SUBCONTRACTING NEWS

Protolabs expands production capabilities

Digital manufacturer Protolabs is expanding the production capabilities of its global CNC machining service, creating new opportunities for product development worldwide. Customers who upload a 3D CAD model to the online quoting platform can now access a range of better-qualified suppliers through Protolabs’ digital supply network. The seamless transition between in-house and network production options opens up a wealth of advanced machining capabilities designed to reduce part costs, increase tolerances and provide a broader range of finishing options.
For further information www.protolabs.com/en-gb

NTG invests in more five-axis capacity

NTG has put its first machine into a new facility in Gateshead and at the same time increased its five-axis machining capacity.The subcontract manufacturer remains on the Team Valley Trading Estate in Gateshead, but has massively increased the size of its premises, up to 45,000 sq ft, from 18,000 sq ft.The first machine into the new facility is a new Mazak VariAxis i-800 NEO.

Mike Hutchinson, group managing director at NTG Holdings, says the investment in both the new facility and the new machining technology opens up opportunities for his company: “Our five-axis capability has become a bottleneck due to demand from customers for this type of complex work. The new machine will enable us to offer shorter lead times by reducing the restrictions around our five-axis work.”

The VariAxis i-800 NEO is a five-axis vertical machining centre that delivers advanced high-speed multiple-surface machining in a large machining area. It will be followed by another 50 machines that will be transferred to the new facility in the coming weeks, including Mazak turning centres, Integrex multi-tasking machines and vertical machining centres.

“We’ve increasingly diversified the business from its roots as predominantly a tooling and oil and gas focused supplier,” explains Hutchinson.“We now operate across defence, food production, energy, subsea, electric vehicles and renewables. The new facility will give us the footprint to be able to continue to grow and service all our sectors, while also giving us the footprint to introduce more capacity and new technologies in the future.”

Mazak has been a long-time partner for NTG, helping the company make the move into complex five-axis work more than a decade ago.
For further information www.mazakeu.co.uk

Subcontractor gets into gear with Quaser machine

Leicestershire-based Sovereign Gears has recently invested in a Quaser MF400UH five-axis machining centre that follows on from three Nakamura turning centres also purchased from the Engineering Technology Group (ETG).

Director Ryan Spring says: “The majority of our work is 1- and 2-off bespoke gears, as well as jigs and kits for holding, assembling and working with the gears. Unfortunately, with so many complex forms, most of our milling work requires two, three or four set-ups, and this can take a lot of time and slow down our throughput. We bought the Quaser MF400UH with Open Mind’shyperMILL CAM software, also supplied via ETG to reduce our set-ups. The Quaser is our first five-axis machine, but we’re already seeing huge benefits.”

Previously, set-up time were frequently in the order of 4-5 hours, but the Quaser has instantly eliminated 75% of this time, and with only a single set-up required for five-sided machining.The precision of each component is subsequently improved.

“As a small business, it’s imperative that we maximise the productivity of both our machine tools and our staff,” says Spring.“By having the Quaser machine and reducing our set-ups, we’re freeing-up the capacity of two employees. Instead of spending excessive hours repeatedly setting up three-axis machines, staff can be allocated to other tasks.”

He adds: “Since having the Quaser, we’ve improved our ability to machine complex forms and this has ultimately won us new business that previously, we would have turned away. The ability to increase the type of work that we can machine, such as round gear teeth, challenging chamfers, forms and keyways has enabled us to increase our customer base and our offering to those customers.”
For further information www.engtechgroup.com

Wire EDM sparks productivity gains for Go Tools

Set up in 2012 to deliver precision tooling to companies in the north of England, Go Tools Ltd is a specialist manufacturer of precision die-cast dies and injection mould tools for a multitude of sectors. With an unwavering commitment to quality and service, the company has invested in high-end machine tools from the Engineering Technology Group (ETG).

One point of concern was an ageing EDM machine.Recalling this, Go Tools technical director Steve Barrowcliff says: “Our old EDM machine had inconsistent cut quality and poor precision levels that made us rely on the expertise of our staff to retain tolerance and surface-finish requirements. As an old machine, it was also unreliable and a potential concern due to the amount of EDM work going through the shop floor. We investigated the market and the Mitsubishi MV1200R wire EDM was the perfect fit for our business. The programming platform of the Mitsubishi EDM was 10 times better, as was the accuracy and the speed of cutting. Simultaneously, we needed a spark erosion EDM, so we also invested in the OPS Ingersoll Gantry Eagle 400 – both machines were the result of the technical expertise and support of ETG.”

This first delve into Mitsubishi EDM technology proved a resounding success with productivity, reliability and quality improving significantly. So, when the company found its Mitsubishi MV1200R EDM at capacity some years later, the company naturally went out and bought another machine that was the same as the first.

“Our first Mitsubishi MV1200R improved our cycle times by more than 50% and the precision levels and surface finishes were impeccable, so when it came to buying a second machine, we didn’t need to look anywhere else,” concludes Barrowcliff.
For further information www.engtechgroup.com

Protolabs posts new speed record with System 3R

When it is seen how Protolabs uses a System 3R pallet system in the ever-tougher ‘lead time race’, it is easy to see why the company asserts that it is the world’s fastest supplier of both CNC milled and injection moulded components.

Regarding speed, operational reliability and repeatable precision, Protomold and Firstcut, the two elements in the company’s operations, both benefit greatly from System 3R’s Macro system. This applies equally to the manufacture of moulding tools and the milling of components.

All workpieces are mounted on Macro pallets. Thanks to the properties inherently offered by the patented 3Refix system’s guaranteed positioning, Protolabs can move the pallets from one machining process to another without jeopardising precision, no matter how many such moves the total process requires.

“Over the past four years, System 3R has undoubtedly helped us cut lead times considerably, if not to say dramatically,” reveals Lee Ball, production director.“Speed is the essence of our mission to supply customers with injection moulded or machined components. Protomold is really fast in supplying injection moulded parts to customers. We would not be able to produce moulding tools fast enough if we couldn’t first make the necessary graphite electrodes. Macro is with us all the way. Furthermore, the system is so easy to use.”

By combining the production processes in its Haas CNC milling machines and Agie-Charmilles die-sink EDM machines, Protolabs can rapidly supply parts made in the desired material. This is vital not only in each prototype project but also in the production of test pieces and the reproduction of unavailable, obsolete or faulty components.
For further information www.system3r.com