MEDICAL EQUIPMENT MANUFACTURER BRINGS MILLING AND TURNING IN-HOUSE AND STARTS SUBCONTRACT MACHINING DIVISION

Medical systems manufactured by Hollingworth Design Ltd (HDL) at its Stockport factory
now contain components milled and turned in-house, avoiding the unreliability and cost of
sourcing from subcontractors. Now, third parties only produce sheet metalwork. The first
CNC lathe and mill were installed in 2017, followed by another turning centre and a
German-built Index G200 twin-spindle, triple-turret, turn-mill centre supplied in 2020 by
sole agent Kingsbury.
Since then, the number of lathes and mills on-site has doubled to eight, including a smaller
capacity Index C100 and HDL’s first automated prismatic machining cell: a robot-fed, five-
axis, HSK-A63 spindle C12 from Hermle, Germany, also represented exclusively in the UK by
Kingsbury.
The same period has seen the arrival of a CNC mitring saw, an Aberlink co-ordinate
measuring machine, a Keyence optical inspection system and the company’s first quality
control inspector, Simon Tweedie. Other new members of staff are Richard Binks, who is
dedicated to subcontract sales, and Nick Mort, lead engineer in charge of the CNC section.
Mort says: “The subcontract side of our business has increased fivefold to 25% of turnover
in the past two years and we’re aiming to increase it to 50% by 2026.”
The 65 mm bar capacity Index G200, which is fitted with a 3 m bar magazine, is playing a
major role in fulfilling the growing number of contracts. The upper, double tool carrier has a
360° B axis and a ±65 mm Y axis. On one side is a 14-station, live tool turret rated at 16
kW/16 Nm (25% DC) and 7200 rpm maximum speed. On the other side is an HSK-A40 22
kW/52 Nm (25% DC) milling spindle with automatic cutter exchange, enabling considerable
machining versatility in combination with the two lower turrets that also serve the 6000
rpm/32 kW main and counter spindles.
Arranged in mirror image, each lower turret has an independent, ±45 mm Y axis and an
identical rating to the turret at the top. To optimise productivity, it is possible to utilise all
three turrets simultaneously at either the main or counter spindle, without interference.
Alternatively, simultaneous machining the front end of a component at the main spindle
and the reverse end at the counter spindle, in contrast to sequential machining on HDL’s
earlier lathes, has cut cycle times dramatically. To produce a typical turned, threaded and
engraved brass manifold component, for example, the typical cycle time is just 90 seconds
(down from 4 minutes), with similar gains evident when producing subcontract parts for
other OEMs.

Given the lathe’s high power and versatility, it is not surprising there was a tendency to
prioritise the use of this Index turn-mill centre when considering which machine to employ
for producing a new or existing part, even if it mostly entailed prismatic machining using the
driven tools. So another lathe from the same source, an Index C100 with 42 mm bar
capacity and a more conventional three-turret configuration, arrived to produce most of the
turn-milled components for internal use. As a result, the larger lathe is free to fulfil mainly
subcontract work, which is often more complex and generally larger.
Mort says: “We had no hesitation returning to Kingsbury for another Index lathe, as the first
proved very reliable and the back up from the agent was prompt, efficient and friendly.”
For that reason, in early 2023, when HDL wanted to acquire its first automated machining
centre, it selected Kingsbury again for the purchase of the Hermle cell. It was preceded by a
stand-alone, five-axis, 30-taper mill-turn machine from another supplier for producing
aluminium parts for a bicycle manufacturer in the north of England. The contract was
growing in variety and volume, especially with the introduction of an electric bike, so
automation was the obvious choice for producing the parts more cost effectively.
As the bicycle components are relatively light, it was decided that a Hermle RS05 robot for
handling individual billets into the machining area and returning finished parts was
preferable to automated pallet exchange. The latter would incur more cost to buy the
pallets and work-holding equipment and entailed extra work for fixturing and removing
parts.
Now, the 30-taper model and the Hermle share machining of the bicycle parts. The
production of prototypes takes place on the former, while larger batch work occurs on the
latter; 50-off, say, if piece-part cycle time is 15 to 20 minutes, or 200-off minimum in the
case of shorter cycles.
To support HDL while its engineers were familiarising themselves with operating the Hermle
cell and programming it with the help of a new seat of SolidWorks CADCAM software,
Kingsbury provided a suite of eight turnkey packages, each comprising a program, set-up
sheet and list of recommended tooling.
“These days, it’s difficult to find skilled setter-operators,” says Mort. “An automated cell like
the Hermle helps to mitigate the situation, as once it is set it just runs, including overnight,
producing parts to tolerances from ±0.25 mm right down to ±10 µm.”
In addition to the medical and bicycle manufacturing sectors, HDL regularly serves
motorsport, aerospace and the marine industry. It also supplies tight-tolerance, mainly
titanium parts that go into test equipment built by Hyderogen, a hydrogen technology
consultancy owned by Kris Hyde, who is joint managing director of HDL together with the
company founder, Paul Hollingworth.
For further information www.kingsburyuk.com

Mazak enjoys ‘packed’ open house




Yamazaki Mazak’s investment in its UK manufacturing facilities was one of the main draws behind a strong attendance at its recent annual open house.The event, themed ‘building for your future’, linked the increase in capacity at the company’s European Manufacturing Plant in Worcester with its ability to now offer significantly shorter lead times on key machines.In total the open house received over 700 visitors over the four days.

Jason Butler, sales director for Yamazaki Mazak UK, says the strong attendance proved Mazak’s strategy in the UK: “I’m very pleased, we had a packed European Technology Centre over each day with plenty of potential new customers visiting us for the first time. That says to me our message of continued investment in Worcester, which has led to increased production capacity and very short lead times on key machines, is really resonating with UK manufacturers.”
For further information www.mazakeu.co.uk

Automated mill-turn cell halves cutting cycles




A British designer and manufacturer of bedpan macerators for healthcare institutions and sewage treatment systems for municipal water companies, Haigh Engineering, has upgraded the capacity on its shop floor in Ross-on-Wye with the installation of a five-axis Hermle C 42 UMT prismatic machining cell featuring turning capability.

Included are a multi-level tool magazine for holding 50 tools in addition to the standard 42 tools, making a total of 92, and a six-pallet storage system served by a three-axis HS Flex Heavy robot for automatically transferring pallets with a maximum capacity of 1200kg into the working area and returning them after component machining. Kingsbury, Hermle’s sole UK agent, delivered the cell in September 2022.

Haigh Engineering’s production manager Neil Phillips says: “As well as allowing for future capacity increase and improved reliability, the Hermle C 42 enabled us to take two older, less efficient machining centres off-line.”Overall, current metal cutting time is today about half of that provided by the older mills (with the equivalent machining cycles).

A majority of throughput at Haigh involves the machining of castings, mainly iron but also stainless steel and aluminium, ranging in size from 400 mm high by 600 mm square, down to 150 mm diameter by 150 mm long. Some weigh as much as 250 kg. While Haigh currently attends the machine full time, as the setters optimise usage, the intention is to set up multiple parts on the six pallets and run the system lights-out. Some unattended machining already takes place at the end of each day shift by loading a raw casting that requires 60 minutes or more of metal cutting time, allowing production to continue past normal working hours.
For further information www.kingsburyuk.com

SPEE3D joins MTC




Metal additive manufacturing technology company, SPEE3D, has enrolled as the latest member of the Manufacturing Technology Centre (MTC). SPEE3D develops metal 3D printers and integrated systems utilising its patented cold-spray additive manufacturing (CSAM) technology. The company says its solutions offer significantly faster production than traditional metal manufacturing for a range of materials. SPEE3D CEO Byron Kennedy says: “We’re excited to bring our CSAM technology to industry across the UK, and MTC has the reach and expertise to help us do that efficiently and effectively.”
For further information www.the-mtc.org

Renishaw opens apprenticeship places




Across its Gloucestershire and south Wales sites, Renishaw has opened applications for 64 apprenticeship roles. The company offers an award-winning apprenticeship programme, where apprentices gain nationally recognised qualifications, some to degree level, alongside on-the-job experience.Roles are available across different disciplines, including: IT, general manufacturing and engineering, software engineering, embedded electronics, and plant maintenance.

Apprentices will benefit from a competitive salary and benefits package and the opportunity to gain insight from industry-leading specialists, while working on real-life projects and products. Applications to become a Renishaw apprentice are open until 12 February, the end of National Apprenticeship Week.
For further information www.bit.ly/3Nt9Clk