press we are involved in our fifthEmerging Technologies business conference. These popular, wellattended events provide a golden opportunity for visitors to learn aboutthe latest technologies across the whole manufacturing process and tosee how their practical application can give them a competitive busi-ness advantage.

In October over 35 GTMA inspection and measurement member companies will be exhibiting their products and services at the sixthMake Measurement Matter Roadshow at CEME. Exhibitors will be dis-playing their co-ordinate measuring machines and portable measuringdevices, process control and software solutions, as well as the allimportant technical supporting services of leading metrology and calibration suppliers. The event also features top class speakers fromBAE, Rolls Royce and NPL.

All member companies can benefit from this roadshow. Why? Face it,wherever you are in the supply chain, when you’ve made somethingyou need to check if it meets the spec! This is an opportunity not to be missed.

Continuing our theme of showcasing manufacturing excellence in member companies this issue is highlighting Precision Machining andPress Tool companies who all benefit from membership of GTMA.

Our next issue will feature the Manufacturing Resource Centre, itsprogress to date and its promise for the future.

Geoff Highley President, GTMA

Cover photo: Courtesy Delcam UK. Photos page 11 courtesy(l to r) top: Erodex, Bayer Healthcaare, Nissan, Sunseeker and,bottom: Bombardier, Rolls Royce, Ninian Peckitt and Airbus.Page 53 (l to r): AgustaWestland, BAE Systems, Airbus andBombardier.

GTMA NEWS ISSUE 2 2012 2/10/12 15:22

in the news... in the news... in the news... in the news...

4

GTMA has launched anew initiative supported byPeter Barnes, who is actingas Tooling Resource Directorfor GTMA, to help memberswin business with some ofthe UK's major OEM andTier 1 companies.

With the working title ToolingAlliance, the move is designedto bring together member com-panies as part of a supply team– or Alliance – able to pitch forjobs they would never be ableto do on their own.

Unique to the initiative is that it isthe GTMA team which will go outand win the business – with pre-sentations to prospects made bya skilled presenter with the tech-nical supplier team in support.

An initial workshop to introducethe idea to members in earlySeptember attracted 50

delegates and as we went toPress the first Tooling AllianceGroup was being set up.

It involves 10 companies andGTMA will now begin matchingthe skills and expertise to possi-ble projects in specific sectors.It will then go in and discussprojects with the targets.

The initiative is strongly focusedon helping OEMs and Tier 1buyers and part of the processis to audit Alliance companies inareas such as traceability.

Benefits for the customer, saysGTMA CEO Julia Moore,include the ability for the ToolingAlliance groups to becomeinvolved in design developmentbringing their knowledge of the tool into the concept stage of design – where 80% of manufacturing cost is determined.

“Tooling Alliance groups canreduce product product cycletimes by eliminating waste,improved product developmentco-ordination, inventory reductionand joint Failure Mode EffectsAnalysis (FEMA),” she said.

Profit improvements for the firstyear for one customer and moul-der, for one product, come fromcutting lead time by a week,commissioning time by oneweek, reduced scrap, and pro-ductivity gains of 10%. Theseare viewed as minimum savings.

The Alliance members benefitsinclude:

• Reduced cost of tendering forcontracts and dealing withsuppliers

• Shorter time to market, partlybecause of openness ofdesign information

• Technical Supplier team to

>>>

New initiative to helpmembers win big businessTooling Alliance groups to target OEMs and Tier 1s

Member companieswho want to becomeinvolved in the toolingalliance initiative are askedto contact GTMA for moreinformation, by email [email protected] or tel:0121 601 6350.

CRDM has beeninvolved in a new groundbreaking solution for Marfansyndrome, a hereditary med-ical condition that affects12,000 people across the UK.

The syndrome is a disorder ofthe body’s structural tissuesdue to a deficiency in fibrillin - astructural protein fibre. It canaffect many areas of the body,including the aorta – the mainarterial conduit from the heart.

CRDM worked with TalGolesworthy, the founder and

technical director at Exstent, asufferer himself who realisedthat if the aorta is only weak intensile strength in the wall, thesolution could be an externalsupport with a bespoke sleeve.

The result is EARS (ExternalAortic Root Support), a sleevemanufactured using magneticresonance imaging, computer-aided design and rapid proto-typing.

As he developed the project Talcontacted Imperial College, whocalled in CRDM as it knows of

its unmatched expertise in RPand its strong commitment toinnovation. CRDM then convert-ed the CAD stl files into solidpolymeric formers for manufac-ture of the EARS implants.

Each implant needs to beunique and distinctively identifi-able and CRDM has solved thisproblem by carrying out analphanumeric recessed textprocess situated on a non-mor-phologically sensitive part of theformer.

To date, 24 patients including

Tal himself have received theimplants, all of them manufac-tured by CRDM.

www.crdm.co.uk

CRDM helps treat hereditary syndrome>>>

present to the customer• Shared risk with a team

approach on market correctpricing and affordability

• Shared marketing costs on the big projects

• Project management to bedone by GTMA appointedmanagers.

Over-riding these however is thatonce the Alliance has successfullyworked together the aim is thatthey continue to do so.

GTMA NEWS ISSUE 2 2012 2/10/12 15:22


5

...

An innovative start-to-finish process for manufactur-ing titanium tibial trays forsurgical knee implants hasbeen unveiled by GTMA mem-bers GF AgieCharmilles andEOS Electro Optical Systems.

The machine tool firm and addi-tive manufacturing machinebuilder are co-operating on theventure, which was first seen atthe IMTS exhibition in Chicagoin September.

The process starts with anFEA/CAD design, developedusing medical software, of alightweight, strong tibial tray.The part’s complex geometrycombines variable pore sizes onone side to promote osseointe-gration with a smooth surfaceon the other to support theloads on the tibia.

An EOSINT M 280 direct metallaser-sintering system automati-cally builds the component fromtitanium powder, layer by layer,to produce a near-net-shape

piece. It then undergoes con-ventional machining, first on aMikron HPM 450U 5-axis milland then on a CUT 20P wireEDM machine, both from GFAgieCharmilles, which unveiledthe venture on its stand.

“This blend of technologies goesfar beyond what most otherproduct developers are present-ly doing,” said Gisbert Ledvon,Business Development Directorat GF AgieCharmilles in the US.

“The result is a cutting-edgeturnkey manufacturing systemthat operates with very littlehuman intervention and a mini-mum of scrap material.”

Andrew Snow, Regional SalesDirector, EOS of North America,said: "While the demonstrationat IMTS was of a medical com-ponent, this type of processchain is applicable to practicallyany industry.

“A look around the standallowed visitors to see a rangeof parts for the aerospace,automotive, tooling with confor-mal cooling, consumer andother sectors.”

www.gfac.com.ukwww.eos.info

Knee implant is innovative>>>

A titanium tibial tray for a surgicalknee implant – it was produced byadditive manufacture, 5-axis millingand wire EDM.

over 70,000 items from stockContact STOCDON, The Tooling Specialists....

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Survey moves on

Over 2,600 companies havenow been contacted as partof the GTMA's UKToolmaking Survey 2012,the first such detailed look atthe sector for over a decade.

Final calls are being made aswe went to Press and thenumbers declining participa-tion or due for call back isjust 8%.

Work on analysing theresponses will begin shortlywith the final report due outearly in the new year.

Information:[email protected]

First for BriefingThe Energy Briefing publication nowbeing produced for GTMA has beengiven a boost with the announcementthat RenewableUK will be co-branding the initiative.

It is the first time a third party organi-sation has been as closely involved inthe highly successful series.

RenewableUK represents about 500 companies in the supplychains for offshore and inshore wind, tidal energy and others.The organisation will help with editorial and distribution, including placing it on its website.

To take part call Colin Swindells on 01243 828358([email protected]).

GTMA NEWS ISSUE 2 2012 2/10/12 15:22

new members spotlight... new members spotlight...

6

Sector solutions: SpectrumMetrology is a specialistcompany providing measurement solutionsacross sectors includingaerospace, automotive, calibration, medical and precision engineering.

The product range is used for arange of applications through-out the world and covers:

• Portable 3D coordinate measurement systems

• Workshop surface roughness,

roundness and form• Electro-Optical Metrology• Laser Tracker Accessories• Dimensional measurement

products (contact and noncontact)

• Gauging and Transducers.

The company is agents for

Taylor Hobson (workshop surface finish/roundness,Alignment, Angle and Level),FARO (Gauges) and Brunson(laser tracker accessories).

• But with many years metrology experience SpectrumMetrology is not just a distribu-tor: It takes the time to understand customer applica-tions – study their drawings –measure their components –and then offer them the bestsolutions to their measurementproblems.

www.spectrum-metrology.co.uk

Spectrum Metrology

Man and Machine Patterson & Rothwell

BEC GlobalBrunson InstrumentGTW Developments GroupKillala PrecisionLonsdaleParagon Design SolutionsStocdonSuccinct SolutionsTinius OlsenTriune Precision Engineering

New Members:

Autodesk Partner: Man andMachine is a PlatinumAwarded Autodesk Partner,specialising in the supply ofCAD solutions to manufac-turers, engineers and prod-uct designers. With over 60years of combined technicalexpertise, it can empoweryou to design and visualisebetter.

Autodesk suites and itsAutoCAD and other softwareare powerful tools for designaggregation, helping to connectand streamline your design anddocumentation workflows.

Man and Machine prides itselfon delivering honest guidancefor its customers’ digital designrequirements. From a simple 2Dsketch to a complex engineer-ing design solution it has thetechnical expertise and experi-ence to deliver the right soft-ware and hardware to supportyour CAD needs.

Its services embrace:

• Technical Support - A rangeof levels to suit your budgetand needs: from telephonesupport within guaranteedtime lines to engineer call outcontracts.

• Consultancy – includingdesign reviews, project man-agement, license compliance,2D to 3D process transitionand best practice.

• CAD Training – both sched-uled courses and bespoketraining.

www.manandmachine.co.uk

In-house Injection Mould Designincorporates Moldflow, the out-standing polymer predictionsoftware package.

The range of sectors coveredhas broadened the company'smaterials usage experience,from exotic materials for thedefence industry to parts forautomotive, white goods, elec-tronics, packaging and con-struction.

Its toolmaking skills, whichstretch over 25 years, is cou-pled with investment in plant,personnel and training whichallow P&R to compete success-fully at the highest levels.

www.patterson-rothwell.co.uk

Strong, loyal: Attention todetail at every stage andstate-of-the-art InjectionMoulding and InjectionMould Toolmaking facilitieshas helped Patterson &Rothwell (P&R) build astrong and loyal customerbase across 25 industry sectors.

Toolmakers of P&R's calibrerarely exist within an Injectionmould company and its in-house tool room commissionsover 60 injection mould tools ayear - all covered by the com-pany's ground breaking 10 yearwarranty.

With ISO 9001 and TS16949accreditations P&R is qualityconscious and system focused.

GTMA NEWS ISSUE 2 2012 2/10/12 15:22

new members spotlight... new members spotlight...

7

Best supplier: IndySoft isrecognised as a supplier ofthe best 'commercially avail-able' Enterprise-wide rangeof gauge management,instrument calibration andtool management softwaretools on the market.

The company constantly listensto customer needs and closelywatches for changes in the market to stay ahead of thecompetition. This ensures itscustomers software is never out of date.

With almost 20 years of continu-ous real-world development –and thousands of global licencesales - IndySoft understandsindustry requirements, andspecifically needs for complianceto standards including QS9000,TS16949, ISO9000, FDA 21CFRPart 11 and ISO 17025.

It has customers across indus-try sectors including aerospace,automotive, medical, defence,food, electronics, rail, R&D,space and commercial labora-tories.

A major advantage of usingIndySoft software products is itgives you the benefits of yearsof feedback and pooled

resources from other industry-leading professionals.

www.indysoft.co.uk

IndySoft

Techni-modulEngineering

Werth Metrology

Composites innovator:Techni-modul Engineeringhas over 25 years experi-ence in tooling, design andmanufacture for the produc-tion of composite parts. It's expertise in various processing methods meansit can define the best tech-nology for your compositeproject.

It was a finalist in the JEC 2011Innovation Awards for its innovative development of aheating fluid circuit that optimis-es the thermal reaction of com-posite tooling.

Among processes it is familiar

with are RTM (Resin TransferMoulding), Infusion,Thermoforming, Prepregs andFinal Pressure TransferMoulding (FPTM), which is anadaptation of the RTM andPrepreg technologies. It con-sists of injecting resin on pre-impregnated fibres under pres-sure in a closed mould.Sectors served include aero-space, automotive, marine,energy, sport and leisure.

The company is also a leaderamong machine builders, producing standard and spe-cial, made-to-measuremachines to exact requirementsincluding laboratory and ther-moplastic presses; and com-paction, cutting, preforming,control and injection machines.

www.techni-modul-engineering.eu

projectors with standard solu-tions for optical 2D and 3Dcoordinate measurement tech-nology, to highly-advancedcoordinate measurement equip-ment with multiple sensors.

The company’s goal is to attaina high degree of customer sat-isfaction through world classtechnical solutions and unlimit-ed user-orientation.

www.werth.de

Quality Innovation: Quality,precision and innovation arethe basis of success atWerth Metrology, part ofWerth Messtechnik GmbH.

With over 60 years servingindustry the company has builtan admired tradition in finemechanics and optics.

It has installed over 10,000measuring machines in manyindustrial fields. Applicationexamples include: aerospaceengineering, automotive manu-facturing, electronics, jewellerymaking, toolmaking, plasticinjection moulding, medicaltechnology, turbine manufactur-ing, and aluminium or plasticextrusions.

It is a leader in coordinate measuring technology with optical sensors, multisensorsand X-ray tomography, as wellas in the measurement of microfeatures.

Its product range extends fromclassic profile and measurement

GTMA NEWS ISSUE 2 2012 2/10/12 15:22


8

This year's annual meetingcoincided with the GTMA's70th anniversary dinner atthe Nailcote Hall, Coventry.

A special guest was JohnBoneham of Boneham &Turner, the association'slongest serving company whichjoined on July 2, 1943. GTMACEO Julia Moore said: “It wasdelightful to welcome John andpay tribute to the work of hiscompany in our industry over allthese years.”

The event also saw a newPresident, Geoff Highley, andtwo new Board members: JonRackley and Bob Tunks.Tribute was paid to outgoingPresident Alan Pearce of SGSCarbide (UK) for all his workduring his three years in office.

Geoff Highley: Geoff was previously General Manager atMcLaren Racing for nine years,and before that worked in vari-ous divisions of BAe. His back-ground allows him to bring a dif-ferent perspective to the GTMA.

As he points out: “Although Idid run a toolroom at BAe, Ihave not worked as a toolmak-er, or even within an SME. I amtold this gives me the ability to

ask the questions that manyothers don’t think of, as well asthe knack to quickly cut to thecrux of an issue.”

He is passionate about theassociation’s supply chain initia-tive, the ManufacturingResource Centre (MRC), andlooks forward to its ongoingdevelopment.

“The MRC considers every stepof the supply chain as a valueadding opportunity. This is aroute to a more engaged inter-face between the customer andGTMA members supplying spe-cialist support services andexpertise.

“Initiatives such as this, therecently introduced interactivewebsite and the commercialisa-tion of the EU technology projectIncremental Sheetmetal Forming(ISF), will all help the associationretain its members and attractnew ones,” said Geoff.

The GTMA’s strap line is‘Supporting ManufacturingExcellence’, he noted. It is nocoincidence that SME featuresin there. “It still fires me up,” hesays. “My goal is for us all –every part of the manufacturingindustry – to get better at whatwe do.”

There were also two newBoard members elected:

Jon Rackley, WolverhamptonUniversity: Jon has been involved in theDepartment of Engineering forfive years, and is responsible for

mould tooling developmentusing additive layer manufactur-ing techniques in the InjectionMoulding and Pressure DieCasting industries.

His 33-year career has centredon tooling technologies. Origi-nally a mould design apprenticewith Metal Box, he has workedin roles including: tooling andmoulding development withRPC, Technical Manager, DME(Asia/Pacific), UK managementof hot runner companies andBusiness DevelopmentManager, Jordans Toolmakers. Jon is interested in the develop-ment of new technologies in theToolmaking industry.

Bob Tunks, MD, BK ToolingLtd: Bob served a formalapprenticeship in toolmaking

before moving into productionengineering, a discipline that hestrongly feels should be inte-grated with the toolmakingprocess.

At 25, he was manager of ahigh pressure sub-contract tool-room; at 29 went into partner-ship forming a mould toolmak-ing company in Plymouth; andfive years later in 1991 set up B K Tooling in Hertfordshire asa plastic mould toolmaking andmoulding service, where he isdeveloping a rapid tooling system which he sees asimportant for the future of UK toolmaking.

He is strongly committed topromoting training of the next generations of UK toolmakers.

New President backsManufacturing Resource Centre

Jon Rackley, WolverhamptonUniversity:

Bob Tunks, MD, BK Tooling Ltd

GTMA NEWS ISSUE 2 2012 2/10/12 15:22


9

Craftsman Tools' DesignEngineer David Boothroydpresented the CyrilJohnson Memorial Awardat the GTMA's 70thAnniversary Dinner andAGM at Nailcote Hall,Coventry in June.

The award winner wasMichael Clack of ThomasKeating Ltd in recognition ofhis achievements and dedi-cation to both ThomasKeating and the engineering

industry as a whole.

The Cyril Johnson memorialaward has been established inrecognition of the outstandingcontribution by the late CyrilJohnson to the precision engi-neering industry.

Cyril was a founding partner ofCraftsman Tools in 1953 andled the company for more than40 years. He contributed greatlyto the precision engineeringindustry and the GTMA. Under

his guidance, the companygrew substantially and has beenat the forefront of work andtoolholding technology through-out its almost 60 year history.

Michael Clack is an outstandingtoolmaker with wide technicalversatility – covering presstools, moulds, jigs and fixtures.He joined Thomas Keating asan apprentice in 1970, and hasbeen a Director since 2003.

Among many achievements he

manages a steady stream ofprecision machine tools, maintains the ISO 9000accreditation, and is respon-sible for recruitment andapprentices.

Michael is closely involved in the company's export-ledinstrumentation productsincluding for the world'slargest ground-based tele-scope project which led to aQueen's Award for Enterprisein her Jubilee year.

...

New award goes to an award winner !

Hexagon Metrology has cre-ated the ROMER BikeMeasurement System, amobile 3D measurementsolution fully approved bythe International CyclingUnion (UCI) for the measure-ment of bike frames at rac-ing events.

The system is based onHexagon Metrology’s portablemeasuring arm, the ROMERAbsolute Arm with integratedlaser scanner, and was devel-oped in collaboration with theLaboratory of Polymer andComposite Technology (LTC) atthe Swiss Federal Institute ofTechnology (EPFL).

The system includes 3D inspec-tion software and is configuredfor user independent non-contact measurement ofbike frame geometry, ensuringtotal transparency and stabilityin professional bike racing.

The system is the UCI’sapproved instrument for check-

ing bike frame legality, irrespec-tive of where the measurementtakes place.

The scanner gives excellentperformance even on high glosscarbon fiber surfaces and thedifficult to reach areas typical ofprofessional bike frames today.

During measurement the inte-grated laser scanner collects30,000 3D points off the frameevery second, allowing the userto create a highly accurate 3Dmodel of the frame itself. The

user can measure an entire bikeframe, compare it to its respec-tive CAD model and generate afinal measurement report in lessthan ten minutes.

Prof. Jan-Anders Månson,Director of the EPFL’sLaboratory of Polymer andComposite Technology, saidthe system helps to make surethe dimensions of racing bikesare completely above board,even during a race.

www.hexagonmetrology.com

Racing bike system gets international approval

New websites for Trac GroupTrac Group & Divisions; TracPrecision Machining, TracTooling and Trac MeasurementSystems, all part of theEngineering Group, havelaunched their new linked web-sites offering a single onlinepoint of reference for all Traccustomers, globally.

Michael Parry MD of TracMeasurement Systems and aDirector of Trac Group in the UK,led the development of the web-site. He said: “Our customers andprospective customers can find allrelevant information on the TracGroup companies including prod-ucts & services offered, corporate& product films and technical infor-mation easily and efficiently.”

The site was launched onSeptember 10. Web addressesare:

www.trac-group.com www.measurement.trac-group.com www.tooling.trac-group.com www.components.trac-group.com

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

THE ERODEX GROUPDesign and Technical Services

Since it’s foundation over thirty years ago BWP has been providing a fast,

first-class design service to industry and the aerospace sector. Now, as part

of the Erodex Group we can offer a full project management, procurement,

build and certificate service to make BWP a one-stop-shop for all of your

design, tooling and EDM electrode needs. All aspects of any project are

simultaneously designed by one team to provide a streamlined process, opti-

mum technical solutions and shorter project lead-times.

■ Jig and Tool Design and Build■ 2D - 3D Conversion■ Electrode Design■ 3D Printing■ Special Purpose Machinery and Automation

BWP Technical ServicesLion Works, 543 Wallisdown Road, Poole

Dorset, BH12 5ADTel: 01202 546732/546733

Fax: 01202 522526Email: [email protected]: www.bwptech.co.uk

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

At the heart of…

MANUFACTURING UK

Precision excellenceat your service 12-13What we do:Precision Engineering 13A-Z: PrecisionEngineering 14

Erodex leads in EDM 15Moorland is anaward Winner 16Aspin has knowledge 16Craftsman's big investment 17

Angstrom is innovative 17Press Tools - marketleaders to serve you 19-20A-Z: Press Tools 20What we do: Press Tools 21

Stocdon has quality 21Roemheld helps UK 22ND Precision is excellent 23Bropel celebrates a lot 23

In this Section…

New SeriesGTMA - At the Heart of... Manufacturing

UK is a new series to highlight the cross

industry skills and experience of GTMA

companies.

Buyer ResourceIt will build into a resource for buyers and

specifiers across all sectors, allowing

them to find more easily companies with

the products and services necessary to

bridge supply chain gaps.

Case StudiesAs well as Case Studies exemplifying best

practice, At the heart of... will include

A-Z’s of relevant companies, many of

them European and world leaders.

11

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

Well over 100 GTMA memberscarry out precision machiningin-house when producing tool-ing for customers – with manyoffering specialist services tonon tooling clients.

They include leading manufac-turers of precision engineered

parts and special die mouldbases to companies who spe-cialise in delivering prototypesand low volume productionparts.

“Precision machining is thebackbone of much of the workour members do for their cus-

The precision machiningresource within GTMA stretchesright across industry sectorsfrom aerospace and automo-tive, including Formula 1,through to medical devices,packaging, rail, marine, energy,defence and, of course, generalengineering.

At the heart of…MANUFACTURING UK

12

GTMA - At the Heart of... Manufacturing UK is a new series tohighlight the cross-industry skills and experience of our member-ship. It will build into a resource for buyers and specifiers acrossindustry sectors from aerospace and automotive to medical,marine, rail, energy and packaging.

Many of these companies have gained experience in specific indus-try sectors which are easily transferrable to others. These sectorsrange from aerospace and automotive to medical, marine, rail,energy and packaging.

This issue features Precision Machining – both CNC andConventional machining – and Press Tools, where companies not only have in-depth knowledge of manufacturing tools but

Global leaders give GTMA the edge...Precision excellence for YOUR sector

also of standard parts and components, as well as services.

Future issues will cover Jigs & Fixtures, Tooling Technologies,Moulds & Dies, Metrology, Materials, Workholding & AncillaryEquipment and Miscellaneous – itself a huge resource with compa-nies supplying everything from Analysis and Design Services toInjection Moulding Machines and Shopfloor Data Systems.

Each At the Heart of... will include an A-Z of member companieswith websites, a break down of the range of products or services available, case studies and summaries of some of theleading players in their fields, many of them on a European andglobal stage.

These companies have sponsored this At the Heart of... section.

tomers,” says GTMA CEO JuliaMoore. “It is also key to thehelp we can give major buyersin our priority sectors when theyapproach us to build strength intheir supply chains.

“Many of our members areEuropean and global leaders.”

Precision machiningexpertise in GTMA isacross the full spec-trum of manufactur-ing needs – frommicro machiningthrough to large-scaleprojects exampled inthis photo from mem-ber company AccuraGeometric. Manymembers have sec-tor-specific qualityaccreditations as wellas ISO 9000 andenvironmental standards.

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

A 'can do' attitude is combinedwith commitment to investmentin people and state-of-the-artequipment, which includes CADsystems, vertical machining sys-tems, EDM systems, 4- 5- and6-axis machines, and muchmore. The whole package fromGTMA promises quality serviceand on-time delivery.

It is the combination of tradi-tional skills – some membershave been in the business for50 or 60 years ! - and the latestdesign and engineering thatresults in outstanding perform-ance and innovation.

Skilled engineers and toolmak-ers work closely with customersand suppliers to ensure accura-cy, precision, on-time deliveryand above all excellence in qual-ity. Complex machining to tighttolerances are second nature.

Members also have built upexpertise in dealing with highspecification aluminium, magne-sium, titanium, stainless steeland a range of exotic materials;and there are members alsowho have worked in areas suchas satellite microwave compo-nents, finished to microns inexotic materials.

In-house experience oftenembraces areas such as sur-face treatments, includinghand-finishing and polishing ofhydraulic components.

Many of the precision engineeringcompanies are specialists in spe-cific areas – there are those withexpertise in deep hole boring,EDM, prototyping, gun drilling,water jet cutting, profile grinding,and all kinds of finishing.

Others are leaders in carbon and

CNC Horizontal Milling CNC Jig Boring CNC Jig GrindingCNC MachiningCNC MillingCNC Precision Machining CNC Routing CNC Sheet Metalwork CNC Sink and Solid Sink CNC Sliding Head Turning CNC Spark Erosion CNC Turning CNC Vertical Milling CNC Wire Erosion

Cold Rollforming Tooling Custom Lapping Die SinkingEDM Drilling EDM Spark Erosion EDM Wire Erosion Engraving Fast Hole Drilling Form Grinding Free Access CuttingGun Drilling High Speed Hard Metal

Machining High Speed Milling Large CMM Inspection

Long Bed Grinding Micro EDM Machining Micro MachiningMulti-Spindle Copy Milling Optical Profile Grinding Precision Machining Profile GrindingPrototype Machining Solid Sinking Spark Erosion Surface Grinding Thread Grinding Turning Vertical Milling Water Jet Cutting Wire Erosion

13

Precision Machining

What we do…Expertise within GTMA covers a wide range of disciplines. Those listedhere are a small sample ofwhat is on offer usingstate-of-the-art equipment.

5-Axis Machining5-Axis Milling Boring – Deep Hole CNC Cylindrical GrindingCNC High Speed Milling

graphite applications (includingsemi-conductor tooling); in zero-point fixture systems, which areincreasing the size of parts thatcan be machined; and in materi-als analysis.

GTMA members are also awareof the need for practising envi-ronmentally-aware strategies(and have the Quality standardsto prove it) and in the need forstrict confidentiality. They aretrusted suppliers where securityis paramount.

It is no surprise therefore thatso many work within the aero-

space and defence industries,motor sport, packaging, med-ical and pharmaceutical andconsumer electronics.

Buyers requiring special preci-sion machining can callGTMA on 0121 601 6350 forhelp in identifying the compa-nies best suited to theirneeds, either direct orthrough the ManufacturingResource Centre.

www.gtma.co.ukwww.manufacturingresource-centre.co.ukEmail: [email protected]

Photos courtesy (l to r): Erodex, Proto Labs, Waveney, Superite, Agie Charmilles and Aspin Engineering. Below: Craftsman Tools.

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

14

At the heart of…MANUFACTURING UK

More than 60 GTMA membersare included on the GTMA web-site as offering CNC and/or con-ventional Precision Machiningservices. Many others use preci-sion machining in providingtooling and other products totheir customer bases, and someof these also use their specialistexperience on a sub-contractbasis.

Please call GTMA for moreinformation on 0121 601 6350 or email: [email protected]

3D Lasertecwww.3dlasertec.co.ukAccura Geometricwww.geometric.co.ukADS Precision Tools Ltdwww.plasticinjectionmouldtool-ing.co.ukAdvanced Tooling Systems UKwww.atsuk.com

Agie Charmilleswww.gfac.com/ukAlphateqwww.alphateq.co.ukAmtek Precision Engineerswww.amtek-precision.comAPI Precision Toolmakerswww.apiprecision.co.ukAspin Engineeringwww.aspin-engineering.comBedestonewww.bedestone.co.ukBrafe Engineeeringwww.brafe.comBurcaswww.burcas.co.ukCraftsman Toolswww.craftsmantools.com CTL Engineeringwww.ctl-eng.comCube Precision Engineeringwww.cubeprecision.comDelcam UK (Tooling Services Division)www.delcam.co.uk

EDS Engineeringwww.edseng.co.ukErodex (UK)www.erodex.com Fenland RPwww.fenlandrp.co.ukFirst Cutwww.firstcut.euFSG Tool & Diewww.fsgtoolanddie.co.ukGB Precision Engineeringwww.gbprecision.co.ukHadleigh Castingswww.hadleighcastings.com Harper & Simmonswww.harperandsimmons.co.ukHanson Thorpe PrecisionToomakerswww.hansonthorpe.co.ukHockley Pattern & ToolCompanywww.hockleypattern.co.ukIsomachwww.isomach.com Thomas Keatingwww.terahertz.co.ukKemet Internationalwww.kemet.co.ukMoorland ToolmakingCompanywww.moorlandtools.comN.D. Precision Productswww.ndprecisionproducts.co.ukNewcastle Tool & Gaugewww.ntg-ltd.co.ukDG Mortimer & Cowww.ukplasticmouldings.co.ukPDQ Engineeringwww.pdqengineering.comPhoenix Engineering [email protected] [email protected]

A-Z of companies - Precision Machining

Powell ManufacturingTel: 024 7668 5131 Fax: 024 7663 7886PP Injection Mouldswww.ppmoulds.co.ukProto Labswww.protolabs.co.ukwww.protomold.co.ukwww.firstcut.eu/gbQuick Toolswww.quicktoolsltd.co.ukRyetools

www.ryetools.co.ukSGH Mouldswww.sghmoulds.co.ukShield Engineeringwww.shield-eng.comSmithstown LightEngineeringwww.sle.ieSolent Mould Toolswww.solentmouldtools.co.ukSuperitewww.superite.co.ukTokai Carbon Europewww.tokaicarboneurope.comTRAC Heatonwww.trac-group.comTRAC Precision Machiningwww.trac-group.comTremic Toolswww.tremic-tools.co.ukUnijigwww.unijig.co.ukWaveney Precisionwww.waveneyprecision.co.ukWhiteland Engineeringwww.whitelandengineering.co.ukWines Groupwww.winesweb.com

Aspin Engineering Ltd

Aspin Engineering has been designing andmanufacturing a range of quality productsand components for more than 20 years.

Among the company’s wide range ofproducts are standard and customdesigned dieheads, extrusion crossheadsfor wire and cable production, and specialmixing heads. A full refurbishment andrepair service is offered that includes on-siteattendance to measure up and manufacturespare parts.

The firm’s expertise and capacity also includes:

• Machine Tool Parts Manufacture• Plastic Moulding Tools• CNC Machining• Thread Grinding of Plastic Moulding Cores• CNC Turning• Polishing and Universal Grinding• CNC edm Wire Cut Machining

Contact: Anton Aspin

Address: Unit 5, Egremont Close, Moss Lane Trading Estate, Whitefield, Greater Manchester M45 8FH Tel: 0161 766 9622 Fax: 0161 766 1423Email: [email protected] Website: www.aspin-engineering.com

Photo courtesy EDS Engineering

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

15

An electrode-led designprocess has become thefocus for Dorset-based BWPTechnical Services, part ofthe Erodex (UK) Group.

BWP specialises in projectmanaging a one-stop shopsolution from design to manu-facture of work-holding and lift-ing solutions for complex andprecision parts, especially in theaerospace sector.

Too many companies, it says,make the mistake of having atooling-led approach to thedesign process for EDM, ratherthan an electrode-led designprocess.

“The design and performanceefficiencies of electrodes aretoo often sacrificed because theholders are designed first,” saidBWP Director, John Rolinson.

“The key is to design the elec-trode first, then design the hold-er to correctly fit the electrodewith a dedicated tooling solu-tion. It is the electrode thatdoes the work, and is processcritical – not the holder.”

This process, combined with

•DESIGN AND MANUFACTURE OF NEW TOOLING

•TOOL SERVICING AND REFURBISHMENT

•TOOL MODIFICATIONS

•CAPACITY UP TO 10 TONNES

•PRECISION MACHINING

•LASER WELDING SERVICE

SPECIALISTS IN

Moorland Toolmaking LtdLady Ann Court, Lady Ann Road,

Batley, West Yorkshire, WF17 0PY

Tel: 01924 470666 Fax: 01924 472666e-mail: [email protected]

web: www.moorlandtools.com

Erodex – at the leadingedge of EDM applications

approved toolmakers and guid-ance from Erodex which is oneof the market leaders in EDMelectrodes for aerospace appli-cations, is the key to success.

Its choice of toolmaker is alsocrucial – often bringing reducedproject costs and lead times bysplitting a tool or suite of toolsbetween several companies.

Recent successes include EDMtooling for aerospace clients inthe UK and US; a large bliskhandling solution for a leadingaero engine producer; and asafety-led lifting project drivenby the need to separate opera-tors from aggressive acids usedin aerospace production.

In all cases, BWP providedinnovative, robust and costeffective designs which met or exceeded project parameters.

This commitment to excellenceis paying dividends, with thecompany seeing 58 per centgrowth in turnover year on year and a strong customerbase in the aerospace sector.

www.bwptech.co.uk

Photos courtesy Erodex (UK)

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

16

As one of the UK's leadingprecision engineering com-panies, and a recent UKToolmaker of the Year,Moorland Toolmaking hasbeen providing first classtooling solutions for theinjection and compressionmoulding industry for over25 years.

Moorland Toolmaking isn't justa tooling manufacturer; it is acomplete solutions provider.

Superior, innovative tooling solu-tions come as a direct result ofbeing constantly at the forefrontof technological advances. It hasinvested heavily in state-of-the-art CAD and technology over-seen by a highly experiencedteam supported by the latestmachine tools and software.

Recent investments include the

latest version of Delcam'sPower Shape 3D softwarecombined with new generationcomputers and Heidenhainmachine controls - all of whichensure you get the very besttooling for the job.

Moorland Toolmaking engineerscan collaborate with your ownteams, in real time, to providecustom-built applications. Theycan meet your brief, budget andlead times whether workingfrom your own drawings ordesigning a solution fromscratch.

As an award winning companyMoorland Toolmaking personi-fies the best there is. Operating from a customised16,000 sq ft factory and techni-cal centre close to the M1 andM62 in West Yorkshire, it hascapacity to manufacture tooling

from small precision multi-cavitycomponents to suites of toolsup to 10 tonnes.

The company offers a completemanufacturing facility to cater forall general engineering require-ments. Specialist servicesinclude:

• Sub-contract machining • Jigs and Fixture work • 1 off's to multiple batchwork • Spark Erosion • Wire Cutting

• Deep Hole Drilling • 3D Machining • CNC Milling • CNC Turning• Laser Welding Service

As well as precision machinedcomponents manufactured tofine tolerances, short lead times,and with personal service,Moorland also offers a full refur-bishment service for injectionand compression mould tools.

www.moorlandtools.com

Precision Machining

Award winner Moorland isa complete solutions provider

Aspin Engineering is typicalof GTMA companies whoapply knowledge-basedtechnical solutions to meetand exceed the exactingstandards of its clients in awide range of sectors.

It has been designing and man-ufacturing a wide range of quali-ty products for customersthroughout the UK plastics andrubber extrusion industries forover 15 years.

It also manufactures compo-nents and assemblies for the

textile, machine tool and foodsectors and is the main world-wide manufacturer of the patentRAPRA Cavity Transfer Mixerfor RAPRA licencees.

Other sectors served by AspinEngineering include power gen-eration, plastic moulding andmixing (batch and continuous).

As a specialisist in the manufac-ture of extrusion equipment forthe rubber and plastics industry,it offers a range of Crossheadsfor wire and cable production. Itcan also make Dieheads for

hose and tube manufacture.

Aspin has a reputation for quali-ty, excellent service and cost-effectiveness and itssphere of operations embracesmachining, thread grinding, universal grinding, surfacegrinding, turning, polishing, pro-totyping, tool room fitting, horizontal boring and verticalboring.

More information from its web-site or call: 0161 796 6122.

www.aspin-engineering.com

Aspin uses knowledge-basedsolutions to meet needs

GTMA NEWS ISSUE 2 2012 2/10/12 15:26

17

Precision EngineersCraftsman Tools has invest-ed £300,000 in extending itsOtley design and manufac-turing facility. The invest-ment has so far added fournew jobs, taking the skilledworkforce to over 60, withtwo further apprentices join-ing the company this year.

A leader in the tool-holding andwork-holding markets,Craftsman has added an addi-tional 5000 sq ft to the shopfloor, allowing existing space tobe used as a dedicated appren-tice training area and creatingroom for a new DoosanDBC110S horizontal boringmachine.

This provides a substantialincrease in production capacityand is already generating signifi-cant interest from companies inthe oil, gas and power genera-tion sectors.

The new machine enables further development ofCraftsman’s zero-point fixturesystems, increasing the size ofparts that can be machined.Existing work-holding rangesare currently experiencingincreased interest from a number of high profile UK andoverseas customers.

Further efficiencies are beingrealised at the West Yorkshirebase with the installation of anew and automated verticalstorage system. Meanwhile,investment continues atCraftsman’s Chevin Tools oper-ation in Chicago, essentially asales and distribution centre forproducts designed and manu-factured in Otley.

At the forefront of work andtool-holding technology,Craftsman fields the skills andexpertise to meet the mostexacting and demanding preci-

sion engineering tasks, withcontinued investment in the lat-est design techniques, state-of-the-art machinery and plantmaintaining industry leadership.

Other recent products includeSplit Boring Bar Holders, providing excellent vibration

absorption, deeper boringcapability and improved stabilityduring machining; and aportable hardness tester for on-site components inspection,developed in partnership withCameron USA.

www.craftsmantools.com

Precision Machining

Why the energy sector likesCraftsman's £300,000 investment ...

Craftsman Tools managing director Robert Johnson (right) and businessdevelopment manager Tim Thorburn with new products in the company’snew extension.

Continual investment isoften at the heart of manu-facturing and no-where is itmore recognised than withmember company AngstromEngineering.

Established in 2010 to providesmall toolroom flexibility andprices, but with the technicalability of larger concerns, itsinvestment policy means it cancontinuously look for new andinnovative ways to produce tool-ing faster and more efficiently.

At the same time, Angstrom’sIT set up enables it to work withcustomers throughout the UKas well as France, Germany,Holland and Spain.

It has extensive knowledge ofprogression, separate op, andprototype tooling forming mate-rials such as aluminium 5754,stainless steel in bright-workgrades, and dual phase steels.Not only automotive driven, ithas experience in sub sea, elec-trical contractor, solar power

generation and white goods.

Its abilities include full associatedassembly modelling, with motionsimulated tool designs to enhancecustomer confidence; full 3Dmachining capability; and state-of-the-art wire EDM machinesallowing reliable, accurate andunattended die production.

Forming simulations can be car-ried out from basic 'look andsee' at the quotation stage, tofull incremental solutions for risk

reduction during the designprocess. One of the attractionsof working in toolmaking is thechallenge of the next project -each new component presentsa fresh set of problems to solve,and that is a core strength atAngstrom.

For those who might be inter-ested, (and it is often asked!) anangstrom is one ten-billionth ofa metre!

www.angstrom.uk.com

Angstrom's investment spurs on innovations

GTMA NEWS ISSUE 2 2012 2/10/12 15:35

ND Precision ProductsToolmakers / Precision Engineers

Mould Tools

Press Tools

EDM/Spark Erosion

WEDM (Wire Erosion)

High Speed Milling

Electrode Design

Jigs & Fixtures

0 1 2 7 1 3 4 5 4 9 [email protected]

Looking to improve productivity?Look no further

Roemheld Workholding. The one to watch. For full details contact us on 0121 453 1414or visit www.roemheld.co.uk

Shenstone Drive, Northgate, Aldridge, West Midlands WS9 8XU

Technical Welding Ltd

We offer an exceptional service for precision specialist welding of plastic injection, pressure die casting and press tools.

• Fast Turn Around - while you wait or next day

• Laser Welding

• Tig and Micro TIG Welding

• Onsite Welding - Fast Call Out

• Collection and Delivery up to 500kg within 25 mile radius

• Reliable courier service for customers further afield

• Flame Hardening

• Welding of all Tool Steels, Aluminium,Stainless Steel and Cast Iron

• Batch & Repitition Welding

• Handling Capacity up to 10 Tonnes

If we can be of any assistance please contact Welding Enquiries

Darren Cook or Sue Lloyd - Tel: 01922 745745On site Welding: Neil Baggott: 07866 611235

www.bropel.co.uk Email: [email protected]: 01922 745745 Fax: 01922 745746

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

The pedigree of GTMA presstool companies is at the lead-ing edge of the sectors theyserve right across industry.

GTMA companies are leaders intheir chosen markets – fromaerospace and automotive topackaging, nuclear, defence toinvestment casting and GasTurbine industries.

At the heart of GTMA PressTools are people skills andinvestments in state-of-the-artequipment.

Member companies are some

of the best equipped press toolmanufacturers in the UK andIreland with policies of continu-ous improvement and accredi-tations. They are committed togive their highly skilled work-forces the means to achieveexcellence.

It has paid off with healthy orderbooks and globally recognisedrespect. For example CrossenEngineering in Northern Irelandhas been working with theworld’s leading gas turbinecompany in the US to developa new method of producingaero engine air seals. Instead

of being rolled they are pressedusing a tool machined by PaulCrossen.

A further press tool aerospaceproject was to design a presstool for forming a sector ofengine nacelle lip skin from asheet metal blank, currently aluminium but looking to titani-um for the future. The prototypewas exhibited at the ParisAirshow.

Often the investment in newmachinery and technologies hasa direct impact on cost effective-ness as the productivity gains

are passed on to customers.

Across the membership therehas been spending on anextensive and diverse range oflarge capacity technology.

From small mock-up tools tolarge tooling suites, CubePrecision Engineering has thecapacity to project manage andmanufacture a wide range oftooling for the aerospace, automotive and white goodsindustries

With machining capacity up tofive metres and lifting capacity

Press Tools

Market leaders are at your service....Press tool suppliers invest to keep ahead

Photo courtesy ND Precision, Quick Tools, Roemheld.

continued on page 20

Press tool companies in the GTMA really are At the Heart of… Manufacturing UK, with members serving leading companiesacross many industry sectors.

“The skills and experience we have is second to none,” says GTMACEO Julia Moore. “Many of our members lead in Europe and the

work they do is often ground-breaking and the solutions theyimplement are sometimes among the most innovative in the world.

“As an organisation we are UK leaders in tooling and ourToolmakers' Forum is bringing even more focus to the help we cangive manufacturing supply chains.”

19

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

20

up to 35 tonne, its tryout facili-ties up to 1000 tonne offer aviable alternative to home linepresses for tryout and emer-gency breakdown back-up.

The company are specialistpress tool makers so whether itis for automotive body sides, aclass 'A' panel for interior run-ning boards or dashboards, oreven the front strutted case forthe latest medium range air-craft, Cube Precision has theexperience and knowledge.

Another leading company is Accura Geometric whichrecently added 2.5metre sur-face grinding to its varied list ofmanufacturing capabilities

which includes 5axis machining,large milling, EDM and compo-nent prototyping.

The ability to provide all this in-house has seen it expand itstraditional offering of press toolmanufacture into new sectorsincluding the chemical, motorsport and power generationindustries, taking employeenumbers above 70.

However aerospace now repre-sents 40% of sales. To achievethis Accura adapted its tool-making skill set and knowledgeof manufacturing methods tothis industry. It now both manu-factures the tools for pressingaero engine components in high

temperature materials and pro-duces complete processedparts, delivered in Kits, readyfor assembly, to a Kanbanscheduling system.

A recent project included themanufacture of a complete setof engine parts, necessitatinglow volume pressing, 5-axismilling, wire erosion and 5-axislaser cutting. To support all

this Accura has gained AS9100and Nadcap (EDM) accredita-tions.

Finally, there are specialist companies in the supply ofPress Tools Standard Parts and Components, includingDayton Pogress the world'slargest manufacturer of con-sumable precision press toolcomponents and accessories.

Press Tools

continued from page 19

A-Z of companies - Press ToolsGTMA members in the cur-rent Buyers Guide servingPress Tools are listed below– with the strength of theirexpertise very wide.

It covers not only manufacture,often in specialised areas, butalso services such as presstools trials and the supply ofstandard parts and compo-nents.

Please call GTMA for moreinformation on 0121 601 6350or email: [email protected]

PRESS TOOLS - MANUFACTURERS

Accura Geometricwww.geometric.co.ukAngstrom Engineeringwww.angstrom.uk.comAPI Precision Toolmakerswww.apiprecision.co.ukBedestonewww.bedestone.co.ukBruderer UKwww.bruderer.co.ukCasting Support Systemswww.cssltd.infoCrossen Engineeringwww.crossengroup.com

CUBE Precision Engineeringwww.cubeprecision.comDelcam (Tooling ServicesDivision)www.delcam.co.ukEDS Engineeringwww.edseng.co.ukErodex (UK)www.erodex.com FSG Tool & Diewww.fsgtoolanddie.co.ukHarper & Simmonswww.harperandsimmons.co.ukHockley Pattern & Tool www.hockleypattern.co.ukIsomachwww.isomach.comThomas Keatingwww.terahertz.co.ukMoorland Toolmakingwww.moorlandtools.comN. D. Precision Productswww.ndprecisionproducts.co.ukPortway Tool & Gaugewww.portwaytool.co.ukPowell Manufacturing Co [email protected] Engineeringwww.shield-eng.comSurface Generationwww.surfacegeneration.comToolritewww.toolrite.co.uk

Quick Toolswww.quicktoolsltd.co.ukWaveney Precisionwww.waveneyprecision.co.uk

PRESS TOOLS – SERVICES

3Dnorth CADCAM Serviceswww.3dnorth.co.ukDutton Simulationwww.duttonsimulation.comFSG Tool & Diewww.fsgtoolanddie.co.ukHarper & Simmonswww.harperandsimmons.co.ukThomas Keatingwww.terahertz.co.ukMouldtech Solutionswww.mouldtechsolutions.com

N. D. Precision Productswww.ndprecisionproducts.co.ukStrandwww.strandeng.com

PRESS TOOLS – StandardParts/Components

Boneham & Turnerwww.boneham.co.ukBruderer UKwww.bruderer.co.ukDayton Progresswww.daytonprogress.comTalbot Tool Cowww.talbot-tool.co.ukUnijigwww.unijig.co.uk

Photo courtesy WNT (UK) – a GTMA member with over 45,000 items oftooling in its catalogue. It is listed under Special purpose equipment on the website.

Single operation form tool for off-road vehicle panel – images courtesyAccura Geometric

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

21

Tooling specialists StocdonLimited of Cheltenham is aGTMA company offeringEurope’s premier line of pre-cision thread gauges - over70,000 items, from stock.

It can deliver more than 7,000different thread dimensions andtolerances, covering all kinds ofthreads from 1 to 250 mmdiameter. All are high precisionand have enormous resistanceto wear.

Going one step further, thedevelopment of MultiCheck dra-matically cuts the time to checkthreads over a specified depthby measurement with a depthgauge. It has a depth measur-ing sleeve which is screwed inand the depth up to 3 x nomi-nal thread diameter can be eas-ily read off the sleeve. Alsoavailable is a VernierMultiCheck with 0.1mm resolu-

tion, and a digital readoutMultiCheck with 0.01mm.

Another great product is itsextremely hard-wearing line ofTiCN coated, calibrated HSSThread Plug Limit gauges whichare the choice for 10 x gauge life.It has excellent anti-friction prop-erties, and reduces checking.

Stocdon are sole UK agents forJBO of Germany which hasbeen providing tooling for over70 years and successfully mak-ing high quality thread gauges.All JBO thread gauges comecalibrated and certified by DKD(UKAS).

Continual development of grind-ing and lapping techniques hasresulted in above-average sur-face finish of the thread flanks,so JBO thread gauges are par-ticularly good because of theirhigh precision and enormous

resistance to wear. The bottomline is quality.

The attraction for Stocdon isthat, as with all of its tooling, itknows quality is top priority formanufacturers such as JBO,and so can safely assure itscustomers they are purchasingcost-effective, problem-freeequipment.

JBO-manufactured gaugesconform to national and interna-tional standards. Inspectionand documentation are carriedout at high-tech measuringmachines in climate-controlledconditions separately from pro-duction.

Stocdon serve sectors fromengineering and the valveindustry to motor sport andaerospace. All agree, it says,that “…Stocdon have thelargest thread gauge pro-

gramme ever seen of standardproducts, with quick delivery,too”, and “…the best pricesin the UK, with plug gauges less20% and ring gauges less 45 –50% of market prices.”

Stocdon are proud to be asso-ciated with JBO, and consi-tently supply the very best inthread gauges, thread millingtools & dies.

www.stocdon.co.uk

Foil ToolsForming ToolsHot Forging ToolsLaminate ToolsPanel ToolsPiercing ToolsProgression ToolsTungsten Carbide ProgressionToolsPin Tooling TechnologyPress ToolsPress Tool ModificationPress Tool RepairPress Tool ServicingPress Tool SparesPrototype PressingsPunch Press ToolsReverse Deep Drawing ToolsSemi-Conductor ToolingSilicon Carbide Semi-ConductorTooling

Subtractive Pin ToolsTransfer ToolsTugsten Carbide LaminationToolsWarm Forging Tools

SERVICESAnalysis and DesignBlank DevelopmentComponent DevelopmentPress Tool DesignPress Tool TrialsProgression Tool Design

STANDARD PARTS / COMPONENTSAluminium Die SetsCam Piercing UnitsClevis PinsCustom Die SetsGas Springs

Gas Spring ManifoldsGrinding Long BedsGrinding SurfaceIn-die Tapping UnitsJig and Fixture ProductsPillars and BushesPress Tool Feed EquipmentPunch and DiesSealing PlugsShimsSteel Die SetsStripper BoltsTapping UnitsTooling AidsUrethane Parts for Press Tools

Photos courtesy (l to r): Erodex,Proto Labs, Waveney, Superite, GF Agie Charmilles and Quick Tools

What we do…Here are just some of thepress tools manufactured byGTMA members, along with asmall cross section of presstool services and the manyhundreds of standard partsand components supplied.

MANUFACTURE:Automotive Panel ToolsBlanking ToolsCanning ToolsCold Forging ToolsCombination ToolsCompound ToolsDeep Drawing ToolsExtrusion ToolsFine Blanking Tools

Press Tools

Quality at the heart of Stocdon's premier line

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

22

As well as providing precision machining andpress tools there are alsospecialist GTMA memberswho support UK manufacu-turers with equipment tohelp them achieve excel-lence.

Among these is workholdingsystems specialist Roemheldwhich helps companies com-mitted to investing in the bestmachines and the best toolingwith products such as its Hilmavices which are being used,among others, by world leadinghydraulic tool manufacturer, Hi-Force Limited.

The Hi-Force UK headquarters,based in Daventry, is rapidlyexpanding with investment of£1.7 million-plus on machinesand over £90,000 of tooling on-site. Its manufacturing capacityhas recently grown from 15,000to 47,000 sq. ft. with plans togo to 67,00

Hi-Force's emphasis in manu-facture is on accuracy and relia-bility and this is why it pur-chased two Roemheld HilmaMC125Z hydraulic vices. Theyare being used on its new MoriSeiki NMV 5-axis machiningcentre, which has a five palletworkload system. It primarily

makes components forhydraulic wrenches, includingmain bodies from TWS17N andTWH27N up to TWS100N andTWH120N, plus JAS Jacks andmany other high volume smallcomponents.

Hi-Force Workshop Manager,Paul Dutton, said: “We werevery impressed with the perfor-mace of a Hilma MC125Z vicewhich was previously fitted onanother Mori Seiki machine.This vice has been workingacross two shifts for two and ahalf years and it has maintainedfull accuracy despite both jawsmoving. So Roemheld was anobvious choice when we werelooking to fit further vices on ournew machine.”

He said Hi-Force is so pleasedwith their quality and reliabilitythat it plans to fit at least twomore Roemheld vices as itexpands its machine shopcapabilities.

The company produces over1700 products and specialisesin high volume production. Itexports 87% of its products toover 100 countries in sectorsincluding Oil & Gas,Petrochemical & Refining,

Power Generation, Steel &Aluminium Plants, Paper Mills,Sugar Refineries, Railways,Mining, Construction, ShipBuilding & Ship Repair,Aerospace, Defence and HeavyEngineering.

Group Managing Director, KevinBrown, said Hi-Force is commit-ted to manufacturing products ofthe highest quality, using the bestmachinery available, to ensure itsproducts meet the most stringentquality requirements possible –and yet retain a competitive pricein its global markets. “That is whywe only work with quality toolingsuppliers, such as Roemheld,”he said.

Roemheld is committed toresearching and developingproducts designed to meet notonly the demands and expecta-tions of today’s discerningbuyer, but also emerging mar-kets and applications. Throughcontinued improvement ofproducts and services, theRoemheld Group intends toremain an innovator at the fore-front of technology. For moreinformation call 0121 453 1414or visit the website.

www.roemheld.co.uk

Press Tools

Roemheld - helping theUK to better performance

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

Press Tools

23

Member company N DPrecision Products is anoutstanding example ofGTMA members with a longhistory of tooling excellence.

It was 40 years ago the NorthDevon based company begantrading with aspirations to be aleading supplier of high qualitytooling for the manufacture ofelectrical and electronic connec-tors for the automotive industry.

A wide range of metal stamp-ing/forming tools were being

produced from high speedmulti-stage progressions to ter-minal crimping applicator tools,all based around wire to wireconnection technology.

Four decades later, the samehigh quality tooling is still beingdesigned and manufactured at N D Precision Products - but toa much wider spectrum ofindustry sectors. The press andforming tools supplied todayproduce components that canbe found in sectors from oil &gas right through to medicalapplications.

The combination of this wealth ofexperience and investment insophisticated machinery and soft-ware ensures demand for their

products continues to be strong.

www.ndprecisionproducts.co.uk

ND Precision – a history of excellence

Bropel Technical Welding iscelebrating its second yearof full trading – 40-plus yearsafter the seeds were bornfor the company, which hashuge expertise in the tool-making sector.

It was formed in September2010 on the reorganisation ofwhat was previously BropelSpecialist Welders (founded1969).

Since then Bropel TechnicalWelding has made a big impactin the sector and, says MD SueLloyd, daughter of the originalBropel founder John HigginsonSnr, its success in its first twoyears is down to “a fantasticteam.”

Many of these have workedwith Sue for over two decadesand their expertise helped thenew entity to ISO 9001 accredi-tation within 18 months.

“We basically went back to ourroutes,” she said. “We haveachieved an enormous amountin these two years and have avery loyal customer base. I amvery proud of what the teamhas done.”

At the heart of the company isits core skills including:

• Laser Welding – with over 10years experience its laserteam are among the leaders –and the fastest - in the sector.The process is used to repairand modify tools and dies.

• TIG and MIG Welding – theoriginal company were pio-neers and this tradition of highlevel service continues to pro-vide quick and efficient solu-tions to industry. It is oftenused for larger repair areas.

• Tool Repairs – specialists inmodification and repair of

tools, with minimum down-time in your production. Thisincludes on-site service within24 hours when required.

Bropel Technical Welding are

always happy to discuss yourspecific requirements. Pleasecall 01922 745745 or email:[email protected]

www.bropel.co.uk

After 40 years experience Bropel Technical Welding celebrates its 2nd anniversary !

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

technology... technology... technology... technology...

24

Emerging Technologiesthat give competitive advantageAnother sucessful GTMA Emerging Technologies event was held atDelcam's facilities in Birmingham on September 19 with the focuson new technologies in manufacturing that can provide a competi-tive edge.

Keynote speaker was 'growth' entrepreneur Mike Smith, CEO ofBromford Industries, who spoke on ‘How an SME can be success-ful at pitching for a multi-million $US contract’.

Bromford Industries was formed in 2009 out of a management buyout funded by Darwin Private Equity and is a privately owned enter-prise trading on a global basis serving the aerospace market.

Through their expertise, Mike and his board of directors, have pro-vided a strong platform for growth in the company and have suc-ceeded well in the acquisition of businesses, investment in machin-ing and wins of major contracts.

Mike has held various senior roles in manufacturing based busi-nesses, covering brown goods, white goods, automotive and aero-space. He sits on the board of the CBI council; is an Ambassadorof the STEM program; and is passionate about investing and sup-porting young people into apprenticeship programs, harnessingfresh new talent into his business.

The presentations included:

Brian Castelino, MD, Machine Vision Technology.

In a very hands-on presentation Brian demonstrated live a machinevision system to demystify the technology and give examples of itsuse. Brian is one of the most experienced people in the UK in thefield having been involved in the technology since it emerged herein 1985. Today, it is found throughout industry performing highspeed inspection and non contact measurement.

Machine Vision in The Production Environment

Graham Waters, GTW Developments Group.

In the textile industry yarns need to be joined together at somestage of production and traditionally were knotted. Now pneumaticyarn splicers are virtually universal in textiles to make joints whichare smooth, strong, and unobtrusive. But pneumatic splicers arelargely unknown in the composites supply chain. Graham looked atthe problems and how new splicers have been developed for com-posites.

Yarn splicers and the composites industry

Steve Creron, Delcam

Steve, now responsible for all UK sales activities for Delcam, joinedthe company in 1985 and toured the UK as part of the then DTIsponsored road show promoting CADCAM to UK industry for twoyears. Prior to that he was with General Motors. He was part of themanagement team that purchased Delcam from the Delta group in1989 and was appointed General Manager in 2008. His presenta-tion covered Vortex high-speed roughing.

Vortex Machine DNA

Steve May Russell, Smallfry

Steve is a graduate in Industrial Design and Engineering fromLeicester De Montfort University. Following a condensed MBA atWarwick University he studied consumer marketing underrenowned 80’s marketing guru Philip Kotler at the JL KelloggGraduate Management School in Chicago. He has worked withblue chip companies worldwide including Boots, Unilever and GSKand represented the creative industries on the UK Trade &Investment’s bi-lateral partnerships in the Far East. The focus of hispresentation was on how to “realise opportunities you have yet toimagine.” To inspire a business effectively you need a bold com-pelling vision. Created Futures™ is for business leaders and seniormanagement teams looking for insights, business cases andhands-on experience to inspire teams and deliver tangible out-comes. Visionaries conceive and embrace a world ahead to imag-ine the way things will be and the way people will want to live. Hispresentation looked at how leadership can help teams be morecreative, entrepreneurial and have greater confidence.

The best way to predict the future is to create it

GTMA NEWS ISSUE 2 2012 2/10/12 15:36

technology... technology... technology... technology...

25

Hot desks at the event were manned by BirminghamUniversity, Delcam UK, EOS, ES Technology, Fenland RP,GTMA, GTW Developments, HR4 UK, Renishaw, SFJ Systems, SGS Carbide Tool, Starrag UK, Steinbichler andVero Software.

Stuart Jackson, UK Manager, EOS Electro Optical Systems

Although DMLS (Direct Metal Laser Sintering) Tooling has beenaround for many years uptake has varied greatly. Stuart showedwhy and where DMLS has succeeded, and gave a future perspec-tive of expected growth and technical developments. EOS is theworld-leading manufacturer of laser sintering systems used forrapid prototyping, rapid tooling and rapid manufacture. Laser sin-tering is the key technology for e-Manufacturing, the fast, flexibleand cost-effective production of parts directly from electronic data.

A Global Perspective on the uptake of DMLS for

Production Tooling

Daniel Lainchbury, Physical Digital

The presentation dealt with the 3D scanning of the last remainingMk11a Spitfire that saw service in the Battle of Britain: How thecompany conducted the scan, the processes involved in scanningsuch a large object, and downstream applications for the data (SeeGTMA Issue 1/2012). The company was called in by Amalgam FineModel Cars who needed the digital data to create a highly accuratescale model. Physical Digital used a combination of photogramme-try and three systems which were used to capture the data: GOMTRITOP, GOM ATSO and GOM Touch Probe.

Preserving a National Treasure

Photo courtesy Roemheld

Dr Sein Leung Soo, School of Mechanical Engineering

Leung is currently Head of the Machining Research Group atBirmingham University, which is widely regarded as a centre ofexcellence in its field. He explained how engineering materials usedin high performance aerospace applications such as gas turbineengines and aircraft structures are typically characterised byadvanced physical/mechanical properties such as high strength toweight ratios, large stiffness modulus or the ability to operate underextreme temperatures and loads. Despite aspirations for netshapemanufacturing, machining operations remains a key process forboth roughing and finishing of components in aerospace. The pres-entation gave an overview of current research into the challengesassociated with the machining of advanced aerospace materialssuch as nickel based super alloys, titanium alloys and carbon fibrecomposites from the perspective of workpiece integrity. Some ofthe latest developments in new innovative processes to improvemachining efficiency and flexibility were also covered.

Research and Technology Developments in the Machining and Advanced Aerospace Materials

Dr Moataz Attallah, lecturer in advanced materials processing atthe School of Metallurgy and Materials, University of Birmingham.

The use of powders is a resource-efficient approach to producecomplex net-shape structures, with potentially low buy-to-fly ratiosand much reduced materials waste. compared to other manufac-turing processes. Challenges of net-shape manufacturing includeimproving productivity to produce high throughput technologies,securing the supply chains for powders, and the development ofprocess modelling capabilities. Dr Attallah summarised the keyissues.

Resource-efficient high value net-shape manufacturingusing powders

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

27

Automotive eventsupply chain appeal 28-29Hot Desks 29

Dutton saves money for auto 30-31Proto Labs is keyto success 33

WNT's 25 yearsof service 33Boneham's uniquesolution 35

Cube grows in automotive 35

In this Automotive 2012 Focus:

automotive

SpecialGTMA recently hosted a special

automotive event with Vero

Software featuring advanced

materials and processes.

Supply ChainsCEO Julia Moore told delegates

there was a need for supply chains

to be supported.

Best PracticeThe programme saw a range of

presentations highlighting manu-

facturing best practice in a sector

employing around 130,000

in the UK.

Photo from Delcam UK – see pages 42-43

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

automotive... automotive... automotive... automotive...

28

GTMA and member company VeroSoftware co-hosted a sheet metalevent for the automotive industry inJuly, featuring advances in materialsand processes from right across thesupply chain.

The event was held at the Coventry factoryof another GTMA member, Agie Charmilleswhich is a supplier to the British FormulaOne manufacturer Lotus F1 team. It wasJames Robinson from Lotus who gavethe keynote presentation in which helooked at challenges for the future.

He also detailed the team’s close workingrelationship with Agie Charmilles since1997. Lotus leases 10 Agie machines –wire EDM, EDM machining centres andmills – updating them every three years, tomachine around 60,000 parts a year. Lotuswill be taking delivery of six 5-axis multi-palette machines shortly.

GTMA Chief Executive Julia Moore tolddelegates the UK motor industry employsaround 135,000 people. Car manufactur-ers, she said, need to support and nurturethe supply chain, and the GTMA’sManufacturing Resource Centre provided afocal point for taking the supply chain tothem, and demonstrating that toolmakersprovide good quality products, on time.

Delegates learned how VISI Modelling fromVero Software, combats springback, whereresidual stress after a bending operationcauses the sheet metal to spring out ofshape due to the material elasticity. TrevorDutton, of Dutton Simulation (see pages30-31) said this was critical for componentssuch as outer panels on vehicles.

“Springback causes geometrical fit andfunction problems, along with cosmeticflaws.”

Vero Marketing Manager Marc Freebreydemonstrated VISI tools which compensatethe original CAD geometry by a preciseamount at pre-production stage to achievethe desired form. “These steps use the dif-ference between the original CAD data andthe mesh analysis to change the relevantparts of the geometry to adequately com-pensate for springback once productionstarts.”

Other topics included Chris Buxton, CEOof the British Automation and RobotAssociation, explaining that Governmentgrants are available to help companies

implement automation. The UK AutomatingManufacturing Programme provides aware-ness and education about the benefits ofrobots and automation, along with expertsupport and financial assistance.

For further information go towww.automatingmanufacturing.co.uk.

With the event held at Agie CharmillesTechnology Centre, the machine toolmak-er’s Product Manager Steve Burrowssaid the main benefits of the linear motortechnology which features in theirmachines, are accuracy, surface finish, andrepeatability. “We have seen a ten-foldimprovement in surface finish over twoyears, with linear motors.”

Dr Per Hansson, SSAB’s ToolingProduct Manager, said die making manu-facturing time had been reduced by 32%using pre-hardened tool steel. He gave anexample where pre-hardened tool steelwas used to make the tools for the stamp-ing of 1.8mm 600DP, and the tool manu-facturing time was reduced by two weeks.

Auto event hears appealto 'support the supply chain'

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

automotive ...

29

Another benefit is its stability and strength. A company using pre-hardened steel for the tools to stamp 1mm 400DP found the die dis-played no visible wear after stamping 1.6 million components.

Developments in low cost sheet metal processes were demonstratedby Roger Onions, Business Development Director at the MRC.He said low tooling costs and reduced lead times, along with high tol-erances and level of detail on parts, meant Incremental Sheet MetalForming was becoming increasingly popular over traditional presstools for manufacturing low volume body parts in the automotive,aerospace, rail and marine industries.

ISF is also popular for repairs in aftermarkets, architectural features, sig-nage, personalised or customised products and medical plate inserts.

SMIRT software, from Vero is a manufacturing process managementtool designed specifically for the Die Build stamping industry. CosimoGalante showed how it integrates with design data giving an effort-less and clear 3D representation, reducing errors, leading to overallimproved data management. Best practices are captured and madeavailable as a template for use in future projects.

The event was rounded off by Mike Richards, Managing Directorof press toolmaker Accura Geometric. In his overview of the tool-making industry, he said the sector was now in a positive period ofhigh activity, after ten years of UK manufacturing outsourcing press-work, which saw toolmaker numbers reduced by 60%.

UK toolmakers, he said, need to demonstrate the total life cycle costsavings of British-made tools compared to those from abroad, andchallenge the willingness of customers to accept inferior overseasproducts.

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Hot Desks at theevent:

Delcam UKDutton SimulationForegone SolutionsIMSMIndysoftMantech/Werth Omega PlasticRoemheldSSABTRAC MeasurementVero Software

2 Agie Demonstrations

Photos from the GTMA AutoEvent held at member com-pany Agie Charmilles'Coventry facility. Hot desks,left, and the ManufacturingResource Centre stand. Left,bottom, Marc Freebrey, VeroMarketing Manager. Vero co-hosted the event and Marcdemonstrated VISI tools.

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

automotive... automotive... automotive... automotive...

30

Trevor Dutton, founder of DuttonSimulation, presented the latest meth-ods for sheet metal cost estimationand optimisation at the GTMA automo-tive event in Coventry.

He told delegates how computer-aidedcosting and process planning systems cangive five or six figure savings on a singlebody-in-white panel over the vehicle life-time.

Dutton, with its partner FormingTechnologies, is a leader in sheet metalcost estimation and optimisation.– especial-ly in the automotive sector where the com-pany works with major OEMs such asHonda in Swindon, through to individualtool designers who need to determine ablank size for a tool.

Modular ApproachTrevor demonstrated how FTI's Forming-Suite is used. It is fully integrated softwarewith a modular approach depending onrequirements within a single user interface.He showed how FTI'S FASTBLANK andBLANKNEST/PROGNEST systems can becombined with layout editing to determinenot just the optimal material usage for apart but also how, by editing the layout andidentifying critical nesting points, the yieldcan actually be increased.

Just a few millimetres adjustment can givethe five or six figure savings on a singlebody-in-white panel over the vehicle lifetime.

And as a typical car might have 350 sheetmetal parts (20 outer panels, 20 inner pan-els, 150 structural and 160 small parts)overall cost savings can be enormous.

Now, with FTI’s latest option –ProcessPlanner – benefits can be evengreater as this goes to the next stage bydeveloping a process for the part. It ulti-

mately calculates the tool cost and is atechnology recently adopted by BMW.

Getting it right at the start influences costsenormously and Trevor emphasised theimportance of upfront analysis to optimisecost, manufacturing and product function.

In the presentation Trevor looked in detailat blank development, where special blankprediction software calculates the minimumblank size from a 3D CAD model. Themethod is fast, accurate and widely adopt-ed throughout industry.

The best material yield for sheared blanks,nested coil or progression strip layouts arecalculated using blank nesting and progres-sive die nesting software.

A key issue with the method is that materialcost is based on CAD only. It confirms pro-gramme budgets at each “gateway,” andprovides reliable benchmarks to reviewsupplier quotes.

While raw material dominates the Total PartCost, both Process and Tooling costs arealso needed: Process Cost takes account ofthe number of operations to make the partand factors such as whether manual or auto-mated press facilities will be used. ToolingCost calculations are based on size, numberrequired, type (direct vs cam operations) andother factors such as location.

ProcessPlanner uses process templatesbased on legacy methods. All featuresmust be assigned to an operation and tool

How to save money in AutoDutton shows savings of “five or six figures” on a single panel

Images, courtesy of Dutton Simulation,which highlight some of the modulesmaking up FTI’s FormingSuite software.It brings huge cost savings in vehiclepanels by upfront analysis to optimisecost, manufacturing and product function.

Above is the new ProcessPlanner whichgoes a stage further by developing theprocess for the part.

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

automotive ... automotive... automotive... automotive…

31

cost calculations are – again - based onCAD data only. The system offers cus-tomisable cost formulas and reports.

Part cost data reports are used as bench-marks to check part cost vs. budget foreach part – and these highlight outliers forfurther analysis. Reliable benchmarks likethese help to review quotes from suppliers.

Cost contoursEvery part, of course, has critical nestpoints which control the pitch and widthdimensions.

Optimising the shape (contact) of thesepoints yields higher material use, and ifengineering changes are made, it is veryimportant to know if the changes are in thefree material zone or at a critical nest point.Trevor showed how cost contours are usedto highlight critical contact points for partmodifications to save material – with thesecontours on both the blank and the part.

Once again a key benefit is that the cost opti-misation is based on CAD data. The informa-tion flow of the system not only improvesmaterial use and design efficiency but alsogives immediate feedback to part design.

Automated Material Utilisation Analysis takesplace by exporting from the vehicle modeldata the part geometry (batch process fromV5 to IGES) to the FTI costing system.

This checks design efficiency and when it isnot acceptable the parts are reviewed usingthe FTI CostOptimizer in Catia V5. Part

changes to improve efficiency are identifiedand the changes confirmed as acceptablefor all functions. Only then is the designdatabase updated.

Forming FeasibilityTrevor also explained methods used forupfront analysis to establish manufacturingfeasibility. This covered issues including:

• Formability • Splitting• Wrinkling/Loose Material• Excessive Thinning • Processing• Trimming & Piercing considerations• Number and type of forming operations

required and Forming force required• Depth of Draw• Dimensional Control (Springback

Compensation)

The full feasibility assessment, therefore,requires consideration not only of the geom-etry and material but also the intended man-ufacturing route (press line size and forceconstraints, number of forming stations, etc).

In the presentation Trevor looked in moredetail at 'Formability' where FASTFORMformability analysis software is used.

Failure criteria on a Forming Limit Diagramshow the effect of thinning of material, high-lighting when wrinkling limits are exceededand where there would be splits.

The automotive sector needs differentanalysis methods at different stages of the

development process. FASTFORMMultistage allows upfront analysis of parts that are not formed in a single operation: the system needs to track strains between operations, and developtrim lines between forms.

The FTI Multistage solver produces fastsolutions allowing an iterative approach toprocess design. Solution times for completesequences can be under one minute. At alater stage, incremental analysis becomemore important. FTI FAST Incrementalstamping analysis (e.g., based on LS-DYNA) is the most accurate simulation toolbut requires tool design data to operate –particularly for wrinkling prediction.

Therefore a method is needed to automatetool creation from final form geometry, andDutton uses the Auto Generate function inFAST Incremental for this. Part tool geome-try is created including punch, blankholderand die.

Simplified user interfaces enable non “FEA”specialists to apply the method as there isminimal effort to create required input data.

Benefits of this modular approach includeearly analysis of part formability usinginverse methods for fastest calculation, aswell as the ability to use incremental meth-ods earlier in the tool development phase.

Springback CompensationIncremental solutions, said Trevor, alsoallows Dutton to consider one of thebiggest remaining challenges – springbackcalculation and, especially, tool compensa-tion for springback.

Springback causes geometrical fit andfunction problems but also causes cosmet-ic problems which are critical for outer pan-els. “By calculating the deviation from therequired shape we can apply this in reverseto correct the tool,” he said.

“The method is iterative and once predic-tion is within tolerance we can map themodified CAE model to the CAD data.”

www.duttonsimulation.com

GTMA NEWS ISSUE 2 2012 2/10/12 15:38

GTMA NEWS ISSUE 2 2012 2/10/12 15:38


33

GTMA member Proto Labs has beeninvolved in bringing to the mainstreamautomotive market car keys “cloned ata touch.”

The concept has been devised byBirmingham-based 1st Call LockoutsLimited a traditional locksmith companywhich has entered the automotive lock-smith market.

The company’s latest plan to tap into anew revenue stream provided some verydifferent challenges.

Most modern car keys feature an electroniccoded chip (transponder) and a lost orstolen car key requires far more than a tripto the local key-cutter. 1st Call planned tooffer the market a quick and cost-effectivemethod of programming these transponderswithout an expensive visit to the car dealer.

1st Call’s solution is called TouchClone™:“keys cloned at a touch”. Essentially, theproduct is a merger of technologies incor-porating a traditional transponder, an elec-tronic reader, and a cloning device. Thisthree-in-one functionality makesTouchClone unique; its cost is less than

half that of existing technologies.

A big challenge in manufacturing was todesign a suitable enclosure. Investors want-ed to see and feel prototype productsmade from real engineering materials,rather than those used in RP processes.

1st Call Lockouts called in product designagengy Nebulem, and it was Nebulemwhich developed a design with some keyelements 1st Call wanted. These included a‘tablet’ format currently popular for portablePC devices; smooth edges and roundedcorners so it was easy to hold; and abilityto have the product’s name in large letterson the front cover (beneath the screen).

Fortunately Nebulem has worked withProto Labs before and when it completedthe design concept it was passed to ProtoLabs. Using the company’s Firstcut® ultra-fast, CNC machining service, two proto-types were produced in nylon.

“Such was the accuracy of the machinedsamples that we were able to use the pro-totype covers to scrutinise the entire prod-uct design very closely,” says Michael Hims,Project Manager at 1st Call Lockouts.

Cloned at a touch – Proto Labs really was key to success

The latest catalogue from WNT celebrates the group’s 25th anniversaryof providing a unique approach to thesales and support of technical cuttingtools to the metalcutting sector marketacross Europe.

The latest catalogue contains over 45,000items, with many having specific interest forthose operating in the tool- and mould-making sectors, and many of these operat-ing in the automotive industry.

Examples include the latest Centro P OZ

precision collet chucks, with a guaranteedrunout accuracy of 3 micron. The chucksand the new OZ style collets allow users ofcutters with shank diameters between 16

and 25 mm diameter to fully utilise theirmetalcutting capacity thanks to the addi-tional gripping power available.

Similalrly, the new Multi Change solid carbide milling system has been developedfollowing demand from the mould and diesector, which was looking for simple interchangeability, along with high precision,to provide compatibility with the typical lowvolume, fine tolerance work undertaken bymould makers.

www.wnt.de/en-en/

WNT's 25 years of market leading service

Proto Labs’ design reviewing system alsoplayed a very important part in the earlystages of the design process. Credited byNebulem as “getting everyone on the samepage”, the company claimed it workedextremely well throughout the TouchClonedevelopment phase and allowed the projectto be managed simply from start to finish.

Nebulem, which has a history of successfulcollaboration with Proto Labs, says it actsas a vital link between clients and ProtoLabs’ services where projects require prod-uct design expertise.

TouchClone, with volumes likely to be hundreds-off, or low thousands, was dueto be in production as we went to Press.

www.protolabs.co.uk www.nebulem.com)

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

34

ADM Precision Tools Ltd is one of the UK’s premier tool-making companies specialising in injection and blowmould tooling design and in-house manufacturing.

Investment in advanced equipment and a highly skilledteam gives our customers an extremely competitive edgeto their technical requirements.

Our Industry Portfolio includes:Electronics - Medical - Electrical Consumer - Security - Packaging -Cosmetic - Dairy - Food and Drink - Household - Automotive - Car Care.

Injection Mould Tooling, Two Shot Mould Tools, Blow MouldTooling, Repairs and Modifications (Capacity up to 5 tonnes).

Tooling Repair – Aftercare – Preventative Maintenance Tool repair and modification work carried out on a 24/7 basis when required.

Tooling Trials – All our moulds are trialled at our sister company.www.AllianceMouldingServices.com

Quality Approvals: ISO 9000 series

Tel:0161 872 8881 Fax:0161 872 8883 Email:[email protected] Website: www.adm.eu.com

Managing Director: Jim Kelly Sales Contact: Steven Tynan

The Lodge,Westbrook Road, Trafford Park,Greater Manchester M17 1AY

PRECISIONTOOLS

LIMITED

For more information contact Simon Collins onTel: 01494 686820 Web: www.selectmoulds.co.uk

Select Moulds offer a full solutionFrom ‘conception to birth’ we can support our customers by supplying a ‘one stop’ service

Select Moulds offer a wide and diversified product rangeto its customer base, including:

• Automotive • Electrical (Switchgear) • Medical (Devices, Respiratory) • Telecom (Connectors, Mobile Phone) • White Goods • Aerospace (High Accuracy “one-off” Machining) • Repair and Refurbishment (All ranges of moulds, Non

Select Products, Prototype Moulds, Rapid Tooling, SoftTooling)

• Pre-Production Tooling (Fully Hardened ProductionSimulated Moulds)

• Multi-Cavity Moulds • Gas Injection • Multi-Shot Moulds • Full Turn-Key Packages

HIGH PRECISION INJECTION MOULD TOOLMAKERS

From single impression soft prototype tools to high volume fully hardened multi cavity tooling

Small enough to care yet big enough to deliver

T: 01803 846013 E: [email protected]

www.moultechsolutions.com

Why use Mouldtech ?• ISO 9001 accredited• Professional friendly service• Quality Tool making• Over 40 years experience• Efficient complete service• Set time scales• Peace of mind• Reliability

B K Tooling is a specialist

in the design and manufac-

ture of rapid tooling for

low to medium volumes of

plastic injection moulded

products.

B K Tooling

“Taking plasticinjection moulded products from concept to creation”

B K ToolingPleasant ViewGaston GreenBishop’s StortfordHerts CM22 7QS

Tel: 01279 600970Fax: 01279 600980

Email:[email protected]:www.bktooling.co.uk

GTMA NEWS ISSUE 2 2012 2/10/12 15:44


35

For over 94 years Boneham & Turner'sreputation for quality and excellencehas long been established – and it hashelped it become a valued supplier intoautomotive and motor sport.

B&T also provides engineering solutions toa wide variety of customers, both large andsmall, across other sectors including aero-space, power generation, defence andmachine building.

One of its products widely using in autom-tive is the KOENIG-expander®, a uniquesolution and global leading sealing systemfor drilled holes, represented by Boneham& Turner since the 1970s.

The system has been continuously devel-oped but maintains a core principle.

Designed primarily for hydraulic applicationsof low and extreme pressures, the Koenig

plug is now used across the automotiveindustry, including engine, power transmis-sion, steering and fuel injection systems.

Easy to install in a production line and withno special preparation needed, theExpander is proven to reduce operationscosts and provide a zero defect, 100%inspected solution for sealing drilled holes.

www.boneham.co.uk

Boneham's uniquesolution serves automotive

Cube Precision Engineering is expand-ing after seeing a surge in its automo-tive business.

It recently invested in a £300,000 CNCmilling machine Hurco DCX32 with a 3.2metre by 2.2 metre capacity. It was pur-chased with the help of a Regional GrowthFund grant of 35 per cent.

Cube manufactures press tools and com-ponents, selling mainly to the defence andautomotive industries, but also into aero-space.

Managing Director Neil Clifton said: “Rightnow manufacturing is buoyant. We aredoing very well, particularly in automotiveand defence. We are currently making a lotof tools for German customers whose partsthen come back to the UK for the likes ofLand Rover, Honda and BMW.”

The new equipment means smoother pro-duction, particularly as its integrated toolchanger “helps us work 24 hours a day andcomplements our shift patterns” Neiladded.

The 35 employee firm had a turnover of£3.1 million last year and expects that torise to £3.5 million in 2012.

The Hurco investment will see five newemployees taken on – two machinists, twotool makers and a CAD/CAM operator.

On the defence side, the work of Cube,established in 2009, involves products forengines, wings and interiors. It recently com-pleted projects on the Rolls-Royce BR725engine, and A350 Airbus planes as well asthe machining content on the recently over-

hauled CVR(T) personnel carriers.

Although aerospace/defence and automotive are its core industries, 20 percent of revenue comes from a variety ofother sources including: production oftooling for the low volume-high value furniture industry; machining for engine protection systems in trains; and machiningof items for ultra-precise measuring equipment including for Formula Oneteams.

www.cubeprecision.com

Cube's £300,000 investmentresponds to auto growth

Johnathan Dudley,

Midlands managing

partner of Crowe Clark

Whitehill which advised

on the Regional Growth

Fund, Julie Cranmer of

Lombard, which also

helped, and Cube

Precision MD Neil

Clifton.

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

World Leader in Coordinate Measuring Machineswith Optics, Tomography, Multisensor System

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

37

Roadshow focus ontechnology transfer 38-39The Exhibitors 39Renishaw's radicalsolution 40Showcase for newSpectrum 3D system 40

More from Delcamon PowerINSPECT 42-43Bower's takes thepressure off 42-43Micron movesinto new era 45

New branding atHexagon Metrology 47Indysoft makeslife easier 47Innovation fromThird Dimension 49

Smartphone firstfor Mahr 49New lease of lifefrom Heidenhain 5115th Queen's Awardfor Renishaw 51

In this MMM 2012 Focus:

MMM 2012

ImpressiveGTMA's Make MeasurementMatter Roadshow is all set to gowith an impressive line-up ofexhibitors and speakers.

ShowcaseThis year's event at the Centre forEngineering and ManufacturingExcellence in Rainham will oncemore be showcasing new productsand upgrades from member com-panies.

TechnologyIt is evidence again of how highlyregarded MMM has become as itfocuses on technology transfer.

M a k e M e a s u re m e n t M a t t e r

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

This year's MakeMeasurement Matter roadshow is again a sell out withover 35 of the top UKinspection and metrologycompanies exhibiting successful engineering solutions for current andfuture demands of all indus-try sectors.

The event on Oct 17 at theCentre for Engineering andManufacturing Excellence(CEME), Rainham, Essex, is thesixth hosted by the GTMA and,once again, says CEO JuliaMoore, “is providing a focalpoint for a technology transferfrom the science of measure-ment into the most demandingmanufacturing environments.”

Visitors can gain first-handknowledge from leading industryand academia key note speak-ers. These include PhilipBamforth, MeasurementManager, Rolls-Royce plc. He isresponsible for leading themeasurement and inspectioncommunity across the Rolls-Royce global manufacturingbusiness, principally focused on:

• Technology development anddeployment

• Standards & inspection qualitysystems, and

• External networks, partner-ships and suppliers.

Also at the event is MarkThomas, Principal

Instrumentation Engineer, BAESystems - Submarine Solutions,who will be speaking aboutmeasurement within LargeScale Manufacturing; and fromacademia will be GrahamMachin, Head, TemperatureStandards, NPL Fellow.

Graham joined the TemperatureGroup at NPL in 1991, aftercompleting his DPhil at theUniversity of Oxford on thePhysics of Compact StellarBinary Systems. He has pub-lished more than 100 papers ontemperature related issues andhas given numerous invited lec-tures around the world.

He has twice worked as aninvited guest researcher atNMIJ (Japan) and also at NIM(China). He is also the NPL rep-resentative on the BIPMConsultative Committee forThermometry (CCT), chair of theCCT working group on radiationthermometry and a member ofthe CCT taskforce for the Kelvinredefinition and CCT workinggroup on temperature scales.He is also NPL’s representativeon Euramet TC Thermometry,chair of TCT strategy group andmember of the Euramet TCTcmc review group.

In the chair will be Mike Excell,Contributing Editor of MWPMagazine.

Many of the exhibitors arereturning after successful previ-

ous attendaces. Among theseis Alicona, the non-contact 3Dmeasurement specialists. “Wewill be exhibiting at the MMMroadshow for the fourth timeand it is an event that Aliconaconsiders very important in theexhibition calendar,” said SalesDirector, Brian Kyte.

It will be showing, for the firsttime at this event, the

InfiniteFocus SL system, whichis based on the well establishedfocus variation technology andallows quick and easy measure-ments in a manufacturing andlaboratory/measurement roomenvironment.

Many GTMA members are tak-ing the opportunity to shownew products or upgradesincluding:

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Measurement event shows off solutions2012 Roadshow is focal point for technology transfer

The venue (above): The Centre forEngineering and ManufacturingExcellence, a world-class research,skills, education and business cen-tre in Rainham.

Left: Photo courtesy Alicona and(opposite) Phase Vision, two of sev-eral GTMA exhibitors who will beshowing new products or upgrades:testament to the standing of theevent.

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GTMA NEWS ISSUE 2 2012 2/10/12 15:44

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Bowers Metrology: demon-strating the completely newintegral digital readout featureon its compact two-pointMicroGauge bore gauging sys-tem, which is designed foraccurate measurement of boresfrom 1 to 6.00 mm.FARO Technologies: launch-ing the new Vantage, a truelaser tracker that combines dis-ruptive new features and asupremely portable design.Dramatic reductions in size andweight make the deviceextremely portable.

Mahr: giving a world premierefor its innovative measuring system MarSurf One whichcombines Mahr technology withthe comfort of a Smartphone.The premiere offers advantagesto manufacturers at affordableprices.Phase Vision: exhibiting a rangeof new, innovative non-contact3D measurement solutions formanufacturers. Phase Vision,says these new options offerindustrial users competitiveadvantage through improvedinspection capability.

Verisurf: the metrology soft-ware development companycommitted to deliveringadvanced computer-aidedinspection and reverse engi-neering solutions, is demon-strating its brand new X6 prod-uct. “The new X6 is loaded with

innovative features that greatlyexpand the capability of metrol-ogy devices,” says Verisurfpresident, Ernie Husted.

www.makemeasurementmatter.com

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Exhibitors3D Scanners UKwww.3dscanners.co.ukSpecialist 3D scanning services

Alicona UK www.alicona.comNon-contact optical 3D measurement

ATS Quality Productswww.ats-global.comAdvanced metrology anddata collection

Blum Novotest www.blum-novotest.comIn-process metrology solutions

Bowers Metrology Groupwww.bowers.co. ukPrecision measurement equipment

Brunson Instrumentwww.brunson.usLaser tracker accessories etc

BTMAwww.btma.co.ukBritish Turned PartsManufacturersAssociation

Conway PrecisionEngineering Group www.gauges.co.ukMechanical engineering, fixturing, tooling & gauging

Creaformwww.creaform3d.com3D scanners, measuring systems

Delcam UKwww.delcam.comInspection software

Europac 3dimensionalwww.europac3d.com3D scanning systems, portable systems etc

Faro UKwww.faro.com/ukCoordinate measurementdevices and software

GOM UK www.gom.uk.comHigh-end measuring system solutions

Heidenhain (GB) www.heidenhain.co.ukLinear, angle and rotaryencoders, digital readouts etc

Hexagon Metrologywww.hexagonmetrology.comComprehensive metrologyproduct range

IMSMwww.imsm.comISO specialists for industry

Indysoft Europewww.indysoftco.ukMetrology, tool managementand calibration software

Mahr UK www.mahr.comProduction dimensional measuring technology

Metrology Directwww.metrology-direct.comMeasurement and inspection solutions

Micron Metrology 2000 Limitedwww.micronmetrology.co.ukLeading EU UKAS calibration laboratory

Marposswww.marposs.comGlobal supplier of precisionmetrology equipment

Nikon Metrology UKwww.nikonmetrology.comInnovative metrology and visionmeasurement systems

NPL – National PhysicalLaboratorywww.npltech.co.ukCentre for measurement standards

Phase Vision www.phasevision.com3D shape measurement systems

Physical Digital www.physicaldigital.comService bureau / ReverseEngineering

Piccadilly PrecisionEngineeringwww.piccadillyprecision.co.ukSpecialist gauge manufacturers

Renishawwww.renishaw.comIn-process measurement systems

Solartron Metrology www.solartronmetrology.comMeasurement transducers andinstrumentation.

Spectrum Metrologywww.spectrum-metrology.co.ukMeasurement solutions including electro-optical

Steinbichler UKwww.steinbichler.co.ukLeader in optical measuringand testing technology

Taylor Hobsonwww.taylor-hobson.comHigh precision specialists in surface, roundness and formmeasurement

Third Dimensionwww.third.comNon-contact optical metrology system

Tinius Olsen www.tiniusolsen.com

TRAC Measurement Systems www.trac-group.comInspection, testing servicesand equipment

Verisurf UKwww.verisurf.comMetrology software development

Vision Engineeringwww.visioneng.com Optical systems

Carl Zeiss www.zeiss.co.uk/metrologyCoordinate measurementmachines

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

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Renishaw will exhibit its newline of versatile gauges atMake Measurement Matter.

Visitors will see live demonstra-tions of Renishaw’s Equator™gauging system, which is a rad-ical alternative to traditionalgauging systems.

Equator is capable of high-speed comparative gauging forthe inspection of high-volumemanufactured parts.

The thousands of points collect-

ed during 3D scanning with theindustry standard SP25 proberesults in better metrology andenables effective form measure-ment. Every data point can beused for comparative measure-ment - one Equator can per-form the same function of thou-sands of DTIs, LVDTs or hand-held instruments.

The Equator’s innovative gaug-ing technology is based on thetraditional comparison of pro-duction parts to a referencemaster part. Installation of

Equator is possible in minutes,and re-configuration is now pos-sible in a fraction of the timetaken with conventional gauging.

One of the UK’s first users ofEquator is aerospace supplierFGP Precision Engineering Ltd.Head of Quality, Nigel Manningsays: “Renishaw's Equator is asmall, bench-top system thatallows an operator to quicklyand easily check a partbetween ops.”

www.renishaw.com

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Radical solution on show by Renishaw

Spectrum Metrology will beshowcasing its new non-contact three-dimensionalmeasurement system, theConoscan 4000, at MakeMeasurement Matter.

The ConoScan 4000 is a highprecision, non-contact scanner,capable of measuring a varietyof materials with complexgeometries for applicationssuch as reverse engineering,part inspection and research.

The scanner includes Optimetsconoscopic holography sensors– which have the unique abilityto scan very steep angles up to85 degrees - integrated in asophisticated scanning platform.

The Conoscan is part of arange of contact and non-con-

tact dimensional products available from SpectrumMetrology, which includesportable CMMs, multisensoryCMMs, shaft measurementmachines and 2D Geometrysystems (full details are on theirwebpage http://www.spectrum-metrology.co.uk/dimensional-measurement/).

This comprehensive rangeallows Spectrum Metrology tostudy individual measurementrequirements and find the rightproduct for the job.Applications range from intricateprecision components to largescale engine parts.

Customers are invited to sendsamples of their precision com-ponents to Spectrum Metrologyfor no obligation evaluation and

measurement and visitors toMMM can discuss their applica-tions on the Spectrum stand.

The company are specialists inelectro-optical metrology, sur-face roughness, roundness,contact and non-contact metrol-ogy applications and are agentsfor Taylor Hobson (workshop

surface finish/roundness,Alignment, Angle and Level),FARO (Gauges) and Brunson(laser tracker accessories).

Full details on the website orcall 0116 2766262.

www.spectrum-metrology.co.uk

MMM showcase for the new 3D system from Spectrum

GTMA NEWS ISSUE 2 2012 2/10/12 15:44

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GTMA NEWS ISSUE 2 2012 2/10/12 15:49

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Delcam will demonstrate the2012 R2 version of itsPowerINSPECT software forinspection and reverse engineering at MakeMeasurement Matter. Thisnew release includesenhancements to its inspec-tion capabilities and furtherdevelopments of its reverseengineering functionality,including an expansion ofthe “Digitised Curves” optionto create a powerful re-engi-neering and modelling tool.

A new module is also now avail-able that allows PowerINSPECTto create efficient inspectionsequences for use on dual-column CNC coordinate-

measuring machines. This con-tinues the drive to makePowerINSPECT the preferredinspection software for all typesof metrology equipment.

Inspection improvementsinclude a simplified procedureto quickly calibrate the probeassembly by probing a singlepoint anywhere in the measur-ing envelope; an offset-align-ment method that aligns thepart with the CMM axes whilesetting the position with a singlepoint measurement; and extrapoint-cloud options to make iteasier to modify and reuse digitised curves and points.

There are options to edit, delete

and resume measurement ofthe points and curves.

The automated section-meas-urement functionality, previouslyonly available in thePowerINSPECT manual version,is now available in both theOMV and CNC offline-program-ming versions. This strategy tocreate probe paths along a sec-tion of the component providesquick and easy comparison of across-section against the CADmodel - important for themeasurement of blades, aerofoils, and for automotiveinspection.

New options within “DigitisedCurves” allow edges, holes and

gaps to be identified as the partis being probed. Curves canalso be created from CAD mod-els within PowerINSPECT orthey can be imported directlyfrom other software packages.

Once created, curves can beexported as polylines as well asin the previously-availableNURBS format. This enhance-ment is part of a generalincrease in the ability to exportsurface and geometric items foruse in modelling applications,with VDA export added to theexisting IGES format.

The new creation and editingoptions for curves can be usedwith a new marking-out feature

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More and more from Delcam'sPowerINSPECTDemonstrations will highlight inspection and reverse engineering upgrades

An advanced Bore Gaugingsystem from GTMA memberBowers Metrology is playinga key role in quality controlat Wavin Limited, one of theUK's leading suppliers intothe building and construc-tion industry.

Wavin invented the first push-fitplumbing system through itsHep20 brand and remains aleader in its field. It supplies arange of products for watermanagement, plumbing, heat-ing and drainage systems.

Hep20 products carry a 50-yearguarantee and are precision-

manufactured in Wavin’s high-tech Doncaster plant using themost advanced injection mould-ing and extrusion machines.Strict quality control systemsare adhered to and compo-nents in the Hep20 range haveextrememly demanding toler-ances to help guarantee thereliable sealing characteristics ofall Hep2One fittings.

Bowers was called in when theneed arose for a reliable way ofprecisely measuring the criticalinternal diameters of Hep2O fit-tings, said John Templeman,Quality Supervisor of Wavin,Doncaster.

“Our policy of continuousimprovement means that we areconstantly investigating ways toimprove our processes, “ hesaid. It was the company's“unremitting quest for progress”that led Wavin to buy an

advanced Bowers BoreGauging system.

“Although previous traditionalmethods, such as the use ofplug-gauges, gave us a goodindication of size and fit, we

Bowers takes the pressure offfor a UK market leader

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for refining or completing claymodels – a requirement for cre-ating automotive and marinestyling models.

The combination of a dual-col-umn CMM and PowerINSPECTenables inspection times to bereduced by allowing the simul-taneous measurement of differ-ent features on larger parts. Acommon application is automo-tive body-in-white inspection,

where the evaluation of a large,complex and relatively symmet-rical assembly requires intricatemeasurements on each side,combined with an assessmentof the structure as a whole.Using this new module givesthe ability to measure parts onthese devices in a single coordinate system withoutrepositioning.

www.delcam.com

MMM 2012…

A new module allows PowerINSPECT to be used with dual-column CMMs

were looking for an advancedinternal measuring system thatwould increase our gaugingcapability and allow us to fur-ther control our process.

“The pressure exerted by manyof the available measuring sys-tems precluded their use on ourproducts, as they are liable todeform some of our thinnerwalled plastic components. Tohelp overcome this problem,Bowers was able to reduce thespring pressure of its DigitalPistol Grip XT Bore Gauges andto retrofit a depth stop tospeed-up operation.

In fact, Bowers’ understandingof our requirements and willing-ness to adapt its standardproducts to our needs, ledBowers to suggest the fitting of

‘wireless’ modules to our newgauges, enabling the sending ofmeasured data without theneed for a physical link.”

Now in contant use, the adapt-ed Bore Gauges have proved agreat success “and are makingan excellent contribution toguaranteeing the continuingquality of our output.”

Bowers Metrology’s state-of-the-art XT Xtreme Bore Gaugingrange boasts advanced elec-tronics that have an impressiveIP65 rating. This renders themresistant to coolant, water andairborne particles and makesthem ideal for use within hostilemeasuring environments, suchas near to Machine Tools.

www.bowers.co.uk

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

+-

urmete r | pa r i s | 1791

PRECISION LENGTHMETROLOGY

SURFACEMETROLOGY

THE STANDARD METRE GAVE US ORDER, MAHR GIVES YOU PRECISION.

In the beginning there was the standard metre – which in turn

laid the basis for ever greater precision. Mahr has been a leading

light in this evolution for the last 150 years. Today, our measuring

instruments are employed wherever high precision and reliabi-

lity are paramount, from the automotive industry and semicon-

ductor production to medical technology and the aerospace

industry. Precision is universal. Mahr crosses all borders.

Mahr U.K. Plc - 19 Drakes Mews, Crownhill, Milton Keynes, MK8 0ER, GB

www.mahr.com

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

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Micron Metrology, whoselaboratory in Birmingham isone of the largest of its typein Europe, is pleased toannounce it has becomepart of the Rhopoint Group,a privately owned companywith offices in Surrey,Sussex and Hampshire.

The Group designs, manufac-tures and distributes high quali-ty electronic components andscientific instruments for nichemarkets worldwide.

“This is a very important timefor both Micron and theRhopoint Group as a whole,”said Micron General ManagerAlan Smith who predicts “aprosperous future.”

“The synergy between Micronand all the divisions of theRhopoint Group means that weshould all look forward to con-tinued growth. Working intoday’s technically demandingindustrial climate means that wehave to deliver excellence andinnovation across all of our calibration services.

“With the added services thatare now available across thegroup we will strengthen ourcapabilities and we will continueto enhance our long-term relationship with our cus-tomers.”

Rhopoint is made up of:

Rhopoint Components:Meets the exacting demands ofthe international marketplace inprecision electronic compo-nents. It offers very high levelsof field and internal technical

and commercial support,backed by efficient stockingand distribution.

Rhopoint Instruments: Hastwo divisions - AppearanceMeasurement and PackagingTest Equipment, the latter mar-keted as the Hanatek brand. Allproducts ISO 9001 designedand manufactured.

Rhopoint Instruments -Appearance Measurement:Supplies products to measurekey parameters such as Gloss,Haze, Shade, Opacity andDistinctness of Image (DOI) forsectors including automotive,paper and packaging, paints andcoatings, furniture, plastics etc.

Hanatek - Packaging TestEquipment: Hanatek testinstruments are primarily usedin packaging and associatedindustries. The products sup-port the testing of raw materi-als, including paper, cartonboard, plastics, films, inks andcoatings.

With best in class performancethe products measure a rangeof parameters including thick-ness, folding forces and bothstatic & dynamic friction.

Rhopoint Sourcing Ltd:Formed to help customersunable to source an adequatesupply of product, especiallysemi-conductors. It uses aglobal supply network to sourceactive, passive and electromechanical components. Allsuppliers are rigorously vettedto its quality standards.

John Briggs CEO of Rhopoint

said: “We are very pleased tohave acquired a Calibrationcompany of the reputation andquality of Micron. We see thisas entirely complimentary to ourbusiness of designing, manu-facturing and distributing highquality products globally.

“This acquisition will only enhanceour current offering to clients. Wefurther believe that the calibrationsector in itself is particularly excit-ing and set to grow with the con-tinuing advance of regulation andquality control.”

Micron proudly declares that itis “the only Calibration laborato-ry that you will ever need”, andboasts one of the largestscopes of accreditation in theCalibration business.

Micron already has a customerlist including BP, Airbus, BAESystems, GKN Aerospace andRolls-Royce. Since its launch in1978 as Midland Technologiesit has exceeded customerexpectations, offering solutionsto every calibration requirement.

Items that fail calibration can berepaired, refurbished, replaced

and recalibrated in situ andreturned quickly, reducing over-all downtime to the customer.

From its West Midlands laborato-ry Micron can reach all corners ofthe UK speedily, should its collection and delivery, or on-siteservices where required – 48-hour Goldtrack or 5-daySilvertrack turnaround guaranteed.

Micron recognises that it is itscustomers’ peace of mind thatis important. To this end itoffers a complete managementservice to cover the critical, theroutine and the urgent require-ments for calibration.

It is due to the hard work of itsloyal and well-trained team thatMicron can offer the consistent-ly high level of service that itsreputation is built on.

For more information pleaseemail Alan Smith at [email protected] orsee the websites.

www.micron-metrology.co.ukwww.rhopoint.com

Micron Metrology joins Rhopoint GroupSynergy of companies means more services for customers

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

BOWERS METROLOGY: LEADING THE WAY IN QUALITY AND INSPECTION SOLUTIONS

Small Bore Measurement with theNEW Bowers MicroGauge

The Bowers Metrology Group of Companies

Unit 15, Bordon Trading Estate,

Bordon, Hampshire GU35 9HH

Telephone: 08708 50 90 50 Fax: 08708 50 90 60

www.bowers.co.uk [email protected] in Precision

Improved Accuracy with the Sylvac Hi-Cal Digital Motorised Height Gauge

Accurate Thread Measurement for the Oil & Gas Industry from Gagemaker

For more innovative products see Bowers’ all-inclusive 2012/13 product catalogue.

To order your copy [email protected]

Physical Digital LimitedUsing the latest scanning systems, we provide the highest accuracy non-contact digitising available.

Our mobile equipment allows on site 3D scanning solutions which increase

downtime and costs.

Reverse EngineeringQuality Control & InspectionProduction & First Article Testing

Prototype Modelling & SurfacingDigital Archiving & RecordingCompetitor BenchmarkingDeformation Measurement

••••••••

W: www.physicaldigital.com E: [email protected] T: 01483 857537 M: 07880 703010

Sales, Support & Training

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

47

GTMA member IndySoft ispromoting its Gage InSiteEnterprise complete calibra-tion management softwarepackage – which has astrong emphasis on securityand flexibility.

The package offers both largescale corporate environmentsand smaller operations a cus-tomisable system ready to meettheir exacting needs.

IndySoft software has recogni-tion of compliance , among oth-ers, to AS9100, QS9000,TS16949, ISO9000, FDA21CFR Part 11 and ISO17025.

Through an exclusive processmodelling engine, companiescan configure their own event

driven system with checkpointsand rule sets at every pointalong the equipment path,ensuring assets are handledaccording to existing work-flowand procedures.

Searching for equipment is fastand reliable with unlimitedsearch capabilities. The pack-age is designed to hold theentire history for every piece ofequipment in your inventory.

From the date the equipmentwas entered into the systemuntil the date it is retired fromservice, nothing is lost.

During calibration all findings forthe unit under test are recordedin an easy-to-use results grid.,and as data is entered, findings

can be calculated on the flyagainst either formulas or stan-dard tolerances. Technicians aregiven immediate feedback on thestatus of the calibration.

After completion of the calibration,all test point findings are immedi-ately stored and included in a digi-tal certificate. This is stored alongwith the calibration and can

optionally be printed withoutprompting. This reduces steps forthe technician to perform.

The system also supports track-ing of repairs to equipment andassociated parts, with labourand inventory counts of usedparts calculated immediately.

www.indysoft.co.uk

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IndySoft's software makes life easier

Hexagon Metrology haslaunched a new corporatebranding, including arefreshed company logoand updated brand strategy.

The new branding moreclosely aligns HexagonMetrology with the strengthsand synergies of its parentcompany Hexagon, a leadingglobal provider of design,measurement and visualisa-tion technologies.

As part of the rebrandingeffort, Hexagon Metrologyhas repositioned its brandstrategy, and will now serveas the primary presence in

the metrology marketplacewhile still retaining its iconicproduct brands.

By raising awareness of theHexagon Metrology brand, thecompany seeks to promotenew growth opportunities asthe global customer base asso-ciates Hexagon Metrology’sstrengths as a company to itsentire portfolio of measurementand inspection products.

“Looking toward the future, ourcore competency can be sum-marised by proven solutions,customer services, a wideselection of software, precisionsensors, and extensive know-how in the sectors we serve,”

said Norbert Hanke, Presidentof Hexagon Metrology. “Thisnew chapter in our history is anaffirmation of our continuedcommitment to helping cus-tomers reinvent today, outpacechange, and solve problems fortomorrow.”

Building upon the company’snearly 200-year history in themetrology industry, the newbrand emphasises the techno-logical leadership HexagonMetrology provides to some of the world’s most criticalindustries.

The company offers a compre-hensive range of products andservices for all industrial metrol-ogy applications in sectorssuch as automotive, aero-space, energy and medical.

It supports customers withactionable measurementinformation along the com-plete life cycle of a product –from development and designto production, assembly andfinal inspection.

www.hexagonmetrology.com

Hexagon Metrology launchesnew corporate branding

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

Micron Metrology EurolabThe largest calibration laboratory of its type in the EU

MAJOR £300K REFURBISHMENT AND INVESTMENT PROGRAMME NOW COMPLETEDMore services, more equipment, more facilities, more accreditations

“Possibly the only calibration laboratory you will ever need”

Recent additions to UKAS Schedule:

• Pressure Gauges• Combination Gauges• Digital Pressure Indicators• Manometers,Oxygen Gauges• Pressure Calibrators• Pressure Switches• Pressure Transducers• Sphygmomanometers• Dead Weight Testers• Autoclaves

UKAS Accredited Calibration Laboratory (0720)

• Online certification and calibration system management

• Complete managed calibration system consul-tancy service

• Guaranteed turn-around times of five days orless (48 hour Goldtrack Service)

• Emergency response when required• Onsite UKAS calibration service• Electrical and mechanical repair service• Collection and delivery service• Uk agents for Indysoft Gauge InSite• International services• On-shore/off-shore

Specific areas covered include:

• Mechanical• Dimensional• Electrical• Pressure• Torque• Time• Mass......

Contact our sales team for a free no obligation quotation on 0121 784 7498 using extension numbers 201 or 203.

General EnquiriesEmail: [email protected]: www.micron-metrology.co.uk

MARKETS COVERED: AUTOMOTIVE • AEROSPACE • PHARMACEUTICAL • OIL & GAS • MARINE & RAIL

GTMA NEWS ISSUE 2 2012 2/10/12 15:49

49

World leading developer andmanufacturer of non-con-tact, precision measurementsystems, Third Dimension ishighlighting its GapGunseries of products

The GTMA member was estab-lished in 1995, and has a longtrack record of manufacturingand developing innovativemetrology systems for some ofthe largest names in the aero-space, automotive and energysectors worldwide.

With the stability and experi-ence to help manufacturers

realise the benefits of shop floornon-contact measurement,Third Dimension works in part-nership with its customers todevelop solutions for a range ofdiverse and operation criticalapplications.

The latest GapGun + series,includes GapGun+, GapGunR+, GapGun MX+ and GapGunRobot+ for handheld and auto-mated inspection.

GapGun provides manufacturerswith a fully auditable trail of everyproduct that is measured toprove the quality of manufacture.

Based on an industry proventechnology that combines alaser and a camera to create atriangulated co-ordinate system,the GapGun range can meas-ure not just gap and flush, butalso radii, chamfers, weld pro-

MMM 2012… MMM 2012… MMM 2012… MMM 2012…

JK Metrology & Quality ServicesUKAS Laboratory 4505

• Gauge Blocks by Comparison

or Interferometry (Class A)

• Long Slip Gauges, Length Bars & Accessories

• Surface tables, Calibration & re-furbishment

• Optical Flats and Parallels

• Quality system consultancy, 1 day or long term

Unit 11 Holman Road, Liskeard Business Park PL14 3UT

Tel: 01579 324108 Fax: 01579 347714

Web: www.jkmetrology.com

Email: [email protected]

World leader fills the gapswith innovative technology

files, seals, scratches, andbreak edge measurements tohigh levels of accuracy andrepeatability with no contact.

www.third.com

Mahr, one of the world’sleading surface finishmetrology companies, hascreated another ‘first’.

It has launched the innovativeMarSurf One, a simple smart-phone app, which takesportable surface finish measure-ment to the next level.

Mahr has been a leader in blue tooth technology for sever-al years now and the combina-tion of the well proven RD18drive unit and MarSurf One soft-ware enables ultimate portability, with simplicity of useand no sacrifice in terms accuracy.

The breakthrough gives usersthe ability to measure the mostpopular roughness depthparameters Ra, Rz, Rmax, Rt,Rq and to document the rough-ness depth profile.

Its interactive zoom function hasgesture control and you cansave the results and measuringrecords as PDF on the SD card.They can then be sent by email,for example.

Those buying into the productwill be right up to date becausethey are using the advantagesof the Smartphone as well asthe MarSurf technology.

This means easy entry into sur-face metrology for every opera-tor – they can measure immedi-ately without training becauseoperation elements and philoso-phy correspond to the well-known Smartphone processes.

www.mahr.co.uk

Smartphone first for Mahr

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

Flatness ... Angle ... Level ...Alignment ... Squareness ...Straightness ... Surface roughness ... Ra / Rz / Rv ...Twist ... Form... Concentricity ... Waviness ... Diameters ... Lengths ... Radii ...Angles ... Chamfers ... Centres ... Planes ... Cones ... Roundness

Talk to us:With many years metrology experience Spectrum Metrology is notjust a distributor: we take the time to understand your application –study your drawings – measure your components – and offer youthe best solution to your measurement problems:

Email: [email protected] Tel: 0116 2766262www.spectrum-metrology.co.uk

Precision Measurement Systemsfrom Spectrum Metrology -

What do you want to measure?

GTMA NEWS ISSUE 2 2012 2/10/12 16:08

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A retrofitted Heidenhain TNC320 CNC has given an age-ing boring and milling centrea new lease of life at SPXClyde Union, one of theworld's leading pump companies.

SPX Clyde Union, based inSheffield, needed extra line bor-ing capacity for the productionof a range of centrifugal pumpcases, and decided the opti-mum route was re-engineeringthe existing equipment.

The combined result of the re-engineering-CNC retrofit projectis a machine that has effectivelybeen given a new lease of lifefor machining a range of pumpdesigns.

Production Control ManagerBob Scrivens enlisted the re-

engineering and retrofittingservices of Huddersfield-basedC T Systems (CTS), a companywith an established reputationas a specialist in system inte-gration/motion control automa-tion.

Using an old Kearns-RichardsSF125 horizontal boring andmilling centre from another SPXgroup site, CTS’s Chris Haighoversaw the comprehensiveproject involving, for example,new hydraulics and electrics;replacement of gears; installa-tion of new ballscrews; regrind-ing of the machine’s bedway;and manufacture of a new boring stay.

Finally there was the integrationof the HEIDENHAIN TNC 320with new drives and controlgear. SPX already usesHeidenhain equipment and SPX

Heidenhain offers new lease of life

wanted to maintain standardisa-tion of control technology so itsmachine operators were confi-dent in its use.

The TNC 320's clear overviewsof all information and its graphicsupport during program entry,test run and actual machining,were also big pluses.

Today, the new-look machine isconsistently handling work-pieces of up to eight tonnes onits 1,800 mm by 1,500 mmtable - “a cost-effective alterna-tive to buying a new machine”,said Bob Scrivens.

www.heidenhain.co.uk

high accuracy analogue scan-ning probe.

The product is used on co-ordi-nate measuring machines(CMMs) for the highly accuratemeasurement of complex partssuch as automotive and powertrain components.

Speaking to Renishaw employ-ees about the latest award,Dame Janet said, “What seemsto me to be absolutely out-

standing about Renishaw is thatit is so iconic for this particularcounty. Wherever I go to seebusinesses, people talk to meabout Renishaw. It is an icon forwhat is excellent in innovation.”

She was welcomed toRenishaw's headquarters by SirDavid McMurtry, the company'sChairman and Chief Executive.Together with Dave Wallace,Director and General Managerof the CMM Products Division,

he accepted the Award in theform of a crystal bowlengraved with the Queen'sAward Emblem.

Dave Wallace said the awardrecognised the success of theteam behind the SP80 scan-ning probe. It is for “everyoneacross the Renishaw Groupwho has contributed to theSP80 product.”

www. renishaw.com

Renishaw plc was present-ed with a Queen's Awardfor Enterprise 2012 byDame Janet Trotter, HerMajesty's Lord-Lieutenantof Gloucestershire in thesummer.

It is Renishaw's 15thQueen's Award since its for-mation in 1973, and wasgranted in the Innovationscategory for the company'shighly innovative SP80 ultra-

Renishaw innovation wins15th Queen's Award

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

press releases... press releases... press releases...

52

Coal play: Bowers Metrologyequipment is being used to aidcoal production at aNorthumberland based surfacemining operation managed byThe Banks Group. The issuewas wear on steel linings ofexcavators’ buckets and thebodies of dump trucks. Highcosts when heavy plant was outof commission led the companyto Bowers' robust TT-300 ultra-sonic thickness gauge. Regularchecks using the portable TT-300 not only prevent failures inuse but its large memorycapacity and an RS 232 outputalso means it can create a his-tory and better target earlyintervention.

www.bowers.co.uk

Open doors: Man andMachine will be opening thedoors of its Oxfordshire trainingcentre on November 7 to offerfree Autodesk Certification andexam preparation all day to anydelegate who wants to gain aprofessional CAD qualification.Delegates are allowed to sit asmany exams as they want on

the day. Autodesk certificationis a reliable validation of yourskills and knowledge, and canlead to accelerated professionaldevelopment, improved produc-tivity and enhanced credibilityfor you and your employer. Manand Machine will be offeringAutodesk Certification forAutoCAD 2013, Autodesk 3dsMax 2013, Autodesk Inventor2013, Autodesk Maya 2013,Autodesk Revit Architecture2013 and AutoCAD Civil 2013.Register your place now at:

www.manandmachine.co.uk/training www.bowers.co.uk

Faro deal: Faro has signed anOEM and distribution agree-ment for 3D laser scanners withTrimble, which applies technol-ogy to make field and mobileworkers in business and gov-ernment significantly more pro-ductive. It will provide Trimblewith an OEM differentiatedproduct based onits successful FARO LaserScanner Focus3D platform.Trimble will offer the OEM prod-

uct throughout its worldwidesurvey and building construc-tion distribution networks.

www.faro.com/uk

Faster and faster: HexagonMetrology has announced fur-ther developments to its laserscanner technology for portablemeasuring arms. The integratedlaser scanner for the ROMERAbsolute Arm is now significant-ly faster than previous versions,offering an acquisition speed ofup to 50,000 points per sec-ond. This enables users tomove the scanner over themeasurement object faster thanbefore, while achieving thesame high data quality even ondifficult to scan surfaces likehigh-gloss carbon-fibre. Thismeans that users can now scanup to 66% more surface area inthe same amount of time. Also,

laser scanning can now be car-ried out wirelessly.

www.hexagonmetrology.co.uk

Gold offer: PSL DataTrack haslaunched a DataTrack GoldMedal system offer to mark the2012 Olympic year. Betweennow and 31 December 2012,engineering sub-contractors andother companies involved inbatch production can purchase aDataTrack Gold Medal system,with a single user licence, for£2012. The special offer is on itsDataTrack production manage-ment and business administrationsoftware. It has modules forDataTrack Estimates &Quotations; Sales OrderProcessing; CompanyLetterheads; and Reporting.

www.psldatatrack.com

Press Releases Here is a selection of Press Releases received atGTMA offices. If you want to be considered please send yourreleases by email and in a Word document to: [email protected] the Subject: Press Release.

Delcam will demonstratenew versions of its design,machining and inspectionsoftware at the AdvancedEngineering group ofevents to be held at theNEC, Birmingham,November 7-8.

Programs on show willinclude PowerSHAPE forproduct design, toolingdesign and reverse engineer-ing; FeatureCAM for quickand easy feature-based CAMprogramming; the PowerMILLCAM software for high-speedand five-axis machining, and

for the programming of robots;the Delcam for SolidWorks inte-grated CAM system; and thePowerINSPECT inspection software.

The 2013 release ofPowerSHAPE includes

enhancements to its directmodelling and reverse engineer-ing capabilities that will makethe software both more flexibleand even easier to use. Inaddition, the solid and surfacemodelling options have beenmade faster and even morerobust.

The most important new optionin the 2013 release ofPowerMILL will be the newVortex strategy for high-speedarea clearance. Vortex, forwhich Delcam has a patentpending, has been developedspecifically to gain the maximum

benefit from solid carbidetooling, in particular thosedesigns that can give deepercuts by using the full flutelength as the cutting surface.

Finally, Delcam’sPowerINSPECT system hasimprovements to the inspec-tion functionality in the latestrelease including a new, sim-plified procedure for users toquickly calibrate the probeassembly by probing a singlepoint anywhere within themeasuring envelope.

www.delcam.com

Delcam to shine at Advanced Engineering events

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

Aerospace... Aerospace... Aerospace... Aerospace...

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GTMA companies servingaerospace will be promotedat this year's Farnborough2012 Aerolink innovation,sourcing and meet the buyerevent.

The event on November 21 atthe Holiday Inn, Farnborough, isorganised by AeroLink Wales,with which GTMA has forged anew partnership. Among com-panies there will be Rolls-Royceand Boeing.

GTMA is taking a desk at theevent to meet buyers such asRolls-Royce to highlight the

GTMA supply chain of engi-neering companies and the newTooling Alliance of toolmakersinitiative (see page 4).

CEO Julia Moore said they alsohope to discuss the IncrementalSheet Metal Forming processdeveloped as part of an EUR&D project and whichBusiness Development DirectorRoger Onions has already pro-moted in the sector.

The key to Aerolink’s success isthat it provides a forum fororganisations involved inAerospace and Defence and

associated industries to meetand explore business opportu-nities of all kinds.

Aerolink Farnborough will attracta wide range of delegates inter-ested in purchasing, R&D, col-laboration, engineering andinnovation.

The event will also promoteknowledge transfer between theaerospace and other industrysectors such as motor sport,medical, energy and environ-mental goods and services.Aerolink Farnborough enablesdelegates to pre-arrange a

number of relevant and produc-tive one-to-one meetings over asingle day in an efficient andcost effective way.

Among exhibitors is GTMAmember company EOS ElectroOptical Systems, who was alsoat Farnborough 2012 in July.

Also there were members 3TRPD, Denroy Plastics,DeStaCo, Hexagon Metrology,Seco Tools and Trescal.

www.aerolinkfarnborough.co.ukwww.gtma.co.uk

GTMA flies the flagat AeroLink Farnborough

Denroy Plastics has won justunder Euro 1million(£750,000) of EC funding fora pioneering research anddevelopment project for theaerospace industry,

The GTMA member will be thelead partner in a consortiumcomprising industry market lead-ers Airbus & 5M and scientific &technological research organisa-tions MatRI, UK and ITA, Spain.

The EC-funded project aims todevelop a process to injectionmould thermoplastic compositecomponents for aerospacestructural applications.

A successful implementation ofthis process will put Denroy at

the forefront of ground-breakingtechnology opportunities for theaerospace industry. The targetareas will be the replacement ofsmall-to-medium sizedmachined aluminium, titaniumand hand lay-up thermosetcomposite components.

Northern Ireland's First MinisterPeter Robinson and DETIMinister Arlene Foster congratu-lated Denroy on the projectwhen speaking at theFarnborough Air Show.

“Denroy has spent the last 40years building up an unrivalledknowledge in plastics mouldingand they should be warmlycongratulated on this achieve-ment,” he said.

“This company does the vastmajority of its business outsideNorthern Ireland and is regard-ed as a world leader in its field.I’m delighted to announce thisachievement and look forwardto hearing how this company,which celebrates its 40thanniversary this year, plans togrow in the future.”

Denroy’s Chairman, JohnRainey, said accessing of thefunds will now lead the compa-ny into a new era of co-opera-tion with international partnersand R&D organisations.

“Denroy has been quietly build-ing a robust and forward-look-ing business over the last 40years and we are proud to be

the lead partner in what promis-es to be a new and excitingfield of research,” he said.

“The development of this newprocess will offer significantadvantages in widening thescope for component design,faster production rates andlower energy consumption percomponent produced.”

The company is also reported tobe looking at applications for thetechnology outside aerospace,including automotive and energy.

www.denroy.com

Aerospace composites research project for Denroy Plastics

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

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CGTech will be exhibiting onstand 737 at AeroEngineering and CompositesEngineering exhibitions atthe National ExhibitionCentre, Birmingham onNovember 7-8th, 2012.

CGTech will feature the latestversions of CGTech’s VERICUTsoftware products for bothMachine Tool Simulation andAutomated Fibre Placement(AFP) programming and simula-tion at the Aero Engineeringand Composites Engineeringexhibitions at the NECBirmingham on November 7-8.

The GTMA member will alsoshowcase its new product forprogramming and simulation ofAutomated Drilling andFastening machines used forairframe assembly.

On its stand (No. 737) it willdemonstrate VERICUTComposite Applications: VERI-CUT composite Programming(VCP) and VERICUT CompositeSimulation (VCS).

There will be demonstrations ofprojects that highlight the imple-mentation and use of machineindependent off-line NC pro-

gramming software for AFPmachines.

Current customer projects to behighlighted include: a large one-piece fuselage barrel on anElectroimpact multi-machine

Aerospace... Aerospace... Aerospace... Aerospace...

New CGTech product iswinner in airframe assembly

Image shows VERICUT CompositesSimulation (VCS) of a compositelayup of a U tube component on anmTorres AFP machine.

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

Aerospace...

55

AFP fabrication cell; a U-channel structure onon a 7-axismTorres AFP machine; and aircraft skin panels and otherparts using an AFP head mounted on 6-axis robots fromKIKA, FANUC and ABB.

CGTech will also show the recently released version 7.2 ofit's market leading VERICUT CNC machine simulation andoptimization software. VERICUT simulates all types of CNCmachining, including aerospace processes such as multi axismilling, drilling and trimming of composite parts, water jetcutting, robotic and mill/turn machining.

VERICUT 7.2 has a host of improvements over previous ver-sions including significantly improved performance resultingfrom 64 Bit processors and multi-threading.

VERICUT Drilling and Fastening is a new software applicationfor simulating and programming auto-drilling and fasteningmachines. These machines are used to assemble largeaero-structures and it is essential to avoid programmingerrors and collisions at such a late stage in the aircraft manu-facturing process.

The CGTech product allows users to programme drilling andfastener assembly operations in a virtual machine tool envi-ronment and provides simulation to check for a variety ofpotentially disastrous error conditions. Like all VERICUT soft-ware the new module interfaces to leading CAD/CAM/PLMsystems such as Dassault Systemes CATIA and Siemens NX,and is independent of the assembly machine manufacturer.

www.cgtech.com

The new VERICUT drilling and fastening product during an airframeassembly operation.

A collision detected on an aircraft rib during machining on a MazakVTC800 Machining Centre. All images courtesy CGTech which isexhibiting at the Aero Engineering and Composites event.

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

TCT Live... TCT Live... TCT Live... TCT Live... TCT

56

Almost 30 GTMA memberswere individual exhibitors atTCT Live 2012 at the NEC,Birmingham (Sept 25-26)where GTMA once again hadits own stand to promote theassociation's supply chain ofengineering companies.

Many members had livedemonstrations as they show-cased what they have to offerat the event for ProductDevelopment, AdditiveManufacturing and 3D Printing.

On the show floor there wereover 200 exhibiting companiesand alongside the exhibitionwas the world-leading AdditiveManufacturing and 3D PrintingConference with a line-up ofleading industrial and academicexperts in the sector.

Once viewed as a niche area ofproduct development and man-ufacturing the AM and 3D print-ing sector has escalated signifi-cantly in the last 12 monthswith global awareness of theprocesses increasing at anunprecedented rate. ManyGTMA members are specialistsin the area.

Conference presentations cov-ered a number of specific busi-ness applications of AM and 3DPas well some of the latest devel-opments across the industry.

Among the speakers were PhilDickens, Professor ofManufacturing Technology atLoughborough University; PaulDoe, Lead Engineer at ProdriveBMW Mini Team; Sean Horning,Project Engineer, Burton

Snowboards; Stuart Burns,Technical Director, RotiteTechnologies; Anthony Reeves,Lead Engineer,GlaxoSmithKline; and DanJohns, Process & TechnologiesEngineer, Bloodhound SSC.

This year also saw the introduc-tion of a dedicated jewellerysession looking at how additivemanufacturing and 3D printingprocesses are being used inthis innovative sector. It gavejewellery designers, manufactur-ers and silversmiths an opportu-nity to hear how their peers arealready reaping the benefits andenhancing their designs. Thisyear also provided attendeeswith clear insight into the latestadditive manufacturing develop-ments with gold.

Within this conference sessionspeakers included JoergFischer-Buehner, Legor GroupSpA; Mark Bloomfield,Electrobloom; Luke Orford,Grant Macdonald; SilviaWeidenbach, Weidenbach; andLena Thorsson from CooksonPrecious Metals Ltd.

TCT Live also offered a widerange of free live educationalseminars. Spanning the twodays the TCT TechnologyTracks included:

• Inspection, Digitising &Metrology in Product

Development & AdditiveManufacturing, with casestudies and interactivedemonstrations;

• Additive TechnologyIntroduction Session, present-ed by industry-guru GrahamTromans who explained howadditive manufacturing tech-nologies can advance productdevelopment and manufactur-ing processes;

• Digital Manufacturing &Materials for Dentistry, show-ing how more and more labo-ratories recognise the advan-tages of incorporating cutting-edge techniques into theirprocess;

• Software in ProductDevelopment & AdditiveManufacturing - an in-depthlook at some of the leadingCAD/CAM/PLM software cur-rently available; and

• Technical Briefings in Metalsand Non-Metals, aimed atthose wanting to source andpurchase 3D Printing or AMmachinery.

TCT this year also saw theintroduction of the PersonalizePavilion, a dedicated pavilion tobring the industry to life on theshow floor with many productsand services for the 3D Printingand personal manufacturingcommunities — for ‘at-home’makers and ‘from-home’ per-sonalizers.

Running alongside TCT Livewas Mediplas, MM Live UK,MEMS Live and NANO Live —these events combined with thePPMA Show and the SensingTechnology Show made up oneof the largest gatherings ofengineering professionals in theUK in 2012.

www.tctshow.com

Additive manufacturing growthhighlighted at TCT Live event

GTMA NEWS ISSUE 2 2012 2/10/12 15:53

TCT Live... TCT Live... TCT Live... TCT Live... TCT Live...

57

Whilst Micro, Nano andMEMS technologies havealready made a significantimpact on the manufacturinglandscape through their abil-ity to offer new and innova-tive products that have sig-nificantly enhanced perform-ance, there remains a wealthof innovative potential formanufacturers to exploit.

Focusing on the technologiesthat will ultimately change theway manufacturers operate,MM Live, together with MEMSLive and NANO Live staged theUK’s largest annual showcasefrom this ground breaking tech-nology sector.

Providing access to a marketleading resource of Micro, Nanoand MEMS manufacturingexpertise, the event includedconference and seminar pro-grammes covering the very lat-est technologies, trends andapplication based case studies— all presented by industryleading figures.

From fundamental processesthrough to the latest technologi-

cal advances for next generationproducts, the programmes weredesigned to enhance the knowl-edge of visitors whether new tothe technologies or to the mostadvanced practitioners.

Target visitor groups includedsenior level managers anddirectors responsible forresearch and development,design, production and valida-tion within almost any engineer-ing or manufacturing organisa-tion — applications range frommedical, transport, energy,electronics and telecomsthough to consumer productmanufacturing sectors to namea few.

On the show floor, MM, MEMS& NANO Live hosted over 100exhibiting companies, includingthose from GTMA, who show-cased the most innovative anddynamic technologies available.

There was a focus on livemachine demonstrations, with

technologies on display including:

Micro and Precision Machining,Precision Diamond Machining,Micro Milling, Turning, GrindingMachines, Micro InjectionMoulding, Laser Micro machin-ing, Photo Etching, ChemicalMachining, Electroforming,Lithography, Inspection,Metrology and Test equipment,Microscopy, Photo masking,Micro and Precision cuttingtools, Surface abraders, MicroEDM, Contract manufacturingservices, Rapid Prototyping,Nano materials, Micro-fluidicsfabrication, Chemical Vapour

Mediplas 2012, held along-side TCT, was a uniquelyfocused event for the highlyspecialised area of manufac-turing plastic parts for themedical industry.

Plastics production for the med-ical industry is a rapidly expand-ing market, with a diverse rangeof applications for polymers, andMediplas covered all areas of the

GTMA Exhibitors

TCT Live

3T RPD www.3trpd.co.ukJohn Burn & Cowww.johnburn.co.ukCentral Scanning www.central-scanning.co.ukConcept Laserwww.concept-laser.deEOS www.eos.infoES Technologywww.estechnology.co.ukEuropac 3Dimensionalwww.europac3d.comFaro UKwww.faro.com/ukGOM UKwww.gom.comHexagon Metrologywww.hexagonmetrology.comMantech Geometrics www.mantechgeometrics.comMidas Pattern Cowww.midas-pattern.co.ukNikon Metrologywww.nikonmetrology.comPhysical Digitalwww.physicaldigital.com

ProtoLabs www.protolabs.co.ukRenishawwww.renishaw.comSteinbichlerwww.steinbichler.co.ukTrac Measurementwww.trac-group.comWerth Metrology www.werth.deCarl Zeiss www.zeiss.co.uk/metrology

MM Live, MEMS Live, Nano Live

Aliconawww.alicona.comBruderer www.bruderer.co.ukMetrology Direct www.metrology-direct.comNikon Metrologywww.nikonmetrology.comOrlin Technologies www.orlin.co.ukRofin Baaselwww.rofin-baasel.co.ukThe L.S.Starrett Cowww.starrett.co.ukVision Engineeringwww.visioneng.com

Micro, MEMS & NANO Live — advancing innovation in production

medical plastics supply chain.

The event differentiates itselffrom general plastics shows, asit brings to the forefront theaspects and considerations ofmedical device manufacturingthat do not feature in produc-tion for other industries. It wasalso distinct from existing med-ical device shows because itspecialised in plastics.

Event has medical focus

Deposition and Etching solutions.

Alongside the exhibition was theMicro ManufacturingConference with speakersincluding Adriano Nascuiti,Ultra-precision ProgramManager at GTMA member GFAgie Charmilles.

A series of technical seminarsfocused on MEMS & NANOtechnologies. Held in associa-tion with JEMI, NanotechnologyKTN and MANCEF this was afull range of technical seminarsand workshops under the maintheme of Advances in MEMSand NANO Processes forElectronics, Industrial andBiomedical applications.

www.mmnliveuk.com

GTMA NEWS ISSUE 2 2012 2/10/12 15:55

events... events... events... events... events...

58

This has been a busy periodfor exhibitions and tradeshows. These are extractsfrom some of the pressreleases received fromGTMA members who have,or will be, exhibiting:

PHASE VISION: Three-dimen-sional white light measurementspecialist Phase Vision Ltdenjoyed considerable successat CONTROL 2012 in Stuttgart,Germany, the leading interna-tional trade fair for quality assur-ance. The Phase Vision stand

featured the latest Quartz 3Dscanner system, and was visit-ed by customers and partnersfrom more than 20 countries. Phase Vision will also be at theAdvanced Engineering UKExhibition at the NEC,Birmingham (Nov 7-8) where itwill take its innovative range of3D measurement solutions.

www.phasevision.com

CREAFORM: This leader inportable 3D measurement sys-tems and 3D engineering serv-ices, which provides efficientand innovative measurementsolutions for the metal workingindustry, will be at theEuroBLECH 2012 tradeshow.Among others it will show theHandyPROBE portable CMM,the Handyscan 3D andMetraSCAN 3D portable scan-ners as well as the VXtrackdynamic tracking module whichare used for a diversity of tasksin the metal sector.

www.creaform3d.com

CGTECH: The fastest ever ver-sion 7.2 of VERICUT CNCmachine simulation andVerification software will beshown at EuroMold, inFrankfurt, Nov 27-30. Therelease features many enhance-ments to improve speed, there-by reducing the time requiredfor manufacturing engineers todevelop, analayse, inspect anddocument the CNC program-ming and machining process.Customers are reporting atleast a 20% overall performanceboost with some processorintensive operations benefitingeven more.

CGTech will also be at SiemensPLM Europe in Linz, Austria,October 22-24. It will show-case, among others, its newproduct for programming andsimulation of Automated Drillingand Fastening machines usedfor airframe assembly.

www.cgtech.co.uk

ENGIS: The world-leadingsuper-abrasives manufacturerwill be at the Aero/CompositeEngineering exhibition at theNEC, Birmingham on Nov 7-8.Engis, offers a range of solu-tions, including electroplateddiamond saw blades and smalldiamond wheels, for the slicingand grinding of compositematerials, particularly in auto-

motive and aerospace applica-tions. In the case of largerblades Engis also offers a stripand re-plate service. The com-pany is part of the EngisCorporation, which providesproducts, services and techno-logical advances in key areasincluding: diamond flat lap-ping/polishing, diamond andCBN-plated tools, bore finishing tools and machines,tool room products and acces-sories and R&D and technicalsupport.

www.engis.com

MIDAS PATTERN COMPANY:The Bedford-based companywas one of many GTMA mem-bers at TCT (Sept 25-26)where it promoited its expertisein producing large-scale (up to2.5m x 1.5m) low-volume, highquality, polyurethane mouldings.It also offers customers thefacility to create large proto-types in production materials invery short timescales. The largeproduction mouldings are usedin many industry sectors, partic-ularly as equipment enclosuresin medical, analytical and scien-tific applications, where valuableand specialist technology needsto be enshrouded in large andcomplex multi-part mouldingassemblies.

www.midas-pattern.co.uk

Events 20122012

October 17th

October 18th

November 7th–8th

November 21stNovember 27th–30th

2013January 10th–13th

April 18thMay 2013

June 4th–6thJune 18th–19th

GTMA 6th Make Measurement MatterRoadshow, CEME, Rainham, EssexFAST Exhibition, National MotorcycleMuseum, BirminghamAero/Composite Engineering, NEC,Birmingham, Stand 1113Aerolink , Farnborough, GTMA StandEuromold, Frankfurt

Autosports International, NEC, BirminghamFAST Exhibition, RAF CosfordGTMA Manufacturing Event, YamazakiMazak, Worcestershire. Date tbcSubcon, NEC, BiminghamPDM, Telford

NEXT ISSUEOur next issue will see special opportunities for promotion formembers in Jigs & Fixtures, Mould and Die, andWorkholding, Cutting and Ancillary Equipment as we con-tinue the At the Heart of... Manufacturing UK series.Supporting this will be a major feature on Manufacturing andpreviews on Subcon and PDM where the issue will be distributed. For more information call Colin Swindells on 01243828358 or email [email protected]

Here and there: exhibition round-up

Photo courtesy Creaform

GTMA NEWS ISSUE 2 2012 2/10/12 15:55

GTMA NEWS ISSUE 2 2012 2/10/12 15:55

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GTMA NEWS ISSUE 2 2012 2/10/12 15:56

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