SUBCONTRACTING NEWS

High-volume machining of aircraft brake clips

Aerospace is Westley Engineering’s largest market, accounting for 45% of total production by value. A notable aerospace contract involves the manufacture of rotor clips used in aircraft disc brakes. Made from aerospace-grade steel and Inconel, the components see application in both civil and military aerospace programmes.

Three years ago, Westley Engineering improved the accuracy of the manufacturing process by switching from piercing holes in the clip using press tools to drilling them on a 40-taper vertical machining centre. Although it improved precision, the new approach also increased cycle times substantially and made the process more labour intensive. So in late 2023, the company installed a Brother Speedio S700Xd1 4-axis, 30-taper machining centre, followed by a second in April 2025. Supplied by Whitehouse Machine Tools, the exclusive UK and Ireland distributor for the Japanese manufacturer, these high-speed machines have now replaced the VMC for clip production.

In partnership with Whitehouse Machine Tools, Westley Engineering implemented an automated, single-operation process on each Speedio. The new production route features custom-built fixtures with nine inclined bars, each capable of holding 36 clips. This high-density arrangement enables over 300 parts to be machined per cycle, significantly more than the flat fixtures used previously.

Cycle times have been reduced to between two and three minutes per clip, depending on the variant. For example, the Inconel version requires additional milling on the outer arms, whereas the steel variants do not. Typical batch size ranges from 5,000 to 10,000 units.

Before deployment, the process was validated at Whitehouse Machine Tools’ Kenilworth technical centre.

More information www.wmtcnc.com

£250,000 investment enhances quality control

Basildon-based Rodwell Powell, a specialist in precision machining for the aerospace, defence, marine, construction and other industries, has invested £250,000 in a renovation of its inspection department. The centrepiece of the upgrade was the acquisition of two CMMs manufactured by LK Metrology at its Castle Donington factory. The CMMs are delivering high levels of accuracy and efficiency to support increasingly complex quality control requirements for Rodwell Powell’s clients, which include Rolls-Royce Aerospace and Caterpillar.

The two next-generation LK Metrology Altera C CMMs are enabling the subcontractor to handle larger, more intricate parts with greater accuracy and efficiency. One of the new machines is an LK Altera C 10.7.5 equipped with a Renishaw PH10M Plus motorised indexing head deploying an SP25M probe with an SH25-2 stylus holder, which can perform scanning for form measurement and reverse engineering, as well as touch-trigger probing for accurate geometrical measurements. Featured also is a six-port stylus change rack to enable unattended completion of complex inspection routines.

The second CMM is a smaller LK Altera C 7.7.5 with PH10M Plus and SH25-2, and additionally equipped with a Renishaw TM25-20 touch-trigger probe module, allowing the continued use of legacy CMM Manager software alongside LK’s latest CAMIO 2024 R2. The latter is CAD-based metrology software that underpins the use of multiple sensors, intuitive programming, simulation, results analysis, GD&T, reporting and automation.

Andrew Rodwell, managing director, says: “Our investment in LK Metrology’s cutting-edge CMM technology is a game-changer for us. The CMMs allow for increased accuracy, greater throughput and reduced lead times, reinforcing our reputation for uncompromising quality in these highly demanding industries.”

More information www.lkmetrology.com

David Brown Becomes SID President

During this year’s SID (Syndicat International du Décolletage) International Congress in Chicago, it was announced that David Brown, current president of the BTMA (British Turned Parts Manufacturers Association) and director at Neida (Stoke-based precision component supplier), will serve as SID president from 2025 to 2027.

SID was created in 1963 to bring together national organisations representing the precision machining industry. For over 10 years, Brown has been a member of the BTMA and, during his current presidency, has driven manufacturing initiatives related to skills and training, legislation and regulations, sustainability, and process improvements. During his new presidency at SID, Brown’s key objectives will take on a global focus.More information www.neida.co.uk

adi Group Celebrates 35th Anniversary

Engineering a better future for over three decades, adi Group is celebrating 35 years of delivering engineering and construction services. Founded in 1990 by Alan Lusty, adi Group began as a small team under adi Electrical. Inspired by a dream to create a self-delivered ‘one-stop-shop’ for multidisciplinary engineering services, Lusty’s vision was clear: build a business that would add an engineering service or sector specialist delivery division every 12-18 months – a vision that continues to drive the company today. Fast forward to 2025, the group now boasts nearly 40 specialist divisions and a team approaching 1000.

More information https://adiltd.co.uk

Armadillo Additive Expands with AddUp Machines

Armadillo Additive, an ISO 13485-certified contract manufacturer serving the medical industry, is expanding its metal 3D printing capacity with two additional AddUp FormUp 350 laser powder bed fusion (LPBF) machines. The investment brings Armadillo Additive’s FormUp 350 total to three. Now, the company is adding 17-4 stainless steel and Grade 1 titanium to complement its existing offering of Grade 23 titanium.

“By adding two more FormUp 350 machines, our team is uniquely positioned to offer unmatched throughput and material versatility to customers,” says Noah Smith, director of operations at Armadillo Additive. “Our first FormUp 350 has proven its reliability, surface finish quality and overall throughput. We’re excited to continue our growth alongside AddUp and remain a trusted partner for our customers.”

Armadillo Additive says it selected AddUp’s FormUp 350 machines based on their reliability, production efficiency and strong safety features. The autonomous powder module and advanced filtration system contribute to a safer working environment. FormUp 350 machines also deliver high-quality surface finish straight from the printer, reducing the need for extensive post-processing.

The machine’s large build volume and quad-laser configuration allow for increased productivity and flexibility in manufacturing. These features combined with AddUp’s robust software suite ensures consistency and confidence in production that Armadillo Additive expects from their machines.

This expansion allows Armadillo to support a broader range of applications, including R&D, implants, and intricate lattice structures that optimise strength and material efficiency.

Says Smith: “Our expertise in orthopaedic applications – along with our in-house services like laser marking, heat treatment and bead blasting – ensures we deliver complete solutions that meet the rigorous demands of medical engineering.”

More information https://addupsolutions.com/