Investment Casting Systems, which provides a mix of toolmaking and injection moulding services to customers, has seen turnover increase by 51% over the past three years, with forecast growth of 40% to year ending 2019.

This growth, combined with planned future expansion that will double existing floor space, has created a need for even greater manufacturing efficiency. As part of this efficiency drive, the company has purchased its first five-axis machining centre, a UMC-5X from XYZ Machine Tools.
“We started investigating the purchase of a five-axis machining centre about 18 months ago,” says Investment Casting Systems’ technical director James Head. “Initially we were looking at machines with up to 2 m table capacity, but our customer profile changed, which meant we didn’t need such large capacity. This opened the door to the XYZ UMC-5X with its 600 mm diameter trunnion rotary table and 600 mm travels in the X and Y axes.”
The move to simultaneous five-axis machining immediately brought the benefit that Investment Casting Systems was seeking: increased efficiency. The very first job that went on the XYZ UMC-5X was a complex bolster for an injection mould tool that required machining on all six faces. Using existing three-axis machines would have required six set-ups, but this was reduced to two on the XYZ UMC-5X. The result was a saving of 60% in manufacturing time, the elimination of any potential inconsistencies from multiple set-ups and, by making use of a fixture plate, all faces were machined from the same datum point.
“This first experience proved we had made the right decision in adopting five-axis machining to gain efficiency in manufacturing,” says Head. “We have seen similar time savings as we have progressed.”
For further information www.xyzmachinetools.com

Clacton-based Dalau, which says it is the largest specialist supplier and manufacturer of plastic parts in the UK, believes it has identified the ideal five-axis production centre for machining plastics.

Chosen from a list of no less than 18 potential suppliers, the machine is a Hermle five-axis machining centre that has been modified to accept vacuum work-holding fixtures. The machine was supplied by the German manufacturer’s UK sales and service agent, Geo Kingsbury, which also carried out the customisation.
The Hermle installation is part of a £1m spend on machine tools at the Clacton factory within the past year to cope with a steep increase in demand for Dalau’s machined components across numerous industries.
Production manager Ben Bonds says: “Floor space is limited here and so is the roof height. The Hermle C 250 machining centre offered generous axis travels of 600, 550 and 450 mm in a compact footprint and just fitted in below the ceiling by a matter of inches. It was also advantageous that the optional Hermle tool magazine extension we ordered for increasing the number of cutters from 30 to 80 comes as a separate unit, which simplified transportation up a ramp and through a narrow opening.
“Problems during automatic tool change are one of the biggest causes of downtime here, so we were keen to avoid machines with a swing-arm tool changer,” he adds. “In contrast, the Hermle ATC system, where the spindle travels through a shutter door at the back of the machine and picks the tool directly from the magazine, has proved to be very reliable.”
For further information www.geokingsbury.com

Huntingdon-based Encocam has invested in two Mikron HEM 700U five-axis machining centres from GF Machining Solutions. The machines have been installed at Stonehill Engineering, one of Encocam’s eight divisions, and are being used to machine a diverse range of precision components and mould tools for the company’s internal and external customers.

Since being installed, the majority of work undertaken on both Mikron machining centres has involved the machining of precision parts for Encocam’s largest division, Cellbond, which develops, manufactures and supplies passive safety testing products and equipment to the global automotive market.
In 2012 Cellbond moved into the anthropomorphic test device (ATD) sector, designing and manufacturing crash test dummies. Complex and technically sophisticated, Cellbond’s ATD products are made from hundreds of precision machined or moulded parts which undergo rigorous inspection and testing prior to (and post) assembly. All machined parts are produced in-house from a range of different materials that include aluminium, steel, bronze and plastics.
In addition to machined parts, Cellbond’s crash test dummies also include a number of plastic and rubber moulded components that are produced from mould tools. These tools are also designed and manufactured in house.
Says David Sheahan, Encocam’s purchasing and supply manager: “We understand the strengths of five-axis machining and how the technology can be used to machine complex shapes in one set-up and reduce part cycle times, as well as how the technology helps improve component accuracies and surface finishes.
“We have a good relationship with GF Machining Solutions,” he adds. “As well as their state-of-the-art machine tool technologies we, from experience, appreciate and value their after-sales services and support, which we believe is second to none.”
For further information www.gfms.com/uk