Impulse Point of Purchase, a designer and manufacturer of award-winning POP displays across a number of industries, has invested in a new Durma HD-FL 3015 fibre laser cutter with automated loader from Axe & Status. The machine is delivering a 30% increase in speed on thinner-gauge materials, and around 10% on average across all thicknesses, providing a notable impact on bottom-line profitability.

Based in Sandy, Bedfordshire, Impulse POP draws upon many decades of experience in the provision of end-to-end engineering, manufacturing and installation services to retail segments that include sport, music, fashion and jewellery, food and drink, health and beauty, and DIY and gardening. Each solution provides brands with highly effective merchandising opportunities.

Mark McKeown, a man with over 30 years of experience in the POP sector, established the business in 2005. After just three years, the company moved into its current 10,000 sq ft facility and has since grown into a £1.5m turnover business.

“We’re still smaller than some of our competitors but we offer a first-class tailored service,” he says. “We provide an intimacy with our customers that is often missing with many of the larger market players. Our customers use us because they know we can solve their problems.”

The in-house production capabilities of Impulse POP are a major advantage when it comes to winning new contracts, which is why the company insists on regular investment to keep pace with the latest manufacturing technologies. “We had a CO2 laser cutter from another supplier and, although there was nothing wrong with the machine, we knew that investing in a fibre-based solution would bring a number of important advantages,” says McKeown. “I see a laser cutter as a workhorse and, although we scrutinised many machines, we couldn’t see sense in spending top dollar unless we could really monetise that value. We have Durma press brakes, as well as a corner notcher and a guillotine, so it was a proven brand for us. The Durma HD-FL 3015 fibre laser cutter soon became the clear favourite. We also wanted a loader/unloader so we could work unmanned during the day and lights-out overnight.” Installed in October 2021, such is the confidence in the new automated Durma fibre laser cutter that Impulse POP dispensed with its previous CO2 machine.

“We had a couple of teething issues, which is normal, but Axe & Status, including the team from Durma in Turkey, reacted very quickly,” states McKeown. “I’m very happy with the support we received and I really like the machine; it was absolutely a good decision from our perspective.”

The majority of the material that Impulse POP processes is mild steel (for its display customers), but the company also runs aluminium and stainless steel. In addition, the introduction of the Durma fibre laser means Impulse can run copper and brass if needed.

Typically, the company works with material thicknesses from 1 to 12 mm. Impulse selected the 4 kW Durma HD-FL 3015, which can process mild steel up to 20 mm thick, stainless steel up to 10 mm, and aluminium up to 12 mm. However, versions up to 20 kW are available if companies want to cut even thicker materials. The HD-FL 3015 offers 3060 x 1530 x 160 mm in the X, Y and Z axis respectively, although models up to the HD-F 16030 are available from Axe & Status with travels that extend to 16200 x 3100 x 185 mm. Control is via Sinumerik 840D SL with 19” touchscreen.

“We design everything in SolidWorks and use Lantek as our programming software, from where the Durma laser pulls jobs as required over the network – we simply press the start button,” explains McKeown. “Once cut, we bend, weld and finish the parts accordingly.”

A good example of the work that Impulse POP handles is a display completed recently for Candy King, a leading supplier of pick and mix sweets, which wanted 950 units for the UK’s entire portfolio of One Stop convenience stores. This attractive POP solution featured a 1.2 mm mild steel body produced on the Durma laser, with the full assembly undergoing welding, powder coating and the application of branded transfers.

“It was amazing to watch this job on the laser,” states McKeown. “It took just 90 seconds to cut a full sheet of three display bodies, which was very fast. Within 10 hours we had completed the entire 950. Running the job on our new fibre laser with automated loader/unloader was quicker than using our previous CO2 machine, so it gave economies of scale. The Durma is at least 10% faster on average. However, for thinner work, such as the 1.2 mm mild steel display for Candy King, it’s more like 30% quicker.”

The Durma HD-FL 3015 fibre laser cutter features a linear motor motion system that delivers very high acceleration (synchronised 35 m/s2), speed (synchronised 226 m/min) and positioning/repeatability (±0.03 mm). The savings that Impulse POP accrues from the additional speed are supplemented by its use of compressed air as the assist gas.

“This strategy works really well on thinner materials,” says McKeown. “As long as the air is clean, it’s effectively free because we’re running our compressor anyway. We ran compressed air for the Candy King job, which probably saved around £150 of nitrogen. I also like the zero warm-up time with fibre technology. We would previously wait around 20 minutes for our CO2 laser to be ready.”

Being a full service provider with fast manufacturing technologies is key to success at Impulse, which is capable of supplying quickly and efficiently across a wide range of materials, including metal, wood and acrylic. Temporary and permanent retail displays, as well as in-store, pop-up, event and exhibition display stands, are all within the team’s in-house capabilities.

Notably, the Durma laser not only delivers short cycle times, but outstanding quality and flexibility in manufacturing, all of which bodes well for a bright future. “Of course, certain challenges remain, not least the fact that metal prices have doubled since the onset of the pandemic,” concludes McKeown. “What’s more, energy prices are rising almost constantly and transport companies are hitting us with surcharges to cover their growing fuel bills. All of this makes costing tricky. However, we are renowned for our problem-solving and we’ll find a way, particularly with the help of our new Durma laser cutter. Investment remains key to our ongoing success.”

For further information
www.axestatus.com

Founded in 1992, P&T Precision Engineering has an established reputation as a subcontract manufacturer that specialises in the production of jigs, fixtures and machined components for the food, medical and pharmaceutical sector. Historically a manual machine shop, the County Kildare based company has made the transition from manual to CNC machining with the support of the Engineering Technology Group (ETG) Ireland.

Discussing the transition from manual machine shop to CNC facility, Darragh Walsh, managing director of P&T Precision Engineering, says: “We were a small family company with six employees and we decided to invest in CNC machines from ETG. We ended up buying quite a lot of new equipment. This helped us to grow in certain sectors and helped our customers to get more products in shorter lead times. In a short period, we have gone from six staff to 22, but we have also grown our number of machines – and we hope to grow that into the future as well.”

Jamie Fletchmore, managing director at ETG Ireland, adds: “P&T was an up and coming family-run business that was transitioning from manual machines into the CNC world. They approached us and we sat down and spoke about the first machining centre, introducing them to the Quaser MV184. From there, we migrated on every two years and they were buying more technology, which included the Nakamura AS200L turning centre. Two years later they purchased another Quaser MV184.”

The Quaser MV184 vertical machining centre from ETG is a model that provides X, Y and Z-axis travels of 1020 x 610 x 610 mm. This spacious work envelope covers a 1200 x 600 mm bed upon which users can load parts weighing up to 500 kg. The BT40 taper spindle machine provides a maximum spindle speed of 12,000 rpm, supported by a 30-position ATC.

“This type of machine is a big step up from where they were, machining parts on manual machines in multiple operations,” says Fletchmore. “With the Quaser MV184, P&T were able to take those manually machined parts from drawing and CAD model straight into the machine with a finished part coming off. As a result, they were able to get the parts through the shop floor much faster, and that also reduces the downtime involved with going from one operation to another as part of the manual process. Investing in our machines and technology has enabled P&T to move through different types of components and different kinds of materials, especially harder materials. This has allowed them to enter new markets.”

He continues: “It opened doors and opportunities that led the company to then look at the Nakamura AS200L turning centre. The AS200L introduced P&T to a new range of machine tools. They were making parts in multiple operations on a lathe, but by using the Nakamura AS200L turning centre they can finish those parts complete in one operation. P&T are now able to do all of the milling, drilling, tapping – and transfer parts to the second spindle – in one complete operation.”

The Nakamura AS200L twin-spindle turning centre from ETG is a 65 mm diameter bar capacity machine with an 8-inch chuck that offers a turning capacity up to 340 mm diameter with a maximum turning length of 570 mm – providing sufficient capacity for the requirements of P&T. With an 11/15 kW, 4500 rpm main spindle motor and a sub-spindle unit offering 5.5/7.5 kW and 6000 rpm, the Nakamura AS200L is suitable for the productive turning of all material types with its blend of power, torque and spindle speed. A driven tooling unit has a capacity for up to 15 tools with a maximum spindle speed of 6000 rpm and 3.7/5.5 kW spindle power.

“P&T is a very creative company and they do a lot of design work for their customers,” says Fletchmore. “They came to us with particular types of work and asked if they could do it on our machines. We sat down with them and supported and guided them through the different ways that we could approach jobs – in a way that was different to what they were doing in the past. That has enabled P&T to create much better components, much quicker, while retaining and improving upon the precision and the tolerances of parts.”

Says Walsh: “We went to ETG because they provide great support and service, as well as fantastic quality machines with great repeatability and durability. We have never had any issues with any machine that ETG hasn’t been able to fix within a couple of hours. The Nakamura AS200L turning centre has enabled us to machine components in a much faster time because there are fewer set-ups. So, instead of taking jobs from the lathe to the mill, we can now do it all in one shot. This has decreased our machining times, reduced our delivery times and means we can get more parts through the machine shop.”

ETG Ireland provided all of the training, as the Heidenhain CNC control was new to P&T. This included full operator training where ETG Ireland went in and set P&T parts up with the shop floor machinists and went through the full machining aspect. In short, ETG Ireland has taken P&T from manual machining to full CNC.

Looking to the future, Walsh concludes: “The future for P&T will hopefully see us expand to 2000 sq ft and grow our workforce to help increase capacity. This will certainly result in more machine tools from ETG Ireland.”

For further information
www.millscnc.co.uk