Find out more about all of the processes involved in producing some of our more intricate products.

Our Case Studies

Housing

Tried to maintain some very tight tolerances at various key positions on the outside diameter. Subsequent welding to prevent creepage in tight tolerances achieving squaring and roundness.

Processes involved:

Milling

We have a comprehensive range of conventional and CNC milling machining capabilities, which enables us to respond Learn more >

Inspection

All components are inspected using Mitutoyo CMM co-ordinate measuring machines.

Instrument guard

This Instrument guard is an example of a complex one piece manufactured component without any welded joints it therefore avoids weaknesses. Made out of one piece of stainless steel. High tolerances at the top aperture to allow a component to run freely within that aperture due to surgical field use. A risk of failing equals high risk.

Processes involved:

MM Turning

Our Mill/Turn Multi-Tasking Centres provides extreme versatility and accuracy for midsize to large, complex components. Improved milling Learn more >

Wire Eroding

Wire erosion is the process were a metallic wire (electrode) is used to cut a programmed contour Learn more >

Inspection

All components are inspected using Mitutoyo CMM co-ordinate measuring machines.

Milling

We have a comprehensive range of conventional and CNC milling machining capabilities, which enables us to respond quickly to customer needs. With a combined understanding of traditional skills and modern machinery, we have the expertise to machine components in most materials.

Our high performance CNC machining centres are designed for the production of short or long batch runs, enabling us to deliver high quality, with short lead times and lower costs. We run 3 and 4 axis machines with single and twin pallets and carry up to 240 tools which allows us to offer components from a few mm’s in size up to a half metre in length and 300mm width..

Our CNC machining centres provide high-speed precision horizontal machining centre offering maximum versatility and productivity. Increased chip removal rates, multi-plane and multi-piece capabilities.

All of our CNC machining centres are equipped with Renishaw probing to ensure the highest degree of accuracy, repeatability and longer run times; this system is also used for tool setting and to monitor tool breakages.

We have invested in the latest CAD/CAM programming systems allowing us to accurately quote for components, provide accurate lead times as well as machine the most demanding geometries to extreme accuracy. Programs can be written off-line quickly, with the ability to accept drawings or models to ensure components are machined to exact requirements.

All of these elements combine to provide “lights out” unmanned running of the equipment.

Sliding Head

Bushell & Meadows multi axis, twin spindle sliding head lathes offer you accuracy, repeatability, reliability and lower cycle times on turned parts.

The main spindle benefits from a gang type tool post and a multi station turret to enable simultaneous machining operations. The turret includes an independent Z3 axis, this axis allows two different features to be machined simultaneously.
Fanuc’s high specification control delivers full five axis capability enabling highly complex components to be processed. It also allows balanced cross Milling/Drilling and Turning. All machines are programmed using up to date 3D modelling software packages.
This technology allows us to manufacture long slender parts featuring multiple complex features in one operation. We can machine bar between 2-32mm diameter and up to 3 metres in length.

MM Turning

Our Mill/Turn Multi-Tasking Centres provides extreme versatility and accuracy for midsize to large, complex components. Improved milling and turning efficiency provides customers with not only a quick turnaround, but accurate parts.

Complex machined parts are expertly manufactured in a single set up from a solid bar or raw material including steel, stainless steel, bronze, aluminium castings, forgings and even heat treated steel.

With full 5-axis capability, the machine easily processes fully prismatic parts from solid blocks or castings (chucked or bar fed work), round parts, or highly contoured sculptured parts.

In one set up, without having to remove the component from the chuck, components are turned, milled, drilled and, where applicable, gear cut and come off the machine as a finished part. This eliminates multiple set ups, fixtures, tools, handling and waiting time which add to manufacturing costs. Also, by eliminating multiple set ups the accuracy of the component is greatly improved.

All of these elements combine to provide “lights out” unmanned running of the equipment.

All of our Mill/Turn Multi-Tasking Centres are equipped with Renishaw probing to ensure the highest degree of accuracy, repeatability and run times, effectively reducing Operator “hands-on” time.

Grinding

CNC Grinding

Our CNC Grinding machines are ideal for large batch work and small parts with tight tolerances. We can achieve a 5 micron tolerance finish accurately by holding the components in various different ways. Ideally the part has centres, but don’t despair if not, we can hold them with a 4 jaw chuck, 3 jaw chuck or collets.

Surface Grinding

We currently have a Jones & Shipman Surface Grinding machine which enable us to produce a smooth and accurate finish on flat surfaces, for a wide range of metals. Our capacity for the machines varies on the job complexity required and we have an extensive range of tooling equipment.

Laser Cutting

The latest laser cutting technology – CNC laser cutting for laser cut flat profiles and laser cut beams and open sections. Together with traditional flat bed cutting of sheet and plate.

Laser Welding

Deep penetration (or keyhole) laser welding is a line-of-sight, single-sided, non-contact joining process. It is characterised by its high focused energy density, which is capable of producing high aspect ratio welds (narrow weld width: large weld depth) in many metallic materials. It can be performed at atmospheric pressure, although inert gas shielding is required for more reactive materials. Laser welding offers enormous advantages over conventional welding procedures because it is a highly repeatable process that can produce precise welds with minimal heat input and, thus, low distortion. Laser welding is currently being used for highly precise micro-welding of medical devices and components.

Wire Eroding

Wire erosion is the process were a metallic wire (electrode) is used to cut a programmed contour in a work-piece.  Each electrical discharge creates a crater in the work-piece to remove material. The wire can be inclined, making it possible to create components with taper or differing profiles at the top & bottom of the work-piece.  Working repeatedly to tolerances of 3-5 microns of accuracy.

CNC control of our wire erosion machines coupled with sophisticated computer design technology enables the most complex, awkward or three-dimensional and advanced tapered profiles to be processed, allowing us to rapidly deliver exactly what our customers require.

Finishing

Assembly, Vibro Deburr, Blasting, Manual Deburr, Laser Marking, Passivation,

Inspection

All components are inspected using Mitutoyo CMM co-ordinate measuring machines.