Machinery & Manufacturing | Issue 21 | May/June 2025

HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY

ISSUE 21 | MAY/JUN 2025

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“Business as usual”

Exclusive interview with new MD of XYZ Machine Tools

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EVENT PREVIEW Subcon 2025

Revolutioni s ing machining with Iscar Page 28 OIL AND GAS

LET’S TALK : ADVANCED MANUFACTURING Seizing the moment

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YOU Milling Intelligently?

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Contents 7 Is the tide turning? Reports of a strong Q1..

Catch up

What’s been happening?

Policy meets SME An exclusive round-table discussion People of #UKMFG Different minds, infinite possibilities

Publisher - Laura Crawford laura@machineryandmanufacturing.com Technical editor - Steed Webzell steed@machineryandmanufacturing.com Operations - Mark Deadman Mark@machineryandmanufacturing.com Editorial team editorial@machineryandmanufacturing.com Circulation enquiries circulation@machineryandmanufacturing.com Published in an eco-aware format by Engineering Media Ltd The Maidstone Innovation Centre, Gidds Pond Way, Maidstone, Kent ME14 5FY Tel +44 (0)1622 296112 Company Number : 13634129 VAT Registration 397 8226 41 Our registered company address is : 20-22 Wenlock Road, London, N1 7GU In our mission towards carbon neutral, we publish and replant in partnership with:

Let’s talk : Advanced manufacturing Seizing the moment Industry : Oil & gas Iscar tools revolutionises machining Subcontractor celebration 60 year milestone for Wealdpark Supplier spotlight Alwayse gears up with Mills CNC Precision engineering Turning vision into reality Cover interview We sit down with the new MD of XYZ Event review Hexagon’s ‘Future of the shop floor’

Supplier spotlight Engineering escapism with igus Sheetmetal Emsea boosts productivity Sensors in tooling Intelligent machining solutions Additive manufacturing Sculpting speed, with Renishaw Tooling technology Complete know-how in one part Automated storage Streamlining operations with Kasto Engaging with education Rethinking plastic bottle recycling

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CNC machining Optimising manufacturing

Welcome... Welcome to issue twenty one of Machinery & Manufacturing magazine. Crafted by our team of dedicated engineering media professionals especially for you, the CNC machine tool intensive manufacturing community. We invite you to enjoy this immersive reading experience packed with video and downloads. This is a hybrid magazine, to be read on or alongside your desktop, phone or tablet. I’m a hybrid! How do you use me? Click or scan the play buttons for instant video Click or scan the download buttons for instant brochure downloads, discreetly appearing on your device in a separate file ready for you to simply hit save.

EV innovation Casting breakthrough fuels Kings Award Automation Redefining smart automation integration Quality & inspection Mouldings manufacturer meets vision Grinding New solutions from Master Abrasives

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Is the tide turning?

Whisper it quietly, but is the UK manufacturing fraternity started to see confidence - and indeed orders - ebb back? Here at Machinery & Manufacturing we keep our ear pretty close to the ground, with several recent discussions making us think the sector’s general trajectory could well be turning upward. This is certainly corroborated by a notable UK industry barometer - the Qimtek Contract Manufacturing Index (CMI) - which showed a significant bounce in Q1 2025 (up almost 50% on the corresponding quarter in 2024). January was particularly strong, some 200% higher than what had been a quiet December, while the market at the end of March was higher than the average for the final quarter of last year. You’ll find further evidence of a potential upturn in this issue of Machinery & Manufacturing. Our exclusive interview with Wealdpark, a St Helens based subcontract precision engineering company celebrating its 60th anniversary in 2025, sees company Director Phil Smith admit his surprise at recording the company’s best-ever February, while March was the best month in Wealdpark’s history!! A regular attendee at meetings of the BTMA (British Turned Parts Manufacturers Association), Phil says many others are reporting similar. Our new issue also carries an exclusive interview with Martin Burton, who took over as Managing Director at XYZ Machine Tools around 12 months ago. As a major supplier of machine tools to the UK manufacturing industry, he reports XYZ’s sales are on track to exceed that of last year, again indicating gains in market confidence and investment. All this comes as the UK economy registers higher- than-expected growth of 0.7% in the first three months of 2025. Chancellor Rachel Reeves suggested the UK economy is “beginning to turn a corner”. All coincidence, or genuine green shoots? I’m sure UK manufacturers will have their fingers crossed for the latter. Laura Crawford Publisher

Catch up

Mitsubishi materials expands reconditioning in Europe

MMC Hardmetal Europe Holdings (MHE), part of Mitsubishi Materials, has acquired U.F.P. s.r.l., a leading provider of tool reconditioning and custom tool solutions. The acquisition strengthens MHE’s European capabilities, improving service proximity, reducing lead times, and offering more cost-effective, sustainable

solutions. UFP, with two facilities in Italy, serves key industries including aerospace and automotive. This move supports Mitsubishi’s goal of establishing a modern European service hub and accelerating its shift toward a circular economy through localized, efficient operations. www.mmc-carbide.com/gb

New Heckert machine series on its way

Starrag has introduced a new Heckert large machine series, set to launch in phases throughout 2025. Built on proven principles

of rigidity and precision, the machines offer improved productivity, faster speeds (50m/min), thermal symmetry, and a 20% smaller footprint.

A modular construction kit with four sizes and extensive spindle, head, and magazine options enables custom configurations. The new rack magazine holds up to 828 tools, supported by advanced tool management software for greater efficiency and reduced downtime. www.starrag.com

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Machinery & Manufacturing

Catch up

Strengthening for growth

Group Rhodes, a Wakefield- based OEM for metalforming, composite, and ceramic sectors, has promoted Mark Roberts to Engineering Design Manager and Melike Kus to Applications Engineer. Mark will lead a team of ten, driving innovation across all divisions. Melike will focus on aftermarket solutions, machine performance, and CRM

integration, supporting growth targets. These promotions reflect the company’s commitment to pioneering engineering excellence. Recent investments, including £95k in a new CRM system, underscore Group Rhodes’ strategic focus on innovation, sustainability, and future expansion across key markets. www.grouprhodes.co.uk CBM urges manufacturers to join climate change agreement The Confederation of British Metalforming (CBM) is encouraging manufacturers to join its Climate Change Agreement (CCA), which has saved members over £100 million in 25 years.The scheme offers a 100% tax rebate on energy used in metalforming, heat treatment and metal coating, as well as associated activities like air compressors and lighting. Applications for the next phase, running from 2026 to 2033, close on 31 August. www.thecbm.co.uk

Additive Manufacturing UK (AMUK), the UK’s leading additive manufacturing trade association, has named Craig Pyser, CEO of AMufacture, as its new chair. Pyser succeeds Stewart Lane, who stepped down in April to focus on his role as Vice President of the Manufacturing Technologies Association (MTA), AMUK’s parent body. Lane, who led AMUK since 2022, praised Pyser’s deep industry knowledge and connections. Pyser, a former investment banker, co-founded AMufacture in 2018. He said he was honoured to take on the role and help shape the sector’s future. AMUK aims to drive UK leadership in 3D printing innovation. additivemanufacturinguk.org.uk AMUK appoints new chair

Machinery & Manufacturing

Catch up

At the Paris Air Show (16–22 June 2025), HELLER will showcase its F and HF series 5-axis horizontal machining centres (HMCs) at stand F194, hall 2B. Designed for aerospace applications, these machines deliver high precision and productivity for components like engine parts, landing gear, and structural elements. The F-series offers compact, high-speed performance with acceleration up to 7 m/s² and X/Y/Z tolerances of 6 µm. Optional turn-milling HELLER to highlight advanced 5-Axis machining at Paris Air Show

enables one-hit machining, reducing cycle times and boosting accuracy. HELLER’s machines feature digital twins via Siemens Sinumerik One and Automation-Ready options, with flexible configurations including pallet changers, robots, and storage systems, ideal for both single and high-volume production. uk.heller.biz

RoboTrex Compact - Increasing efficiency

LANG Technik UK have announced the launch of the RoboTrex Compact Automation System. Currently available in two larger capacities, the RoboTrex Compact launch was prompted by high customer demand for a smaller option. The popular RoboTrex systems are able to load and unload unmanned machine tools and to provide highly efficient lights-out production. Ever increasing competition, rising cost pressures, the desire to increase machine tool utilisation and the shortage of skilled labour are amongst the reasons existing users cite to justify their purchases of RoboTrex Automation Systems. Thanks to various loading options the cost effective system can be easily connected to almost any machine tool. lang-technik.co.uk

Machinery & Manufacturing

Catch up

Automatic clamping of heavy dies

Roemheld has launched the Flexline R, a robust system for automatic die clamping in presses, ideal for automated lines needing frequent die changes. Designed to handle higher loads, it features a stainless steel pull-push chain, reinforced stops, and enhanced sensors for improved monitoring and safety. Multiple units mount along the press ram’s T-slots, delivering electric and hydraulic power

directly to clamping elements. Available in 660 mm or 1100 mm adjustment tracks, it supports clamping forces up to 104 kN. Compact and low-maintenance, Flexline R minimizes downtime and allows easy servicing. www.roemheld.de

PTC launches CAM studio BETA PTC has launched CAM Studio Beta in Onshape, a powerful new tool designed to accelerate collaboration between design and production teams. This cloud-native solution integrates CAD, CAM, and PDM, enabling real-time planning, simulation, and machining process coordination. With faster workflows and improved productivity, CAM Studio Beta supports tighter deadlines and offers a streamlined path from design to manufacturing for global brands embracing digital transformation. www.onshape.com

New management for SYSPRO

SYSPRO, a leading global provider of digital manufacturing

solutions, today announced the appointment of Leanne Taylor as

Chief Revenue Officer (CRO). This strategic leadership addition

underscores SYSPRO’s commitment to driving revenue growth, enhancing customer success, and expanding its global market footprint. This strategic move follows SYSPRO’s acquisition by Advent International, a global private equity firm dedicated to accelerating the growth of high-potential technology companies. With Advent’s backing, SYSPRO has advanced its expansion strategy, bolstering its technology innovation capabilities and extending its reach into key markets . eu.syspro.com

Machinery & Manufacturing 11

Catch up

Horn introduces modular milling system for high-precision, efficient machining

Cutting tool manufacturer Horn has introduced a new modular, interchangeable-head milling system, the DG range, designed to deliver micron- level precision, faster changeovers and improved sustainability in machining operations. The DG system features a robust interface between the solid carbide monobloc cutting head and the shank, which is available in either solid carbide or steel and includes an internal coolant supply. Its innovative design incorporates a guide pin, a trapezoidal thread and a face-and-taper contact, ensuring high repeatability and stability while reducing manufacturing and set-up costs. The modular approach allows users to quickly switch between standard or custom cutting

heads, helping to minimise downtime and increase flexibility. Standard cutting diameters include 10, 12, 16, 20 and 25 mm, with cutting edge lengths of either 0.5 times or 1 times diameter, depending on the application. Horn offers the cutting

heads in a new carbide grade, RC4P, which is engineered for productive and economical machining of material groups P (steels) and K (cast irons), making the DG system a versatile and cost-effective solution for today’s manufacturing needs. www.horn-eshop.co.uk/en-GB

Ease of use for CAM models and powerful CAD functions

CMY

OPEN MIND has now introduced the 2025 release of its hyperMILL® CAD/CAM suite. The highlight of the new version is the easy-to-use, automatic deburring function. The 2025 release includes a new tessellation algorithm and a simplified element display for CAD models, which helps further accelerate the CAD part of the software. Deburred edges and holes are crucial from a functional perspective and significantly enhance the quality and value of the end product. hyperMILL® 2025 offers a package with three new strategies for deburring directly on the machine. Users can deburr a wide variety of component geometries quickly and reliably. The 5-axis deburring function is an effective solution

for removing sharp edges from a component. Once the edges have been selected, the strategy automatically calculates all toolpaths. The strategy incorporates both a 3-axis and a 5-axis mode, in which machining is indexed wherever possible. The same applies to the deburring strategy for edges on holes and intersecting holes. www.openmind-tech.com

Machinery & Manufacturing

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Policy meets SME

NOTHING IS OFF THE TABLE Machinery & Manufacturing listened in at recent roundtable event attended by notable industry stakeholders and a Member of Parliament. Growth and skills topped the agenda.

NAAME [New Anglia Advanced Manufacturing & Engineering] serves as a trusted forum for industry, academia and the public sector in Norfolk and Suffolk, facilitating the sharing of ideas, challenges and best practices within a culture of mutual support and encouragement. The group recently staged an East of England Manufacturing Roundtable at Suffolk New College in Ipswich, a hotly anticipated event. Bringing together policymakers and industry leaders, the roundtable explored opportunities for growth, innovation and collaboration. A notable attendee was Jack Abbott, MP for Ipswich and the Government’s Mission Champion

for the East of England, who fielded questions from 18 attendees representing industries that included precision manufacturing, heavy engineering, technology and automation. Growth opportunities Andy Heffer-Lamond, all-round manufacturing industry guru and Sales & Project Manager at sheet-metal contractor HF Bond, chaired proceedings. The debate begin with the topic of growth, or to be more precise, barriers to growth. Recent increases in National Insurance Contributions (NICs) and the minimum wage are causing concern among many manufacturers,

Machinery & Manufacturing

Policy meets SME

particularly SMEs. Luke Gusman, Director of 35-employee UK manufacturer Bermar, said there is no doubting the impact of higher NICs: “Although we’re actively growing thanks to herculean efforts by our team, I now have to explain why annual pay rises will be less because there’s only so much to go round. Issues such as increased NICs and minimum wage not only prevent growth by halting new recruitment plans but also thwart investment in existing employees. We desperately want to reward ambitious staff.” Martin Guildford, Area Director for Lloyds Banking Group, suggested business owners could think about different employee benefits: “There’s other schemes out there that could form part of a staff retention strategy. Salary sacrifice arrangements, for example, reduce NI liabilities for both employees and employers.” MP Jack Abbot was keen to address NICs directly: “I understand it’s a really tough ask, particularly for SME manufacturers. In response, I’d say we have to invest in public services. The UK has one of its sickest populations ever with

8 million on NHS waiting lists, which in turn impacts UK productivity. For a long time we’ve seen public services as a separate realm to business but I think that’s fundamentally wrong. Historically we haven’t invested enough in education or health to support the economy, but the money has to come from somewhere.” Level best Touching on education led neatly into the next topic: skills. Leading off here was Alan Burgess, Director in Engineering at host venue Suffolk New College. He is also a lead consultant for City & Guilds and helped co-write the T-Level programme. “The previous Government damaged the credibility of that qualification massively. Today, a lot of education centres are not even using the term T-Level, just Level III.” Some work on T-Level branding is clearly essential, accompanied by more explanation about the value to employers of a T-Level as a credible two-year technical vocational qualification that is designed as an alternative to A-Levels and apprenticeships. Another issue 15 Machinery & Manufacturing

Policy meets SME

hindering take-up involves the scrapping in March 2024 of the Employer Support Fund, which provided financial support to employers for T-Level placement costs. Price of skills Ben Courts, Regional Membership Manager at Make UK, wanted to voice concerns over the recent 18% rise in the national minimum wage for apprentices: “Some of our members are now questioning any previous intentions to take on apprentices.” Jack Abbot hopes the new Growth and Skills Levy, which replaces the previous Apprenticeship Levy, will give learners and employers greater flexibility over their training, particularly as it includes shorter foundation apprenticeships. He also singled out an important change where apprenticeship entry requirements for Maths and English grades are now more flexible. This move could unlock a further 10,000 apprenticeships for those who did not attain their expected grades. A new strategy Adam Dalby, Managing Director at Brafe Engineering, made another pertinent point: “We talk about economic stagnation and the requirement for apprenticeships, but we need more confidence to invest in apprentices. We require a succinct, tied-up strategy from Government that instils industry confidence.”

Andy Heffer-Lamond

“We talk about economic stagnation and the requirement for apprenticeships, but we need more confidence to invest in apprentices.” Jack Abbot took the point and indicated the impending release of the Government’s Industrial Strategy. Due for release in June 2025, the manufacturing sector will pin its hopes on an Industrial Strategy that delivers sufficient substance and clarity to nurture the confidence necessary for investment in both business growth and skills. Further discussions centred on logistics and supply chains, with policymakers and industry leaders exploring ways to collaborate across the sector. n

16 Machinery & Manufacturing

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People of #UKMFG

Different minds; infinite possibilities

NCMT automation guru Phil Cattaneo has always been technically minded. As a child he was constantly trying to fix things or take things apart to see how they work.

“I’ve got a scar on my finger from disassembling a printer as a kid” he says. “I fixed it but received a nasty cut for my troubles. When I look at my scar today, I realise it was all part of my journey.” By his own admission, Phil’s GCSE results were below expectations, which meant no pathway into university. However, there were mitigating circumstances. “I’m both autistic and dyslexic. I really struggled at school: understanding and reading exam questions correctly was particularly challenging.” But Phil never gave up on engineering, eventually gaining admission to an Extended BTEC Level 3 Diploma in Mechanical Engineering at The Sheffield College. “I subsequently self-funded myself on to an HNC in Manufacturing Engineering. During that time I was applying for apprenticeships and machine tool manufacturer DMG Mori showed interest. That was my big break.” Phil completed a three-year apprenticeship with DMG Mori, ultimately leading to an HND. He remained at DMG Mori for a further three years before taking up a more senior opportunity at automation specialist Fastems and, two years later, at UK machine tool supplier NCMT. Joining in October 2023, Phil is now NCMT’s Automation Business Development Manager.

“Companies like NCMT, Fastems and DMG Mori obviously saw the potential in me, despite my neurodivergence.” Passionate about raising awareness of non- neurotypical needs, Phil volunteers his free time in support of individuals suffering from conditions such as ADHD and autism. He suggests that “I was applying for apprenticeships and machine tool manufacturer DMG Mori showed interest. That was my big break.” the logical, analytical way in which many neurodivergent individuals process information makes them potentially “incredible assets” for engineering companies. Last month, Phil deservedly received a ‘Top 30 Under 30 in South Yorkshire’ award, for which he was nominated anonymously. The accolade identifies the county’s brightest young business talent, in this case serving as a clear indication that embracing neurodiversity and employing people with a different spectrum of thought can unlock a world of different perspectives and possibilities. n

Machinery & Manufacturing 18

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Let’s Talk: Advanced manufacturing

‘Seizing the moment’

Traditional manufacturing has been in decline in the UK for a while now. In the sector as a whole, employment levels have fallen for three years in a row, while factory output is expected to shrink by 0.6% this year. We hear from Michael Holmes, CEO of Alloyed how advanced manufacturing can make the UK an industrial powerhouse again

These figures are particularly disappointing given manufacturing is one sector where Britain was once world-leading. Indeed, last year was the first time since the industrial revolution that the UK fell out of the top ten list of manufacturing nations. All is not lost, however. While global demand may have evolved beyond the UK’s industrial roots and manufacturing now accounts for a smaller percentage of the UK economy than 30 years ago, there are other areas which have remained more consistent.

The UK still has a reputation for academic and research excellence. And it had a highly skilled workforce of science and engineering graduates. The door on traditional manufacturing might be closing. But in advanced manufacturing, another door of high growth potential is opening. The opportunity Advanced manufacturing is already reshaping the global economic landscape. From AI-powered design to digital twins and smart factories, global

Machinery & Manufacturing 20

Let’s Talk: Advanced manufacturing

need new materials. Particularly in polluting industries like aviation and the automotive sector, demand for lighter, cleverer, more locally sourced materials is booming. The search is also on for metals capable of withstanding higher temperatures (and therefore more efficient) is growing rapidly. As well as decarbonisation, the other trend driving demand in advanced manufacturing is miniaturisation. Electronics companies are looking to fit more computing power into increasingly smaller forms - which need to be supported by highly specialised metal structures. Think wearable tech that can handle ever more powerful AI. These are not fleeting trends, but fundamental shifts that are defining the products and innovations of tomorrow’s economy. And advanced manufacturing is the driving force capable of delivering them to market at the speed and scale needed. What’s more, the use of ever more sophisticated 3D printing technology offers significant advantages for advanced manufacturing. Particularly in a hostile

demand for technological innovation is only growing. In the UK, the potential is enormous. Last year, the advanced manufacturing sector turned over £117.1bn and received £15.4bn of investment. It is growing at 2.0% per year, while some sub verticals are performing even better. The metal Additive Manufacturing industry, for example, grew by around 15%, far outperforming traditional manufacturing sectors and demonstrating resilience in challenging conditions. With the government urgently seeking sectors of the economy capable of driving immediate progress on its highly prized ‘growth agenda’, advanced manufacturing can’t be overlooked. There’s an innovation argument of course. A renewed focus on putting innovative products at the heart of the UK economy again would bring with it investment, business support and skilled employees - all of which are beneficial for growth. Seizing the moment But there’s a real argument for why advanced manufacturing specifically should be the sector to drive this growth right now. On an international level, we need to reduce our carbon emissions - and quickly. In the race to achieve goals on decarbonisation, manufacturers

Machinery & Manufacturing 21

Let’s Talk: Advanced manufacturing

What needs to happen Now is the moment for the government, private sector and academic institutions to work together to cement the UK’s world leading position in advanced manufacturing. This unique window of opportunity won’t last forever - the UK has already been surpassed in the manufacturing of key innovations, such as semiconductors. But in areas of advanced manufacturing like additive metals, there is still potential to be world leading. One area where the government can act decisively is strategic procurement. The ‘significant’ increase in Ministry of Defence investment in novel technologies, including dual-use, was an encouraging takeaway from March’s Spring Statement. And the fact that the Department’s first ever advanced manufacturing strategy followed days afterwards is a sign that the government is starting to understand its potential. More commitments like this will be important for creating demand, de-risking innovation, and supporting the scaling of cutting- edge manufacturing. Seizing this moment for the UK’s advanced manufacturing sector will require bold investments in R&D, infrastructure, and talent. As well as this, it’s vital that partnerships between industry and academia continue to be supported to ensure that the next generation of engineers is both trained in the latest technologies and also empowered to push the boundaries of innovation. n www.alloyed.com “Seizing this moment for the UK’s advanced manufacturing sector will require bold investments in R&D, infrastructure, and talent.”

international trading environment - where tariffs on exported goods can be introduced almost at a moment’s notice - the ability to be able to build world-leading innovations domestically is invaluable. Not only this, but material waste and transportation emissions are reduced, production costs are lowered, and highly customisable and complex designs can be developed in a much shorter time frame. The UK’s unique advantage With the UK’s rich heritage of engineering excellence and its highly skilled workforce, the foundations for the development of world- leading advanced manufacturing are already in place. A strong focus on high-value sectors such as aerospace, automotive, and pharmaceuticals, means that the UK’s engineering talent is already adept in the environments where advanced manufacturing techniques can offer a competitive edge through greater efficiency, customisation, and sustainability. The UK’s world-leading research institutions also strengthen its position in this field. Investment into university spinouts has grown 240% in 10 years, with world class engineering departments at the likes of the University of Oxford leading groundbreaking research in areas such as additive manufacturing, robotics, and materials science, often in collaboration with industry partners. Indeed, the focus of Oxford and other leading institutions on bridging academic excellence with industrial application means that the UK is well stocked with a steady pipeline of highly qualified engineers equipped with the theoretical knowledge and practical skills needed to drive forwards innovation in additive manufacturing.

Machinery & Manufacturing 22

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Subcontractor celebration

Few subcontract manufacturers can boast 60 years in the service of its customers, which is why Machinery & Manufacturing wanted to speak with Wealdpark about the secrets behind its success. 60th anniversary sparks celebrations at Wealdpark

The CNC machining of components to exacting customer specifications is the lifeblood of the UK manufacturing industry. However, not everyone can do it as successfully as Wealdpark Ltd, a St Helens based subcontract precision engineering company that’s celebrating an impressive 60 years in business. Although supplying parts to a broad spread of industries, identifying a niche can pay real dividends for subcontractors seeking growth. Wealdpark has done exactly that with the electrical sector, producing parts for connectors, fuse gear and standby power equipment. It has two machines running 52 weeks a year producing parts for these applications. On a more general basis, the company serves sectors that extend

from yellow goods and fluid power to fasteners and catering equipment. Exporting is another string to the bow of any successful subcontract machinist. As well as delivering parts across the UK, Wealdpark currently supplies customers in mainland Europe and the United States - success that’s spurring major growth projects. “Not so long ago we acquired the unit next door to expand the footprint of our modern facility and allow investment in additional machinery,” explains Phil Smith, Director of the 29-employee company. “By way of further expansion, planning approval is now in place to extend the original premises and replace the unit next door with a new facility.”

Machinery & Manufacturing

Subcontractor celebration

Turn for the better The shop floor is currently home to 16 Star sliding-head lathes and six Miyano fixed-head lathes that produce parts from bar (up to 64 mm diameter) and billet (up to 200 mm diameter). Also present is a Hurco VMX 3+2 axis machining centre. Wealdpark regularly updates its capacity through ongoing investment programmes. Five new machines arrived in 2023.

Accredited to both the BS EN ISO9001

quality standard and BS EN ISO14001 environmental standard, the company has also been a proud member of the BTMA (British Turned Parts Manufacturers Association) since 2010. Phil Smith even stepped into the role of president in 2017-18, reflecting Wealdpark’s commitment to the engineering community and professional excellence. 25 Machinery & Manufacturing

Subcontractor celebration

“The information we get via the BTMA is invaluable, as are the networking opportunities,” he says. “I would never consider lapsing our membership.” The family way Founded in 1965, Wealdpark’s original owner sold to Phil Smith’s father (an employee of the business since 1968) in 1995. Phil, along with brother Steve, today runs a steady ship by nurturing a happy and rewarding workplace for his skilled staff. One employee, Ken Jones, has been at Wealdpark for 53 years, while shop foreman Joe Savage will reach 50 years of service in August. Although long-serving employees and low staff turnover are testament to the business, the brothers are also proactive about recruiting the next generation of engineers. “A few years back I visited our local school, which had introduced engineering to its syllabus. We ended up taking on two school leavers, who we put through an apprenticeship in lean manufacturing run by the MTC in Liverpool, which they have now passed. Getting young people interested in engineering is key for our business and industry as a whole.” Record revenues Although somewhat surprised, Phil smith says the current market demand for subcontract machining services at Wealdpark is exceptionally high. “After the election last year we expected a market downturn, but it’s gone the other way. We had our best ever February, while March was the best month in our history. Going to the most recent BTMA meeting, it seems many others are seeing the same - unexpectedly busy!” Initiatives at Wealdpark moving forward include the introduction of solar panels that will help cut the company’s electricity bill by

around a third. Adopting renewables is clearly key considering the high operating costs of a manufacturing business. Material prices represent another example. “The best policy with material prices is honesty. Yes, if material prices spike, we have little choice but to raise our prices in turn, but we always lower them again if prices decrease. Customers appreciate our transparency and it reinforces our position as their trusted partner in precision engineering.” As for now, the company is busy enjoying its 60-year anniversary. All staff and their partners were recently treated to a meal at an Italian restaurant in nearby Ormskirk. It was the same venue used for the firm’s 50th anniversary 10 years ago. The taste of success is clearly proving “After the election last year we expected a market downturn, but it’s gone the other way. We had our best ever February, while March was the best month in our history.”

addictive at Wealdpark. n www.wealdpark.co.uk

26 Machinery & Manufacturing

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Industry: Oil & gas

Revolutionising machining in the oil and gas industry

The oil and gas industry is a cornerstone of the global economy, demanding the highest levels of precision, efficiency, and durability in its operations. At the heart of this industry lies the need for advanced machining solutions capable of handling the rigorous requirements of drilling, extraction, and production processes. ISCAR, a leading global manufacturer of cutting tools, has risen to this challenge by providing state-of-the-art tools that are transforming machining practices in the oil and gas sector.

Machinery & Manufacturing

Industry: Oil & gas

As the world’s population continues to grow, with 9.7 billion people expected by 2050, so does the average standard of living driven by sustainable economic growth in emerging and developed economies. Investments in R&D and manufacturing technology are crucial to maintaining a long-term competitive advantage. While making these important investments, companies also must focus on controlling costs, improving productivity, and searching for new technologies. There is a growing demand for machining exotic materials in the oil and gas industry, capable of withstanding the most hostile environments such as high temperatures, corrosion, and extreme pressure conditions. For this purpose, ISCAR brings its customers innovative solutions, combined with the highest quality assurance standards worldwide. The oil and gas industry is usually divided into three main segments: upstream, midstream, and downstream. Midstream operations are often included in the downstream category. The upstream sector involves all the activities related to the exploration and production (E&P) of crude oil and natural gas. The upstream oil and gas segment includes exploration for potential underground or underwater oil and natural gas reservoirs, drilling of exploratory wells, and operating/producing the oil and natural gas wells that “pay” with crude oil and/or natural gas.

Drill bits are part of the downhole equipment used to dig down into the earth’s crust. Like a common hand-held drill, the spinning of the drill bit allows for penetration of even the hardest rock. The drill bit is located at the bottom end of the drill string and is responsible for contacting the subsurface layers and drilling through them. The drill bit is responsible for breaking up and dislodging rock, sediment, and anything else that may be encountered while drilling. Manufacturing of the drill bit includes various cutting operations that represent the main machining processes such as external turning, milling slots, drilling holes for carbide bits, and deep drilling. ISCAR’s portfolio for the drill bit production includes standard and specially tailored tools that allow for high metal removal rate to reduce machining costs. ISCAR offers pipe machining solutions with welding edge preparation profile milling cutters featuring innovative designs based on precise exchangeable segments. Strong tangential inserts enhance the performance of these reliable tooling systems, ensuring minimal cutting tool maintenance costs and fast segment replacement. Coupling machining with the Charpy V-Notch test, a standardized high strain rate test, determines the amount of energy absorbed by 29 Machinery & Manufacturing

Industry: Oil & gas

In pressure control machining parts, high-temperature alloys generate very high temperatures as they are being cut. By effectively removing metal with JET-HP-LINE products, which feature high-pressure coolant (HPC) supply, the cutting-edge tool life is dramatically improved, and the chips become less ductile and thus easier to break. ISCAR also has solutions for frac pump machining. Hydraulic fracturing equipment used in oil and natural gas fields usually consists of a slurry blender, one or more high-pressure, high- volume fracturing pumps such as powerful triplex or quintuplex pumps. The downstream segment of the oil and gas industry covers the refining and transformation of hydrocarbons into more valuable products such as fuels, lubricants, and petrochemicals, including fertilizers, rubbers, and polymers. Compressors, steam turbines, heavy-duty gas turbines, reactors, and steam condensers are widely used in the downstream sector and are present in refineries, oil rigs, liquefied natural gas (LNG) plants, etc. One of the most important pieces of equipment at these industrial sites, especially in the oil and gas industry, is the heat exchanger, which is designed to efficiently transfer heat. Despite their name, heat exchangers can be used for either heating or cooling. In the oil and gas industry, they are typically used for the purpose of cooling. ISCAR’s cutting tools are renowned for their superior performance, reliability, and innovation. The company offers a comprehensive range of tools designed to meet the specific needs of the oil and gas industry, including turning, milling, drilling, and threading solutions. These tools are engineered to handle the toughest materials, such as high-strength steels, stainless steels, and exotic alloys, which are commonly used in oil and

a material during fracture. This absorbed energy is a measure of a given material’s toughness and acts as a tool to study temperature-dependent ductile-brittle transition. It is widely applied in the industry, as it is easy to prepare and conduct, and results can be obtained quickly and cheaply. In wellhead machining, where the “easy oil” era has come to an end, nine out of ten of the world’s giant oil fields are being depleted. The next frontier relies on deepwater and ultra- deepwater exploration research, which is critical to unlocking more oil to meet the world’s growing demand. In pressure valve machining, valves, fittings, and pumps are popular components in pressure control systems, providing the requested security under heavy-duty conditions for surface and subsea operations. The high strength of corrosion-resistant steels as well as duplex and super duplex stainless steels ensure long-lasting pressure systems and are very common in the pressure control system field. Other exotic materials such as nickel-based superalloys are also well known in this sector. ISCAR has a wide range of tooling and carbides for these materials. It is only the process of tooling selection that needs to be addressed, and this is where ISCAR’s experience has a great advantage over any other cutting tool supplier.

gas applications. n www.iscar.co.uk

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Precision engineering

Turning vision into reality

Aegina Technologies Ltd is a precision engineering company based in Havant, near Portsmouth, on the south coast specialising in the subcontract manufacture of components and assemblies to a wide range of industries, including the Aerospace, Oil & Gas and Underwater sectors. Founded in 2000 through the acquisition of Xyratex, Aegina has built a reputation for excellence in precision engineering. The management team have subsequently developed a business model specialising in the aerospace, gas & oil and underwater manufacturing sectors. Under the stewardship of founders Charlie Ralph and Jennifer Copping, Aegina grew steadily from an £800,000 turnover into a £3.2million enterprise. Their vision combined technical expertise with a strong commitment to customer service, building a foundation that allowed Aegina to become a respected name in subcontract manufacturing. Now in their ‘70s, the owners completed a second management buyout at the end of October 2024 – this time passing the business to trusted long-term employees Sales Manager Mick Chalk and Production Control Manager Ieva Kapteine. Compass Business Finance helped raise

capital for the MBO through a blend of asset- based lending, including the refinancing of existing equipment, alongside a new Invoice Finance (IF) agreement with NatWest bank. The MBO echoed the original buyout that launched the company and ensures continuity of values, culture and operational expertise. “Our dreams have been made realised,” said Ieva, now Operations Director. “This pivotal move was made possible through the financial support and guidance of Compass Business Finance, in collaboration with Aegina’s long- standing banking partner.

Machinery & Manufacturing

Precision engineering

“Compass’s expertise in structuring tailored funding packages, such as asset-based lending, was instrumental in facilitating the MBO. Working closely with Allan Robinson, we found the process to be seamless. Allan’s clear explanations and supportive guidance were invaluable during the transition, ensuring that the financial aspects of the MBO were addressed effectively. “It was quite scary at first with all the financial implications, but Compass made the situation so much easier for us and got the deal through. Every step of the way was explained without any jargon. This is what you need, this is what we needed – and there didn’t seem to be too much paperwork. Allan and the Compass team made the process so simple because - we could rely on what was being said, was being done. It was easy for us to always approach Compass and speak to them, you don’t have to wait in a phone queue. “It meant we could concentrate on developing and building the business without having to worry about the finance.” The MBO completion was at the end of October 2024. “For the first three months we didn’t tell staff or our customers,” said Ieva. “It’s not that we had anything to hide, but when we made the announcement, we wanted people to know we’d been running the business successfully ourselves and things were going well.” Mick, who originally started with the “We have been exceeding intake plan, things are really going well.”

company as a machine operator in 1989, moved into planning and estimating 16 years later, and then into sales. “It was quite scary because of the financial implications,” he said. “It seemed a huge deal because of the responsibility, not just in a financial sense, but the fact that you have nearly 30 people working for you whose job security and providing for their families is effectively in your hands. “We have an incredible workforce who are so committed and loyal. Hardly anybody leaves, except when they eventually retire!” Aegina made a small profit in December – traditionally a month where there is a small loss. And since January, orders have gone through the roof. “We have been exceeding intake plan, things are really going well,” said Ieva. “We had a six-month review, and all the accountants and advisers have been saying how well we were doing. “We have a great team. The secret is making improvements and not upsetting the cartwheel. Make slow but consistent change.” Mike and Ieva have now started attending occasional outside forums and seminars as part of the strategy for a next stage of growth. “Aegina’s legacy of quality, commitment and internal development remain firmly at its core,” said Ieva. “Defence is one of the markets we will be targeting for the next chapter for our company while continuing to serve and grow existing clients with precision and reliability.” The new owners’ complementary strengths – Mick’s technical sales acumen and Ieva’s operational and regulatory leadership – will no doubt ensure Aegina’s successful future. n www.compassbusinessfinance.co.uk

Machinery & Manufacturing

Supplier spotlight

Alwayse gears up

A global leader in ball transfer unit manufacture, Alwayse Engineering, has invested in a new DN Solutions Lynx 2100B lathe from Mills CNC. Mills CNC, exclusive distributor of DN Solutions and Zayer machine tools in the UK and Ireland, supplied the two-axis, Fanuc-controlled 8-inch chuck/65mm bar diameter Lynx 2100B. Installed in March 2025 at Alwayse’s large, integrated Birmingham manufacturing facility, the machine marks the latest step in the company’s expansion of its machining capabilities. The investment also includes a Hydrafeed MSV65 servo-driven bar feeder to enable continuous, unattended production, and a ROTA- RACK parts accumulator with integrated belt conveyor to improve component handling and

protection.

The Lynx 2100B is being used to produce carbon steel bodies for the newly redesigned 805 ball transfer units. These units are commonly employed in air cargo applications and feature a low profile with high load capacity. Machining is completed in a single set-up. Operations include front-end boring to create the internal hemisphere and rear-end parting-off to separate each component from the remaining bar stock. Cycle times are around 80 seconds. The machined parts are then transferred to another Lynx lathe, where multi-dirt exit holes are added. These holes help reduce debris build-up and simplify maintenance. After machining, the components undergo case hardening and zinc plating. Each unit is then assembled with small stainless steel balls and a larger stainless steel or carbon chrome load ball,

Machinery & Manufacturing

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