Mould and toolmaker has acquired high-speed and high-performance 5-axis milling machines to increase its productivity and maintain ia competitive advantage.

Market-leading Manchester, UK-based mould tool and die specialist Hanson Thorpe Precision toolmakers has recently invested in 2 new Mikron milling machines from GF AgieCharmilles. The machines - a high-speed (HSM 300) and a high-performance 5-axis (UCP 600) were installed at the company's facility in August 2006 and November 2006 respectively. Both machines are being used to increase Hanson Thorpe's productivity and maintain its competitive advantage in the tough, demanding and global mould tool and die sector.

* Hanson Thorpe - Hanson Thorpe was established 1991 by directors Des Thorpe and Stuart Hanson.

The company operates from a 11,000 sq foot facility in Middleton, Manchester and it specialises in the design and manufacture of small to medium-size plastic injection, compression and die cast mould tools up to about 1.5 tonnes.

The company also provides a comprehensive mould tool repair and modification service.

The tools manufactured by Hanson Thorpe are used in and across a diverse range of sectors which include - medical devices, automotive, packaging etc.

In addition to the tool making side of its business - the company has also diversified its operations by aggressively targeting high-growth and high added value sectors (e g, the medical sector) - and is now also manufacturing complex high-precision medical components (rasps, implants etc) for a growing number of customers.

Hanson Thorpe is a big player in the mould tool and die sector - and the company has an international reputation for the quality of its products and services - and is at the cutting edge of mould tool design and manufacture (multi-impression, twin-shot, 3D-formed tools, etc).

Only a few months ago the company won the prestigious 'Best toolmaker of the Year' award - part of The Plastic Industry Awards 2006.

Hanson Thorpe employs 24 people at its facility of which two are CAD/CAM design engineers and 17 are employed on the machine shop floor.

The company has made (and continues to make) prudent and strategic investment in advanced machine tool technologies - and the two recent Mikron machine tool purchases are evidence of the company's forward thinking approach.

Said Stuart Hanson, director at Hanson Thorpe: 'We are always on the lookout for new technologies to improve our business performance.

Investments that improve our quality, help reduce lead times and make us even more cost competitive are always of interest to us.' * About the UCP 600 - the Mikron UCP 600 is a high-performance 5-axis machining centre.

The machine provides Hanson Thorpe with 5-face and simultaneous 5-axis machining capability which it employs to the full in the manufacture of complex high precision parts for the medical sector.

The machine (as is the case with 5-axis milling technology) helps the company significantly reduce time and resources spent on job set ups and fixturing - and enables Hanson Thorpe to economically manufacture complex parts (in one hit) that are required in low/medium volume.

The UCP 600 is a universal machining centre that delivers high-performance.

Irrespective of whether the requirement is high and precise material removal and/or super fine finishing - the machine can deliver.

Since its installation in November the UCP 600 has been put through its paces machining a variety of components from a equally diverse range of materials - titanium, exotics, aluminium, stainless steels, etc.

The UCP 600 has a 16kW 20,000 rev/min spindle and X, Y, Z travels of 530 x 450 x 450mm.

The machine has rapid rates of 22m/min and a (30-position/optional 58-position) automatic tool changer (ATC).

The UCP 600's rotary tilting table (280mm x 400mm) can handle a maximum table load of 200kg and has tilting capability of +122/-100 deg and rotation speed of 30 rev/min and tilt speed of 20 rev/min.

Continued Hanson: 'If you're involved in and serious about medical component manufacture you need 5-axis machining capability at your finger tips.

It's just not economically viable trying to manufacture complex, high precision components without it.' * About the HSM 300 - GraphiteMaster - the Mikron 3-axis HSM 300 GraphiteMaster services Hanson Thorpe's EDM manufacturing cell - and is dedicated (as its name suggests) to the manufacture of graphite electrodes.

The machine is equipped with a high-frequency spindle (6kW 30,000 rev/min HSK 40) and has acceleration of 17m/s2 on X, Y and Z-axes powered by the Heidenhain iTNC 530 control).

The HSM 300 has a generous tool changer (18 standard - 27 optional) for extra versatility - and the machine's dust extraction system ensures that the workpiece, working area and tool changer remain dust and particle free.

Said Hanson: 'We manufacture electrodes exclusively from graphite.

We use graphite because of its high performance and low wear characteristics.

The electrodes we design and manufacture are complex and intricate.

We often use very small cutters (down to 0.4mm diameter diamond coated) to give us the results we need.

As far as we're concerned the HSM 300 gives us the best in class performance.'.

* EDM capability - in addition to its milling technology Hanson Thorpe has invested heavily in EDM.

The company's EDM capability is formidable and consists of: four die-sink machines; one wire cut machine and one hole driller supplied by market-leading EDM manufacturer - Charmilles.

Hanson Thorpe's EDM cell is serviced by the new HSM 300 GraphiteMaster and an older Bostomatic high-speed machining centre.

The spark erosion machines themselves have built-in automation, i e, electrode holders and workpiece palletisation, which means the company (and its customers) benefit from unattended operations and reduced lead times.

This cell also features a dedicated CMM which allows fast, efficient and direct data transfer of electrode measurement to the EDM machines' control systems and to further ensure higher productivity and avoid manufacturing delays - Hanson Thorpe holds extensive consignment stock of cut, pre-drilled, tapped graphite electrodes which ensure smooth and continuous production.