SUBCONTRACTING NEWS

A new turn in performance for Cogsdill Nuneaton

Cogsdill Nuneaton Ltd has strengthened its turning operations following investment in a
DNX 2100SB multi-tasking mill-turn machine supplied by Mills CNC. Installed in December
2025, the machine is playing a central role in the company’s drive to improve efficiency,
increase capacity and move towards lights-out production.
The DNX 2100SB, one of the first installed in the UK, supports the machining of complex,
high-precision parts in a single set up. Equipped with twin spindles, a B-axis milling head, 60-
tool ATC and FANUC control, the machine also incorporates a Hydrafeed bar feeder, rotary
parts accumulator and Renishaw probing and tool-setting systems to support automated,
unattended operation.
The investment follows an internal audit of Cogsdill Nuneaton’s turning section, which
identified bottlenecks caused by ageing CNC lathes and labour-intensive processes.
According to managing director Lee Donaldson, the decision to invest in a multi-tasking
machine from Mills CNC was influenced by previous positive experience of Doosan machines
supplied by the company, as well as its strong pre- and after-sales support. Training
provided by Mills CNC ensured a smooth transition to the new FANUC-controlled platform,
helping operators and programmers quickly become productive.
Since installation, the DNX 2100SB has been busy machining small batches of precision
components for the company’s standard tooling products in a single hit, achieving tight
tolerances, excellent roundness and high surface finishes.

Ultimately, the investment marks a significant step forward in productivity, flexibility and
overall machining capability. Looking ahead, Cogsdill Nuneaton plans to expand the
machine’s role to include more complex and custom parts, while introducing overnight
unattended running.
More information www.millscnc.co.uk

UK foundry buys estate

A major UK foundry has reinforced its commitment to the Black Country with the purchase of the Moxley Industrial Estate. Alucast, which provides high-pressure, low-pressure, sand and gravity casting services, has spent £1.8m on the site in Wednesbury, protecting the future of it three current units and supporting estate neighbours Kingfisher Enamelling Co and BES Group Testing. Located just a few miles from the M6 and M5 motorways, the 5-acre site is well-known in the local manufacturing community and has been home to Alucast for nearly 65 years.

More information www.alucast.co.uk

€45m casting investment

Horse Powertrain, a global specialist in low-emission propulsion systems, has invested €45m to expand cylinder-head casting processes at its plant in Valladolid, Spain. The new aluminium casting facility will be the first in the country to cast cylinder heads using the tilting gravity die casting (TGDC) process. Compared with traditional high-pressure die casting, TGDC enhances the structural integrity of finished components. Once this investment comes online, Valladolid’s annual production capacity for cylinder heads will rise from 300,000 to 360,000 and yield 150 new roles.

More information www.horse-powertrain.com

Strategic investment underpins growth at ComplexaHPE

Precision injection moulding, machining and tooling specialist ComplexaHPE is reporting a record order book following more than £2m of investment in advanced manufacturing technology and a strategic focus on supplier collaboration, including a close partnership with Erodex UK.

Formed in 2021 through the merger of ComplexaTools and High Precision Engineering (HPE), the business provides a full turnkey service spanning toolmaking, precision machining and injection moulding. The strategy is delivering results, with new contracts secured in the UK, Ireland and overseas, particularly within high-end medical manufacturing.

Group managing director Paul McHugh attributes the growth to sustained investment and integrated capability: “Customers increasingly want a complete solution, from design for manufacture through to final sign-off, including end-of-arm tooling and inspection fixtures. That reduces lead times and ensures consistent quality.

Since 2021, the company has installed high-speed milling machines, five-axis machining centres, spark and wire EDM systems, and a Mazak Millturn, alongside robotics and palletisation to support lights-out production. However, McHugh emphasises that machinery alone is not enough.

“Maximising performance is critical, and that’s where Erodex has added real value,” he says.

Following a review of EDM processes, Erodex recommended POCO EDM graphite grades to optimise electrode performance and consistency. In automated, unattended environments, predictable material behaviour is essential. The result has been improved machinability, longer electrode life, reduced cycle times and enhanced surface finishes.

With nearly 24 months of work secured, ComplexaHPE is experiencing unprecedented demand.

“Our success is built on quality, technical expertise and strong supplier partnerships,” concludes McHugh. “Working closely with Erodex has helped us raise standards and strengthen our competitive position in precision manufacturing.”

More information www.erodex.comTop of Form

Ultimate reliability: 35-year-old wire EDM still in use

When Kress Funkenerosion was founded in 1990 in Mühlhausen, near Nuremberg, its future rested on a single machine: a FANUC Tape Cut W2. As a young tool- and mould-making subcontractor serving demanding sectors such as automotive, aerospace and medical, uptime was critical. The brief for that first investment was straightforward: deliver high-quality wire-cut components with absolute reliability.

More than three decades later, that same machine remains in daily operation, a testament to the durability and engineering philosophy of FANUC.

The machine’s longevity set the tone for the company’s future direction. Impressed by consistent performance and minimal maintenance requirements, Kress Funkenerosion standardised on FANUC wire EDM technology, investing in a further 12 machines over the years.

The most recent additions are two FANUC ROBOCUT α-C400iC models, which provide both precision and versatility. Managing director Michael Schander reports that tolerances of ±3 µm are achieved with ease, supported by reliable automatic wire threading in under 10 seconds. Yet, for Schander, performance figures tell only part of the story.

“What really sets FANUC apart is the build quality,” he says. “The last service call I remember was over six years ago. That level of reliability is exceptional.”

Today, all wire EDM machines on site are FANUC models, forming the backbone of the company’s ISO 9001-accredited operation. For founder Gerhard Kress, the decision remains clear: “The first machine I bought in 1990 is still running. After more than 30 years of experience, I see no reason to change.”

More information www.fanuc.eu