Covering all the bases

This year’s Engineering Technology Group (ETG) open house not only marked the company’s 25^th anniversary – it also provided the ideal opportunity for the business to promote its wide range of precision manufacturing technologies. Ed Hill reports.

A lot has changed in the machine tool world since ETG first opened its doors 25 years ago.

Technologies such as CAD/CAM software, the rise of CNC multi-axis machining, increased use of robotics and automation, lasers and additive manufacturing are just some of the technologies that have transformed – and are continuing to transform – the precision engineering industry.

Over the two days of the company’s open house held at its Wellesbourne, Warwickshire headquarters in early October, ETG showcased a raft of machine tool and associated technologies from a number of its machine tool principals including: Nakamura-Tome, Quaser, Chiron, Bridgeport Hardinge and Bavius as well as Mitsubishi wire EDM technology and additive machines (Markforged and 3D Systems) from its newly acquired subsidiary HK Technologies.

Martin Doyle, managing director of the Engineering Technology Group commented: “We wanted to make a big statement for our 25^th and I believe we’ve achieved this objective. The main theme we wanted to convey is creating better efficiencies for our customers through developments like automation, helping people to get familiar with new kinds of manufacturing technology and promoting the kind of turnkey solutions we are known for.”

[caption id="attachment_47128" align="aligncenter" width="1024"] Martin Doyle, managing director of the Engineering Technology Group[/caption]

Mr Doyle said in an industry where it was increasingly difficult to find employees with basic engineering skills, customers were looking for solutions that would help lower-staffed and lights out production.

“As we know there is a difficulty in the industry with skill levels so many of our customers need technology that allows them to upskill staff to a point where they are not just tending and operating machines but also helping to design parts, create programmes for components and, in effect, be more productive.

“It’s not efficient having staff just doing mundane tasks like loading a machine. That’s also why we have various brands of machine tool and automation options on display because we really want to show visitors the best equipment for a certain application.”

He added: “Our customers also want machines that have a smaller footprint and twin pallet capability so they can work quicker and smarter. Firms now recognise the need to stay ahead of the rest of the world when it comes to technology. By investing in new solutions that we can customise to their requirements, they can reduce cycle times, improve lead-times and look at taking on increasingly complex components. Our aim is to be an extension to their production team and this is going to be our focus going forward.”

More than 450 delegates attended the event which also had many of ETG’s technical partners on the show floor such as: Hydrafeed, Ceratizit, Bott and Jemtech.

Machine highlights for those involved in the automotive, aerospace, medical and renewables sectors included a new Quaser UX500 twin pallet machine (with 15,000 to 24,000rpm spindle), the dynamic 5-axis simultaneous machining advances of a Bavius TR80 machining centre and the compact footprint and powerful performance of a Chiron DZ15 machining cell.

Adding to the complete turnkey solution focus was ETG’s Hyfore workholding products, Filtermist oil filters, Blum-Novotest laser measuring systems, a Robojob Turnassist system and the latest robot from ABB.

Adding additive and EDM

The open house also gave ETG an opportunity to introduce its new business, HK Technologies, to customers with technical experts on hand to talk through balance systems, the Mitsubishi wire EDM MV12000, Markforged’s MetalX metal printer and X7 Desktop Series for composite printing and 3D Systems’ ProJet MJP 2500 plus.

The acquisition of HK Technologies is a strategic move from ETG to add both EDM and additive machines and expertise to its customer offering.

“Our range of machine tools is very comprehensive but we did have a gap in our offer when it came to EDM and new additive processes,” Mr Doyle explained. “HK Technologies has the products but perhaps more importantly also the skill sets amongst its staff to help promote these machines.”

A major theme was the benefits and crossover that additive machines could have for traditional machining as the process can provide quick turnarounds for bespoke workholding parts, jigs, fixtures, soft jaws and robot grippers. Of course it can also manufacture highly customised parts as well if needed.

According to HK Technologies’ new managing director Gareth Jones, who has been appointed to increase the prominence of the business, precision engineering companies still need to be educated about what 3D printing can offer the industry.

He said: “It’s a maturing market; people are still exploring all the possible applications of 3D printing. When additive machines first emerged they were very much aimed at the domestic market – the idea that you could print a new mug at home. Somehow that had a negative impact when people started to think about industrial applications.

“There really is a synergy between additive and machining which helps to make a much faster turnkey solution. Workholding is very price driven but by using 3D printing we can make workholding systems a lot faster and cheaper ultimately helping productivity.”

Mr Jones also said that a wider range of 3D metal powders was becoming available making it useful for a broader span of applications.

“There has been a massive increase when it comes to the development of materials. The additive machine builders recognised that they have not been producing the right materials for industrial applications but they are now addressing this very rapidly,” he said.

“Furthermore, speed is improving all the time. For example, we have a 3D Systems Figure 4 machine here which in the medium- to long-term will replace the way many plastic injection mould parts are made. So instead of manufacturers having to go through a six-month toolmaking process you could design and make a part and have it printed in hours.”

In fact the crossover between additive workholding solutions and machining applications was demonstrated as delegates could be seen on the show floor being directed from one ETG division to another.

Productive partnerships

This new development in EDM and 3D printing demonstrates how ETG’s main aim is to be an enduring turnkey partner for its customers – from pre-sale advice to cradle to grave service and support. The group is effectively a single-source solution for CNC machining, EDM machines, automation, 3D printing and additive manufacturing,

Mr Jones commented: “3D printing needs to be seen as a next generation production technology, capable of producing repeatable quality, quickly and cost-effectively. We’ve got a major task on our hands to get this message across – indeed one of our primary aims for the future is getting the technology out there and firms using it.

“There are a lot of new materials being developed to support changing industrial applications, not to mention the implementation of easy-to-use software. These factors – combined with the new technology and our internal technical experts – are helping us deliver tangible, bottom line results to our customers. It’s an opportunity the sector needs to make more of.”

HK Technologies will now also have a permanent show area at ETG’s UK headquarters.

Mr Doyle concluded: “A turnkey solution could be anything from helping a customer to programme a machine, giving advice about building a factory with the right kind of utilities and the correct construction of concrete bases for machines through to helping them when it comes to interviewing new staff and training.

“Because the technology is constantly evolving there is an ongoing need for customer education. It’s a case of guiding people through the whole process from buying a new machine to providing a complete solution.”

Engineering Technology Group https://engtechgroup.com