64% fail metalworking fluid checks

A freedom of information request submitted by TotalEnergies Marketing UK Ltd to the UK Government’s independent workplace safety regulator has revealed widespread non-compliance relating to the use of metalworking fluids. A total of 285 unannounced inspections were carried out by the HSE on manufacturing businesses that use metalworking fluids or coolants in their machining processes, over a period of eight months. The inspections identified significant safety breaches relating to these fluids at 181 sites between September 2023 and April 2024, equivalent to around 64% of all inspections.More information www.bit.ly/4fKcpC6

King’s Award for AM specialist RYSE 3D

Additive manufacturing specialist RYSE 3D has celebrated its best-ever year in style by securing a King’s Award for Innovation. The company has seen sales increase by 58% over the past 12 months, while its ability to deliver 3D-printed production parts quickly has seen RYSE 3D race towards a near £5m turnover. The Shipston-on-Stour-based business has also created 10 new jobs, added new export markets and launched LANDR 500, a large-format FDM printer designed and built in the UK. Tim Cox, Lord Lieutenant of Warwickshire, was welcomed to its factory as part of the King’s Award celebrations.

More information www.ryse3d.com

PECO on right track with VISI CADCAM

As one of the world’s major manufacturers of model railways, PECO is a forward-looking family business that started trading back in 1946. Initially concentrating the production of trackwork for model railway enthusiasts, the company has grown exponentially. To support its expansion, the Devon-based company relies on VISI CADCAM software from Hexagon at its design and manufacturing facility.

PECO’s toolroom manager Simon Cockerham says: “We use numerous licences of VISI across our processes, from concept through to final press or mould tool creation. In addition, we use VISI to generate laser-cut wooden kits featuring surface textures, and create instructions that guide enthusiasts and users on how to assemble the equipment.”

He continues: “VISI has always been very good for our business as it focuses on what we need to do the job. Some of our previous software packages caused issues due to tight component tolerances and the nature of the machining processes that we have to undertake to achieve the geometries required in our press and mould tools.”

VISI incorporates modules such as: modelling; analysis; mould design; flow; electrode design; die tool design; 2.5, three and five-axis toolpaths; blanks; and reverse. This capability provides PECO with the facility to create solid models, design, analyse, validate and prepare mould tool geometries, and perform pre- and post-production analyses of plastic parts.

With dedicated modules for creating electrodes, designing dedicated progressive die and press tools, comprehensive machining strategies, and even reverse engineering of editable solid models from scanned data – VISI provides a complete package for the company.

“Another key reason why we use VISI is the complexity of our products,” says Cockerham. “We need jobs to be right first time.”More information www.bit.ly/4iX3f8h

New lease of life for large milling machines

The retrofit of Heidenhain TNC 320 controls and drives to three large Elgamill travelling-column bed mills at the Swansea factory of subcontractor Afon Engineering have improved their reliability and performance. It has been an object lesson in how mechanically sound machine tools built in the late 1980s can be given a new lease of life for a fraction of the cost of investing in new equipment.

Engineering director Andrew Beaujean says: “The project has given us more confidence to take on a much broader variety of contracts and is bringing in new business as a result, such as evaporator tube plate machining.”

The refurbished machines at Afon have beds measuring 12, 10 and 8 m respectively in the X axis. The mid-size model, when it was installed in 2009 with an earlier Heidenhain TNC 355 control, was the first CNC machine on site. The other two Elgamills, which arrived five and 11 years later, were fitted with a TNC 155 CNC system. Two smaller, as-yet unmodernised machines from the same manufacturer are also on the shop floor.

The upgrade to the new controls has considerably reduced programming times by up to 50%, making more jobs economical to undertake. A benefit of having identical TNC 320s on three Elgamills is that, from the operator’s perspective, all keys, buttons and switches are in the same place, so swapping between machines is seamless. Moreover, the overall cost of the refurbishments was within budget at approximately £350,000 for all three machines, an order of magnitude less than purchasing three new machining centres of similar capacities.More information www.heidenhain.co.uk

Tadweld Celebrates Record Year

Tadcaster-based engineering and fabrication business Tadweld rounded off 2024 by
celebrating a record year. The company not only saw year-on-year sales climb by 50% in
comparison with 2023, it also created 12 new positions and has plans to create 30 more
over the coming three years.
Further Tadweld achievements in 2024 included winning the ‘Digital Technology in
Engineering’ accolade at the Made in Yorkshire Awards. The business also racked up a new
record of 2400 training hours with six new apprentices, invested in new space and facilities
to the tune of £1m+, and continued embracing innovation through the implementation of
laser welding equipment.
More information www.tadweld.co.uk