Machinery & Manufacturing | Issue 14 | Mar/Apr 2024

Highlighting Machine Tool & Manufacturing Technology

HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY

ISSUE 14 | MAR/APR 2024

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WATCH VIDEO Celebrating

60 years of NCMT Their journey so far and what’s new on their stand at MACH 2024

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Smart Manufacturing Workflows for the machine shop community

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TALKING SKILLS Discussing New MTA Training

LET’S TALK 3D PRINTING All you need to know about MACH 2024 Better 3D Prints by design

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40YEARS OF EXCELLENCE

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Contents 7 Thought : Back to business MACH 2024 is here!

Publisher - Laura Crawford laura@machineryandmanufacturing.com Technical Editor - Steed Webzell steed@machineryandmanufacturing.com Circulation Enquiries circulation@machineryandmanufacturing.com Advertising Enquiries hello@machineryandmanufacturing.com Editorial Submissions editorial@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:

Catch up

What’s been happening?

Smart manufacturing Workflows for the machine shop community People of #UKMFG From apprentice to Managing Director Training & skills The MTA trains its sights on skills Connected manufacturing What Wi-Fi 7 means for manufacturers

Robotics Automation Inspiration Let’s Talk 3D printing Better 3D prints, by design Defence Bringing Striker ll to market

Turning Rebalancing strategy

Composite manufacturing Machining solutions for composite experts

Cutting tools Special attention from Iscar Software Sparking productivity gains

Investment MAN Group in major investment drive Laser cutting Second fibre laser for subcontractor Knowledge Hubs at MACH 2024 Encouraging the adoption of new technology Cover spotlight Celebrate 60 years of NCMT at MACH 2024

© All rights reserved. Machinery & Manufacturing along with it’s contents, should not be copied or transmitted in any format without seeking prior consent from Engineering Media Ltd. You can read our privacy policy by visiting www.machineryandmanufacturing.com where you will find more detail about how we protect your data. The contents of Machinery & Manufacturing does not imply our endorsement, where interviews and articles contain views, they do not necessarily reflect the views of our editors.

Welcome... Welcome to issue fourteen 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.

MACH 2024 Exhibitor announcements

Events calendar See you there!

See us at MACH stand 19-615

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MACH 2024: Back to business

If there’s one event in the calendar with the power to draw the UK’s machining community together, it’s our beloved MACH exhibition. The 2024 show, which takes place at the NEC in Birmingham on 15-19 April, will be no different. This festival of machine tools and manufacturing technologies is a real crowd pleaser, providing the venue for visitors to discuss, secure and complete hundreds of millions of pounds worth of business. Maybe you’ll find your dream machine at this year’s event? With around 26,000 visitors and 600 exhibitors, MACH is exciting for many reasons, not least the industry momentum that this biennial celebration of manufacturing excellence generates. Of course, the show has many more strings to its bow these days, not least the Education & Development Zone, designed to encourage the next generation of UK engineers. As you’ll almost certainly be aware, attracting young engineers into manufacturing has sadly proved problematic for some years now. With everything that’s happened in recent times, it’s today more important than ever to change attitudes and emphasise the benefits that a career in manufacturing can offer. The E&D Zone in Hall 17 will feature a fantastic range of exhibitors, hands-on activities and much more. So if, like me, you’re passionate about helping our youngsters find a pathway into manufacturing, please take the time to visit. Also new at MACH this year will be Knowledge Hubs, an exciting new programme that aims to help manufacturers understand the potential benefits of adopting advanced technologies that include automation and robotics, sustainable solutions, additive manufacturing, and data and artificial intelligence. Look out for dedicated stands across the show. You’ll of course find our friendly team from Machinery & Manufacturing magazine at MACH. Please head over to Stand 615 in Hall 19 to pick up a copy of our information- packed show issue or just to have a natter about all things manufacturing. We would love to see you. Laura Crawford Editorial Director

Catch up

Propulsion Development Laboratory at its UK HQ in Essex was opened in February 2024, underpinning the Dunton Campus’ research and development role in delivering Ford’s European electric vehicle plans. The £24 million facility was inaugurated by UK transport minister Anthony Browne MP as part of a site-wide tour and hands-free, feet- free drive of the Ford Mustang Mach-E with BlueCruise. The minister saw EV powertrain components intensively tested with speeds and loads to accelerate levels of wear which customers would incur only after years of vehicle use. Transport minister Anthony Browne MP said: “It’s great to see a commitment to UK Ford expands UK test laboratories

EV development following our ZEV mandate becoming law earlier this year, meaning we have a clear pathway for reducing car and van emissions.”

‘Get It Made’ makes the FT1000 list

London-based SME manufacturing specialist Get It Made has been recognised as

at £486,900 per employee, making it the most productive manufacturing company, which has grown organically since its inception in 2011, with zero venture capital investment Luke Smoothy, Founder of Get It Made said: “We’re enormously proud of the fact that Get It Made is the fourth fastest growing manufacturing company in the UK, as well as the most productive manufacturing business based on turnover per employee. Our success is testament to the team’s hard work, unwavering attention to detail and delivery of bespoke, high-quality outcomes to help us build a loyal and expanding client base. get-it-made.co.uk

one of the FT1000 Europe’s Fastest Growing Companies 2024 following the publication of this year’s list. In the UK, the 723rd ranked company secured the fourth position as the fastest- growing manufacturer, a particularly noteworthy achievement considering the size and rapid expansion of the UK manufacturing sector. It also has significantly fewer employees per £000,000 of turnover,

Machinery & Manufacturing

Catch up

Visitor registration opens for Automation UK

British Automation & Robot Association (BARA), organisers of Automation UK, are excited to announce the opening of visitor registration for this year’s event. The popular

show will return to the CBS Arena in Coventry on 18-19 June 2024. Last year was the inaugural Automation UK and it proved to be a massive success with over a thousand visitors eager to find out more about the benefits of automation and robotics for their businesses. It is anticipated that in June the event will be buzzing again with visitors keen to see the latest solutions from an even greater number of leading businesses showcasing their innovative products and services. www.automation-uk.co.uk/register- now Apprenticeship tool aims to close Scotland’s skills gap A new platform designed to simplify recruitment and support job seekers looking for apprenticeships and graduate roles could help to address challenges of finding talent and encourage more young people into Scotland’s manufacturing and engineering sector. The initiative is supported with funding through the Scottish Government’s ‘Making Scotland’s Future’ programme. Its launch coincided with Scottish Apprenticeship Week 2024, which took place from 4 to 8 March.

Leader CNC announces James Leet as Sales Director James brings a wealth of experience and is committed to delivering the best

possible solution from Leader CNC’ s extensive machine tool line up.

“I am excited about the future at Leader CNC Technologies, both short and long term. We have a brand-new showroom about to be launched, with quality products in our portfolio of machine tools and a new range to boot, that will open up additional options for our customers and a whole new approach to positioning ourselves in an agile market. There is a buzz in the team and that will inevitably transfer through to the customers experience, watch this space…” www.leadercnc.co.uk

Machinery & Manufacturing

Catch up

World unique research hub set to transform the global forging sector

The world’s most advanced research and innovation hot forging platform is opened this March at the University of Strathclyde’s Advanced Forming Research Centre (AFRC).

FutureForge is a world-unique platform for hot forging innovation with advanced industry 4.0 capabilities that enables companies from overseas to connect in real-time with the AFRC remotely and benefit from the skills and expertise of its people, along with the ground-breaking R&D equipment. The platform provides a safe and secure data rich research arena in which the forging industry can de-risk the development of new products, processes, and technologies for easier adoption

on the shop floor. www.nmis.scot

The Engineering Technology Group (ETG) has made it a double whammy by becoming ISO: 9001 and ISO: 14001 certified. As the UK’s leading machine tool and turnkey solution provider, ETG has implemented the global standards to build upon its already robust business framework whilst demonstrating its commitment and compliance to environmental and quality standards. The Wellesbourne manufacturing experts have implemented an integrated Quality & Environmental Management System (QEMS) for a multitude of reasons – all of which will benefit both ETG and its clients. ETG is now compliant with BS EN ISO:9001:2015 and BS EN ISO:14001:2015 ETG raises the standard with ISO certification

and its QEMS system is now fully integrated with all internal processes, creating one

cohesive management system. www.engtechgroup.com

Machinery & Manufacturing

Catch up

RARUK named Global Distributor of the Year

RARUK Automation has been named Universal Robots’ Distributor of the Year. The prestigious award recognises the distributor that has achieved the largest growth and sales globally over the last year. Danish robotics manufacturer Universal Robots has a network of over 300 distributors worldwide. RARUK Automation has also been awarded Platinum Plus status. As a dedicated automation company that splintered off from long-standing engineering distributor R. A. Rodriguez (UK) Ltd. The business relationship between Universal Robots and RARUK began in 2010. Today RARUK Automation represents Universal Robots and UR+ solutions in the UK, as well as autonomous mobile robots from

MiR and other automation solutions including EffiMat™ automated warehouse storage and

FlexiBowl® flexible part feeders. www.rarukautomation.com

Retirement beckons after 42 years at EDM

engineering and manufacturing company EDM. Neil Bottomley, 64, joined EDM as a pattern maker in May 1982 after serving a three-year apprenticeship at J.J. Harvey in Denton, Greater Manchester. He progressed through the company’s ranks working on subsea, rail, automotive, marine, museum and defence projects which took him around the world. Tony Bermingham, managing director of EDM, said: “Neil has been a loyal, dedicated and hard-working employee of the company for the last 42 years. It’s been a pleasure working alongside him for 28 of those years since I joined the business, and all the directors and employees wish him a long, healthy and happy retirement.” www.edmgroupltd.com

A senior project manager who has worked on assignments from fighter jets and luxury cars to interactive exhibits at children’s museums is retiring after nearly 42 years at Manchester-based

Machinery & Manufacturing 11

Catch up

OSG UK Ltd are excited to announce that Elliot Moore has joined the company as the Area Manager for the South East of England. Greg Johnson, Product Marketing Manager commented “With a wealth of experience as a CNC Turner, Elliot has worked with companies across the UK, Australia and New Zealand, bringing a diverse perspective to his new role. We are pleased to have Elliot join our team and look forward to achieving great success together. Welcome aboard, Elliot!” uk.osgeurope.com New appointment at OSG UK

To mark the occasion of ANCA’s 50th anniversary the company is hosting a series of open-houses, seminars, events, and attending tradeshows world-wide. At the ANCA Open House events, precision manufacturers can experience new hard- and software for micro tool and gear tool manufacturing, edge preparation, closed loop manufacturing and automation. ANCA invites you to be part of an exciting Open House experience at their UK facility in Coventry between 17th-18th April 2024. Promising a day filled with inspiration, cutting- edge technology, and a celebration of engineering excellence. ANCA celebrates with UK Open House

Connect with Elliot

End mill innovation from Mitsubishi Materials

VQ, the top of the range series of carbide end mills from Mitsubishi Materials has recently expanded to include a new innovative type, the VQ4MVM. This latest addition is ideal for machining stainless steels and difficult-to-cut-materials including titanium and heat resistant super alloys. The modern metal cutting world also demands versatility and a reduction of cutting tool inventory, therefore it is also suitable for carbon and alloy steel applications. VQ4MVM is multi-functional with a strong ramping capability of up to 30° on a wide range of materials. This eliminates the need for a pilot hole when machining pockets, thereby reducing

costs through tool consolidation. Compared to direct plunge cutting, ramping enables simultaneous multi-axis feed at high speeds. The reliability and high performance of all the new VQ4MVM end mills can be attributed to the (Al,Cr)N coating which delivers substantial resistance to wear. The special ramping capability of up to 30° is made possible by several innovative features. The end face geometry includes 2 separate gashes. These combine to provide super-efficient chip evacuation that far exceeds conventional designs when ramping. www.mmc-hardmetal.com

Machinery & Manufacturing

Let’s Talk: Smart manufacturing

workflows for the machine shop community

There’s a misconception among machine shops that smart manufacturing is only for primary OEMs like those making aircraft engines or Formula 1 cars. Many believe it involves a laborious, costly transformation process that necessitates the engagement of endless consultants and a myriad of different technology suppliers. Well, not so, at least according to Hexagon, a specialist in digital reality solutions Technical Editor Steed Webzell learns from Jason Walker, VP - General Manufacturing at Hexagon, about an easy way for machine shops to get smarter with their business workflows

that combine sensor, software and autonomous technologies. Hexagon has a new campaign focusing specifically on machine shops, encompassing metal-cutting, metal-forming and additive manufacturing facilities. “Machine shops are unsung heroes within the manufacturing eco-system,” states Jason Walker, VP - General Manufacturing at Hexagon. “However, with vertical markets like aerospace and automotive undergoing transformations due to trends such decarbonisation, electric vehicles and so on, machine shops are under pressure to keep pace via smarter manufacturing workflows that can better meet the requirements of new component designs. OEMs also want more traceability of critical parts. Not just relating to

Machinery & Manufacturing 14

Let’s Talk: Smart manufacturing

component specification, but also the process and environmental parameters present at time of manufacture and inspection.” Single-source solution Machine shops conventionally implement a new manufacturing technology to solve a specific issue, with many typically lacking the budget, confidence or internal expertise to implement a larger, company-wide transformation strategy. This issue indicates a clear need for a one-stop- shop resource that can provide help across a machine shop’s entire manufacturing workflow. Hexagon has a new concept that centres on seeking value in the seams between seven key workflow functions: quoting and planning; designs and reviews; manufacturing preparation; manufacturing; shop-floor measurement; quality inspection; and reporting and analytics. “At present, machine shops will quote for a job only to find [when they win the order] it’s a little more complex and costly than initially thought, squeezing the margin,” explains Jason Walker. “In addition, there’s often a disconnect with subsequent operations such as metrology,

with little if any feedback. That’s why we need a digital thread. Linking data flows across business functions provides more visibility and insight into what’s working well - and not so well - from an end-to-end process perspective.” Seven-step process Hexagon’s machine shop campaign looks intently at optimising each of the aforementioned seven steps, connecting individual point solutions/ technologies, systems of record and specific processes to Hexagon’s new Nexus digital reality platform for manufacturers. Nexus acts as a system of engagement to share data along the entire workflow and drive more business excellence. The concept allows machine shops to start with low-hanging fruit and progress as resources and budgets allow, perhaps reinvesting any savings to help start subsequent optimisation projects. The focus is on enabling more collaboration, sharing data internally across various departments and externally with suppliers and customers, in real time. Some think of Hexagon as a specialist in metrology or CADCAM software, but over the

15 Machinery & Manufacturing

Let’s Talk: Smart manufacturing

Opportunity knocks “Ultimately, this is all about opportunity via a long-term strategy that can benefit the machining community as a whole,” he says. “Small-to-medium sized machine shops may think that Industry 4.0 and digital transformation is out of their reach. Our aim is to make it within every machine shop’s reach, working with them to facilitate their transformation [at their own pace] so they remain relevant, competitive and in-step with customer requirements.” He continues: “At the end of 2023 we held a round table with executives from a cross-section of machining companies, asking them about their biggest concerns and priorities regarding the market from both a macro perspective and that of their individual company. The skills gap came top of the list. For us, it therefore becomes about how digital transformation can help mitigate or solve that challenge. Culture within the organisation was another issue raised: namely as a barrier to transformation. Some are resistant to new technologies because of the perceived threat to jobs. But that’s the exact opposite of the intended purpose, which is to automate and implement technologies that help streamline repetitive, non-value adding activities, releasing operators for deployment on more added-value tasks. With a focus on digital adoption and transformation we can help machine shops address current challenges and build better futures.” n hexagon.com At the MACH 2024 exhibition (Birmingham NEC, 15-19 April), Hexagon will showcase its scalable digital transformation solutions on Stand 731 in Hall 19, bringing everything to life via a number of real-time demonstrations. Company experts will be available to discuss individual machine shop challenges.

past 20 years the company has acquired close to 200 companies, building a complete portfolio of smart manufacturing solutions, including those for design, digital engineering and total enterprise quality. Hexagon also partners with external specialists whenever advantageous for the machine shop, while still acting a single point of contact. The vendor-neutral Nexus platform not only connects Hexagon technologies, but also those of partners and even competitors. Free benchmarking tool Notably, the company will be offering a free digital benchmarking tool that helps machine shops see where they stand in comparison with peers: thought to be a market first. The tool identifies, within the seven-step process, which areas could be improved immediately and what optimisations could come later as part of an overall business transformation project. At no point is there any obligation to adopt Hexagon technology. Of course, if selecting Hexagon then plenty of support is available to refine the machine shop’s transformation roadmap, and help implement technologies and connect to existing software systems, for example. Says Jason Walker: “It’s not simply about installing a new machine, but looking at the overall business and holistic technology adoption process. Every machine shop is different.” The free benchmarking tool will be launched at the MACH 2024 exhibition and Hexagon already has multiple machine shop transformation projects underway in the UK. Recently launched is the ‘Nexus for Developers’ kit, which imparts further democratisation. The kit is a set of programming interfaces that allows machine shops to connect their own technologies to the system. It’s free to sign up, with relevant costs applied as machine shops start developing/ using the system.

CMY

Machinery & Manufacturing 16

OPTIMISATION

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Training & skills

MTA trains its sights on skills

and crisis management to turning and surface grinding. Training through MTA Training will be available online, in the classroom or face-to-face at member facilities. “We consider ourselves very lucky as a not- for-profit organisation with members who are at the leading edge of their technologies; members who can identify what type of training is most useful,” explains James Selka, the MTA’s CEO. Daniel Reed, Education and Skills Manager at the MTA, adds: “With the launch of MTA Training we wanted to look past what’s available at colleges and other further education [FE] institutions. So we worked with our members

The Manufacturing Technologies Association (MTA) is launching a new training platform at MACH 2024 (NEC, Birmingham, 15-19 April), allowing members to access a wide range of ‘soft’ and technical training opportunities for their entire workforce at preferential rates. The courses span everything from health & safety Technical Editor Steed Webzell chats with key MTA figures about the launch of MTA Training, a brand new platform with the potential to supercharge the skills of its members

Machinery & Manufacturing 18

Training & skills

to develop a package of training that caters to actual needs. Moving forward, we’ll continue working with our members to identify requirements for the next five and even 10 years, and collaborate to ensure delivery.” The so-called ‘skills gap’ is of course a common source of pain for many UK businesses. Engineering and manufacturing are extremely broad subject areas, so finding ideal candidates who tick every box is increasingly difficult. Today, it’s more about identifying individuals with the right aptitude and a penchant for learning. Steve Shickell, Sales, Marketing and Service Director at LK Metrology and a member of the MTA steering committee for skills and training, says: “Some SME manufacturers might not have a budget for training, but with MTA membership they can access funding, subject to qualifying criteria.” Good things come in threes There is a saying that manufacturers only need three things to make a productivity gain: technology; the skills to acquire and deploy that technology; and finance. If all three are in place there’s a good chance of achieving a step-change improvement. In contrast, if one element is missing it can prove a genuine barrier, skills being a case in point.

“We often encounter smaller companies who are desperate to become more competitive by looking at automation or additive manufacturing, for example, but simply don’t know where to start with the technology or skills,” says James Selka. “It’s one of the reasons why we’ve significantly expanded our Knowledge Hubs at MACH this year. All the Knowledge Hubs at the show will be run by brand-agnostic experts who’ll be available to provide visitors with expert advice.” Academic or hands-on? Many people in life fall into one of two categories: academic or hands-on. The problem with engineering is that people need a bit of both. And while this was probably the underlying premise for the establishment of T-Levels, some teenagers can struggle to concentrate at school and instead develop later. MTA Training offers the potential to mop up some of these late bloomers with the help of its expert member companies. “To provide an example from my perspective at LK Metrology, we see a massive shortfall of GD&T [geometric dimensioning and tolerancing] training in the market,” says Steve Shickell. “GD&T is there to help manufacture products right first time, so it’s a notable skills gap. For this reason, we’re now thinking we can maybe develop something for those seeking training in this area.”

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Training & skills

Daniel Reed adds: “Many of our members offer excellent advanced training courses and, in the future, we plan to offer some of these courses via the MTA platform.” Defining the need While many manufacturers complain about the skills gap, some struggle to define their actual training requirements, which is where the MTA Training portal can help by providing access to many learning possibilities in one place. “If a particular training need is not available on the platform, we’ll act as a conduit to find and introduce it,” says Daniel Reed. “We’ll talk to partners around the world and work tirelessly to support our members.” The MTA says its members will likely save in the region of 20% when acquiring technical training from the new platform against sourcing it themselves. Steve Shickell outlines why some courses may offer even greater savings: “With the ever- increasing movement in the labour market, many companies may have the requirement to train one of their employees. However, many training providers only offer a standard course for four people, and therefore will still charge the full cost regardless of just one attendee. In contrast, we are now holding courses for people from individual companies so that they pay per person, which can represent a 75% cost saving.” Regional approach Although the MTA is working with Make UK, which has state-of-the-art training facilities, it’s also looking to network with FE colleges and UTCs (University Technical Colleges). When these institutions are not open to students, they can open for MTA Training, thus taking the whole platform to a regional level. The MTA Training offer comprises multiple threads. Online training will be available

immediately following the MACH launch. Numerous online compliance training courses already feature on the platform, including GDPR (General Data Protection Regulation), cybersecurity, fire safety, hybrid working and inclusive leadership. The number of training courses available is likely to grow considerably moving forward. In addition, MTA Training can offer classroom- based compliance training in wide range of subjects, including first aid, health & safety, and crisis management. These courses are also available for delivery at member facilities. As a further offer, the MTA worked closely with industry experts to develop a package of training based around so-called soft skills. “Courses here include Modern Service Ambassador, Modern Inspirational Leadership and Introduction to Consultative Selling,” says Daniel Reed. “These skills were maybe not written down in years gone by, but simply passed down the generations verbally. Many of these courses are completely unique and not available elsewhere.” The Modern Service Ambassador course, for example, is for service engineers, project engineers or other support personnel who make regular customer visits. This two-day workshop provides delegates with a range of customer-focussed consultative communications skills to build customer satisfaction, handle challenging situations and identify opportunities to increase business. Technical courses are also available via the MTA’s collaboration with Make UK, including turning, surface grinding and an introduction to 3D CAD. “Whatever the requirement, manufacturers will almost certainly find it on the MTA Training portal,” concludes Daniel Reed. “And if it’s not there, we’ll do our best to introduce it as soon as possible.” n

www.mta.org.uk/training

Machinery & Manufacturing 20

Starts 1 st April For full details visit: www.mitutoyo.co.uk/promotions

People of #UKMFG

In conversation with Technical Editor Steed Webzell, Mark Eavers reveals his intriguing journey from apprentice to the Managing Director of Burlow Engineering From apprentice to Managing Director Mark Eavers, Burlow Engineering

Mark Eavers describes himself as an engineer, a problem-solver and an advocate for UK manufacturing. “As the owner of Burlow Engineering I sometimes have to pinch myself as essentially I’m still just a guy who likes to make things.” Mark Eavers realised this notable characteristic at quite a young age. “As a schoolboy I wanted to be a vet, but upon reluctantly taking metalwork as one of my third-year options it became apparent that I was quite handy on a machine tool. The next thing I knew I was applying for a four-year apprenticeship at Dowty Rotol, a major aerospace and defence company in Gloucestershire.” He adds: “Completing an apprenticeship like that was quite an experience, working with all the experienced hands who pass on their knowledge. It was a wonderful ‘nurturing’ environment that I would like to recreate at my own company.” The Cold War ended in the early 1990s prompting extensive redundancies, so Mark Eavers went back to college, attaining a HND in Engineering. He subsequently worked in various roles that included a five-year spell as a Workshop Manager. Then a whole new opportunity arose. “A good friend of mine had the chance to buy Cheltenham-based Burlow Engineering in 2012 and wanted me as his partner. Just before the pandemic Neil semi-retired, but he continues

working for me part-time. I’m now the owner and Managing Director of the company, which serves sectors such as oil and gas, dental, semiconductor and industrial.” “As a schoolboy I wanted to be a vet, but upon reluctantly taking metalwork as one of my third-year options it became apparent that I was quite handy on a machine tool.” ISO9001-accredited Burlow Engineering will shortly relocate to a new building, with Mark Eavers setting out a company future based on new machinery investment and the recruitment of vibrant young engineering talent who can maximise their potential at Burlow Engineering. “I believe in living life with absolute integrity, where kindness and opportunity are major priorities,” he concludes. “I follow this through in the experience that my employees and customers receive. Maybe that’s one of the reasons I’ve never been so busy.” n www.burlowengineering.co.uk

Machinery & Manufacturing 22

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Connected manufacturing

What Wi-Fi 7 means for manufacturing

Scaling up securely with the next generation of wireless technology

The Wi-Fi 6E successor is here, and it promises to significantly boost the speed and stability of your wireless connections. With rapid speeds, enhanced capacity and lower latency, Wi-Fi 7 is set to improve the way we connect and protect. However, it’s not just our homes where it will have an impact. Here, Tom Cash, from automation parts supplier, Foxmere, explores some of the potential industrial applications for Wi-Fi 7.

Machinery & Manufacturing 24

Connected manufacturing

WWi-Fi 7, also known as IEEE 802.11be Extremely High Throughput EHT, marks the next phase in the evolution of wireless technology. It ensures faster speeds, improved stability and enhanced security, also involving Wi-Fi Protected Access (WPA4) support. WPA4 builds upon the foundations laid by its predecessor, WPA3, which implemented vast improvements in encryption and authentication methods. The security certification, with Wi-Fi 7, is further bolstering wireless network security,

where digital threats are becoming more frequent and sophisticated. Interestingly, manufacturers have been implementing pre-certified Wi-Fi 7 chipsets in devices since 2022, so let’s explore how manufacturers can benefit from Wi-Fi 7 or at least start the upgrading process — even if they’re a wireless standard or two behind. Cyber security A recent report by Guardz, a cybersecurity company, which analysed small and medium enterprises (SMEs), revealed that 57 per cent of SMEs have experienced a cybersecurity breach. The survey also revealed that 31 per cent of respondents stated that their business had been targeted by a breach in the past 12 months alone. With manufacturers wanting to secure their operations, Wi-Fi 7 integrates a significant security feature — called Multi-Link Operation (MLO). This allows multiple radios inside a device to talk to another device at the same time but across different radio bands. In an industrial setting, Internet of Things (IoT) devices often have limited processing power and memory, making traditional security measures challenging to implement directly on the devices themselves. MLO allows for the integration of security controls across various layers of the IoT ecosystem, including network gateways, cloud platforms and edge computing devices. For example, implementing firewalls, multi- factor authentication and data encryption shields production data from cyber threats. This approach ensures that security measures are distributed throughout the IoT infrastructure, providing in- depth defence against potential threats. Scaling up Plant managers know better than most how essential a reliable internet connection is when it comes to productivity, efficiency and overall

25 Machinery & Manufacturing

Connected manufacturing

business performance. This means that they will want to know exactly where else this new Wi-Fi update will impact their business- critical processes. The improved rate of data transmission and reduced latency will enhance the capabilities of IoT devices, meaning that warehouses and facilities are still leveraging the data from smart devices. Improved data transmission allows cloud- based processes to work faster and support greater capacity, making it ideal for businesses looking to scale their operations. Wi-Fi 7’s reduced latency also ensures workers across sites remain connected, coupled with fewer outages. For example, Wi-Fi 7’s high throughput and low latency will be particularly useful for robotics in manufacturing. This comes as the specification supports more connections per access point than previous iterations, making it perfect for factories with thousands of devices. Pathway to Wi-Fi 7 Therefore, it is no surprise that confidence is growing when investing in wireless technology. According to WBA Annual Industry Report 2024, more than 41 per cent of respondents plan to deploy Wi-Fi 7 by the end of 2024, with

Wi-Fi 7, 6E and 6 at the top of the wireless technologies list. What’s more, the biggest driver for Wi-Fi 6 and Wi-Fi 6E adoption has been enterprise digitalisation initiatives. However, for manufacturers looking to advance their cloud computing, security and scalability, the role of a knowledgeable automation parts supplier is crucial. By offering Wi-Fi 7 compatible hardware, such as routers, access points and IoT devices, manufacturers can upgrade their infrastructure for improved data transmission rates and reduced latency reliably. Whether you’re Wi-Fi 7 ready or still preparing, Foxmere can help manufacturers source automation parts that can integrate with wireless technology of today and the future. Daily, we support manufacturers all over the world in retrofitting production lines by adapting legacy equipment to support hardware that meets modern Industry 4.0 standards. Retrofitting may involve upgrading machinery with modern sensors, automation components or control systems to enhance efficiency and functionality without replacing the entire system. n

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Machinery & Manufacturing 26

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Robotics

Automation inspiration: Can UK manufacturing raise robotics uptake by learning from Europe?

Despite punching well above our weight as a manufacturing powerhouse, the UK is in danger of slipping down the international rankings unless we increase our levels of automation. Now sitting at 25th in the global robotics league table , we are the only G7 nation outside the top 20 and have been eclipsed by most of our European counterparts in terms of numbers of robots per 10,00 workers, including Italy, Belgium, Switzerland and the Czech Republic. Here, factory automation leader FANUC, which has subsidiaries across the world, examines the potential reasons behind the UK’s reluctance to automate – and asks what we can learn from our continental cousins… An improving picture The benefits to UK manufacturing of robotics and automation technology are greater than ever,

helping us to meet net zero targets, boost productivity and underpin our key industries. And with an estimated 70,000 vacancies in manufacturing, robots are also

alleviating the longstanding labour shortages which have only worsened since Brexit and COVID. In regard to automation uptake, it is certainly an improving picture. Led by the automotive sector, UK robot installations were up by 3% in 2022, with operational stock growing by 7%. But at just 98 robots per 10,000 workers we are still well behind European leaders Germany (415).

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Robotics

UK: Focused on short-term ROI Among the many potential explanations for this are a focus on short-term payback rather than longer-term total cost of ownership (TCO); a fear of change; outdated perceptions of engineering as a career; a lack of government incentives; our reliance on cheap manual labour; and no long-term national manufacturing strategy. While some of these are beginning to change – the government recently announced a £4.5bn package of support for British manufacturing, for example – should we also be looking to our European neighbours for some automation inspiration? Germany: Prioritising precision and innovation Dr Bob Struijk certainly thinks so. As the Vice President of FANUC Europe, Dr Struijk has overseen automation installations across numerous countries, and believes there are a variety of reasons why certain nations are further ahead of the UK on their automation journey. “Germany is the clear European automation powerhouse and owes a large part of its success to a profound respect for engineering and manufacturing,” he explains. “The German model emphasises the meticulous craftsmanship of products, fostering a culture that places a premium on precision and innovation. Catapulted by the automotive industry, robotics and automation have been at the forefront of bringing Germany to its position today as a manufacturing leader.” In addition, bridging the gap between industry and academia has helped to boost German innovation. “In Germany, collaborative efforts between industry and academia contribute to a continuous cycle of research, development and implementation, creating an ecosystem that thrives on technological advancement. The German apprenticeship

system also provides a seamless flow of skilled labour into industry, at low cost. The UK can learn from this by cultivating a similar synergy between its educational institutions and industrial sector to breed a culture of continuous improvement.” “By automating dull, dirty and dangerous tasks, these nations have not only increased their manufacturing efficiency but have also enhanced the overall wellbeing of their workforce” In this regard, FANUC UK is working hard to help develop a pipeline of manufacturing talent through a range of different initiatives. The company’s Training Academy at its Coventry HQ offers accredited courses that feed into educational programmes, giving students hands- on robotics experience; it recently held its first ever Work Experience Week, for young people aged 16-18; and the 2023 FANUC UK Open House played host to the finals of the WorldSkills UK Industrial Robotics competition. However, for a nation built on SMEs, Dr Struijk is also clear that UK government support is critical to future success: “The penetration of robotics and automation in the UK is especially low among small and medium sized enterprises. Government tax breaks or accelerated depreciation of robots could certainly help to change this.” Nordic nations: A supportive business environment At sixth place in the global automation league

29 Machinery & Manufacturing

Robotics

in automation, this must also be backed by supportive government policies and incentives,” he states. “In the Nordic countries, robust government initiatives have provided financial support and created favourable conditions for the adoption of automated solutions. For example, in the city of Odense, the government has stimulated the set-up of a ‘Robot Valley’ – a cluster of private companies, start-ups and academic institutions – that is helping to drive the Danish robotics market forward.” Eastern Europe: Putting worker welfare first Finally, Eastern European countries such as Slovakia, Hungary and the Czech Republic have embraced automation as a means of prioritising worker welfare. “By automating dull, dirty and dangerous tasks, these nations have not only increased their manufacturing efficiency but have also enhanced the overall wellbeing of their workforce,” states Dr Struijk. “They have benefitted from their close proximity to the German automotive market and used a combination of skilled labour and investment in robots to take a large share of the tier 1 market, as well as a host of greenfield investments by major European and Asian automakers. The UK could benefit by adopting a similar mindset; using automation to alleviate workers from monotonous and hazardous tasks, thereby improving job satisfaction and increasing overall productivity.” There is no doubt that manufacturing is already one of the UK’s greatest success stories. By investing in automation and robotics, UK manufacturers can help to futureproof their business and ensure we continue to compete on the international stage in the years to come. n

table, Sweden boasts an impressive 343 robots for every 10,000 workers. Neighbours Denmark have 274, Finland has 168 and Norway has 103 – all sit higher than the UK. “With their realistic approach towards return on investment (ROI), the Nordic countries have successfully integrated automation into their industries,” outlines Dr Struijk. “By focusing on the long-term benefits, these nations have cultivated a business environment that encourages companies to invest in automation technologies.” By looking at TCO rather than just ROI – considering indirect cost savings such as reduced energy bills, less waste, higher productivity and increased production capacity – investing in automation could be a far more attractive proposition to UK manufacturers than it is today. But again, the importance of government support cannot be overlooked, explains Dr Struijk: “While the UK could draw inspiration from the Nordic model by fostering an environment where companies can confidently invest

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Machinery & Manufacturing 30

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Lets talk: 3D printing

In an exclusive chat with the directors of 3D printing specialist Inventex, Technical Editor Steed Webzell learns about the expansive opportunities that arrive with a bespoke design service Better 3D prints, by design

Darren and Jo Howton are the directors and founders of Inventex and its sister company The 3D Printers, both based in Kent. While The 3D Printers offers a UK-wide 3D printing service for products, parts, prototypes and models, the launch of Inventex with its in-house design service delivers a whole new take on the possibilities available with this innovative manufacturing process. “Today, the most successful part of our business is undoubtedly bespoke design,” says Jo Howton. “For example, we work closely with a major online retailer, helping them solve ‘pain points’ during refits at their warehouse and distribution centres. A recent product we designed - a robust, easy-to-assemble retrofit racking clip with locking mechanism - saved the customer £500,000 across its facilities in 2023 because of the previous breakages that our solution eliminated Designs on success The success of any 3D printed part clearly hinges on its design. And design for additive processes differs to that for other types of manufacture. “We sometimes have customers who want

to replace an injection moulded part with a 3D-printed equivalent,” says Darren Howton, a man with more than two decades of experience in 3D printing design and manufacture. “When preparing the drawing they tend to copy the same features, including a rake/draft angle for injection moulding, which is not required for 3D printing. Many also design nice radiused edges, which is lovely from an aesthetic perspective but doesn’t add anything to the part’s performance. So why not save some money by having a 45° edge instead of a radius. The aesthetic will be almost the same, but more importantly the print job will be faster, cleaner and cheaper.” 3D printing today embraces a wide range of engineering-grade polymers. By way of

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