NWAA Summer '24 Plane Talk

PLANE TALK

SUMMER 2024

Join NWAA, Composites UK & member companies at Farnborough 2024

Also: Tapping into international talent pools | Digital transformation in the race to net zero | New product launches

The NWAA welcomes the following new members…

NWAA Chairman’s Winter statement By Prof Andy Schofield

NWAA Chief Exec’s Winter statement

CONTENTS

By Paula Gill

A very warm welcome to the latest edition of the Plane Talk Magazine. Since the last edition, the NWAA team have continued to be extremely busy welcoming new members, making arrangements for the Farnborough International Airshow, and supporting key events. As I mentioned in the last edition of the Magazine, 2024 is an important year as we celebrate the 30th year of the North West Aerospace Alliance. In March, we held this year’s Annual Conference at the truly inspirational Concorde Conference Centre in Manchester. The conference was an immense success and even eclipsed the event held in 2023, where I referred to the Pride and Passion for the Aerospace Industry in the North West. In my closing speech this year, I talked about the great people, the world class advanced engineering and manufacturing capability and the immense potential we have in the region. We had a stellar line-up of outstanding speakers who provided great insights into key industry activities and the opportunities there are for the future. The key theme of the conference was digital transformation and how industrial digital technologies are playing their part across the supply chain. A major takeaway was the importance of cross-sector integration and where to get the necessary support. I concluded the conference by reinforcing the main purpose of the NWAA, which is to deliver value to every member of the North West Aerospace Alliance by providing the opportunity to network, collaborate and promote their capabilities both in the UK and Internationally in order to increase future business opportunities. As we progress through 2024, we are continuing to focus on delivering our key strategy themes of providing value to our members, improving the engagement with our key stakeholders and partners, and

Hello and welcome to the Summer of 2024.

future supply chain, business growth, ease of diversification across markets, financial stability and achieving sustainability goals. We will support businesses to enable a better understanding of and how to benefit from new technologies and new ways to manufacture and grow your business and presence, whilst meeting the needs of your customers. Nichola and the team will make you aware of all the dates and locations of these events for your diaries in due course, with the first of these events taking place in late summer at Safran Nacelles in Burnley. In the meantime, you could look to attend the Digital Event @ Siemens Transform on 17th & 18th July, in Manchester, where NWAA members have been selected to share their Digital journey, with business leaders from Aerospace, the AGP and even some ministerial representatives. I will also be attending and speaking on behalf of all the NWAA members. Throughout the rest of this year, we will be bringing you lots of exciting features, events and programmes , to further support and profile your businesses including, Meet the buyers, Mix and Mingle events in association with other regions, Roundtables on various subjects and our fabulous Annual Ball. Our programmes will continue to include ATI SME Programme Support, SC21, DTEP MOD funding rounds, Watchtower, and more. We will keep you posted. The team and I are looking forward to meeting and supporting more of your businesses again this year and we are always happy to help you where we can, please make sure you come and speak to us at any events, including those where we are exhibiting. Also, don’t forget to let us know the events where you will be exhibiting, and we will come and support where possible. So here is wishing you a fantastic summer season full of success, new orders and sunshine, with a holiday or two there too.

ensuring we remain at the forefront of future developments and drive economic and societal impact in the North West. Membership continues to increase on a monthly basis, which is a testament to the hard work of the team. Also, planning is well underway for the Farnborough International Airshow in July, which will be the first time since 2018 that the NWAA will have a stand at the Airshow, and this provides a great opportunity for our members to showcase their capabilities and network with the best in the Aerospace industry. You will be able to see the feedback from the Airshow in the next edition of Plane Talk. As an Alliance, with your continued support, we remain committed to help drive the Aerospace and Defence Industry in the North West forward.

Visit website

02 Chairman’s statement

We are in the season of Airshows, the most exciting and busy time in our calendars and it’s no different here at NWAA. We are very excited to be exhibiting at Farnborough Airshow this year, in the UK hall 1, located at stand 1307 in partnership with composites UK, and with only one pod remaining to be sold, it promises to be a hugely successful show. We are looking forward to seeing many of you there this year, networking and discovering what’s on the horizon. If you are interested in knowing more about this year’s show, or in our remaining pod please get in touch with the NWAA team. During the last few months I have been in discussions with MOD and Regional Employer Engagement Director, for the inclusion of the ex-service men and women and their families in the opportunities for jobs and careers available across the North. At the beginning of May 24, I signed the Armed Forces Covenant on behalf of the NWAA. This is a very important area of support and we are looking forward to working with REED and our members to engage and support wherever possible, and to create and enable a ready to work workforce for our region. To support this, we are looking into developing a webpage for student apprentices, graduates, adult education and armed forces and related individuals, to promote themselves to the industry. This is exciting, but also a time- consuming and costly piece of work, so please bear with us and we will let you know when this is up and running. This is not recruitment by NWAA, just a way of showcasing the individuals that are looking for work and will only be accessible to our member companies. Leading on from this year’s successful NWAA Conference at the Concorde Centre in Manchester, our theme of support this year is focusing on Digital manufacturing. During 2024 and following the success of last year’s ESG series of four events, we aim to do the same in 2024/25 on the subject of Digital Manufacturing we will explore all levels of digital transformation and the benefits, from starting out on the journey, to developing the

03 CEO’s statement

Visit website

04 NWAA News

06 Members’ News

Visit website

22 Team

23 Meet the board

Visit website

24 NWAA Annual Ball 2024

Visit website

Prof Andy Schofield NWAA Chairman

Visit website

Let’s keep building the momentum and putting the NWAA members on the map.

YOUR CONTENT

Please forward all content for future editions of Plane Talk to our editor at Freshfield, Paul Tustin.

Visit website

Paula Gill NWAA Chief Exec

OUR STAKEHOLDERS

nwaa@freshfield.com

Visit website

01772 888400

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

NWAA News

Join NWAA, Composites UK & member companies at Farnborough 2024

Composites UK Member Companies at Farnborough

ROCKWOOD COMPOSITES

Farnborough Airshow has long been considered one of the world’s leading aerospace events. For one week in July, it will once again bring together leading global aerospace and defence companies.

AIRTECH

ASSYST BULLMER

BUSCH

CYGNET TEXKIMP LTD

A world-class reputation With more than 1500 exhibitors, 100,000sqm of exhibition space, a static aircraft and flying display, and over 80,000 visitors over the trade days, organising the Farnborough International Airshow is no mean feat and serves as a platform for showcasing innovation, forging partnerships, and driving business growth.

NWAA are excited to be returning for the first time since Covid and to be Joining forces and exhibiting alongside Composites UK and associated member companies. If you are planning to attend as a visitor, don’t miss the chance to connect and please stop by the UK Member Pavilion / Hall 1 / Stand 1307 and say hello.

This year promises to be BIG as we gear up for another exhilarating week in July, anticipation is at an all-time high. The Farnborough Airshow serves as more than just a gathering—it’s a catalyst for progress, a stage for unveiling groundbreaking technologies, fostering alliances, and propelling business expansion.

SHD COMPOSITES

ZUND UK

NWAA Member Companies at Farnborough

3D 360

BCW DESIGN & MANUFACTURE LTD

BROOKHOUSE AEROSPACE

CGTECH VERICUT

DEPE GEAR

FORG3D

GREEN SHIELD GROUP

HYCAERO

KINGSBURY

METALWEB

NATEP

OXLEY

UCLAN

WALLWORK

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

Please contact AMS on: admin@additive-manufacturing.co.uk Follow them on LinkedIn or visit their website: www.additive-manufacturing.co.uk

titanium aircraft parts as a potential supply the MoD wants and can play a key role in the future supply of AMS’s high value circular economy product, a recycled titanium powder. Used in 100 per cent recycled or a recycled blend (like food packaging), AMS can support the supply chain risk mitigation for the UK and its allies but perhaps more importantly it is a key enabler in a more sustainable future. With critical mineral supply at its heart and unaffected by the geo-politically turbulent world we live in, AMS believes their technology has a bright future.

With the Global Combat Aircraft Programme (GCAP), AUKUS alliance for submarine supply and a buoyant home market for space manufacturing the needs for titanium and the opportunity for AM are large but the risk in supply is also high. AMS has therefore developed a solution, with R2. AMS being awarded funding from Innovate UK to build technical feasibility into their theoretical approach to turn aircraft parts into powder. This project was successful, and the process optimised. AMS’s first major customer was the Ministry of Defence (MoD). Due to the availability of

Additive Manufacturing Solutions create sustainable and secure titanium supply

Find out more

How a Lancashire based company created an innovative solution for a sustainable future

Additive manufacturing (AM), sometimes called 3D printing is a process in which materials are selectively added together to build 3D geometry. AMS has metal powder AM processes in house in which the energy source, electron beam or laser, melts the powder in these selectively defined areas. The titanium powder market globally is worth just a fraction of the global titanium market and the supply fluctuations induced by conflict have a larger impact on the titanium powder market. Over recent months the availability of titanium powder and prices have ranged from £150-275/kg and lead times up to 5 months for supply in some instances.

Russia and Ukraine have long since had key contributions to the titanium supply market and within the whole of the West of Europe there is not a single capability that can process titanium in its rawest form, sponge. Additive Manufacturing Solutions Ltd (AMS), based in Burscough, Lancashire has developed a solution to the titanium supply problems facing the supply of metal powders for additive manufacturing. AMS are world leaders in the metal additive manufacturing with their training academy, the AMA, alongside their process excellence. The final addition to this is their material development capability.

Titanium and its alloys have been readily used in many industries to great effect however it is the aerospace sector which has seen the main benefits. Titanium has very high strength and low mass giving the coveted high strength to weight ratio alongside its chemical and corrosion resistance and ability to work in high temperature environments. Titanium has and continues to be an important alloy across civil and defence aviation. In a world post Brexit, Covid and amid conflict in the Ukraine, alongside increasing tensions in the south pacific, there is a geo- political situation in which the future needs for titanium within our aerospace sector are put at risk for supply.

“AMS was created to bring our process expertise for material development and AM to support the growth of our industry.

Robert Higham AMS founder and CEO

“To do this the need for a controlled supply of feedstock became our mission. We now have proven what is possible for innovation and sustainable minded companies.”

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

Korean Air finalises order for 33 A350s

Airframe Designs helps to lead additive manufacturing industry body

materials such as composites, titanium, and modern aluminium alloys to create a lighter and more cost-efficient aircraft. All of which results in an average reduction in fuel consumption and carbon emissions of around 25% compared with similar sized previous generation aircraft. At the end of February, the A350 Family had won 1,240 orders from 59 customers worldwide.

Benoit de Saint Exupéry, EVP Sales, Commercial Aircraft, Airbus said: “This order from Korean Air is another major endorsement for the A350 as the world’s long-range leader. The airline will benefit from new levels of efficiency across its operations, with significantly reduced fuel consumption and carbon emissions. “The A350 will also be the perfect platform for the carrier to take its in-flight product and world class service to new heights. We thank Korean Air for its ongoing confidence in Airbus and its products and look forward to seeing the A350 flying in the carrier’s iconic livery.” The A350 Family is the world’s most modern widebody product line and is firmly established as the world’s long-range leader, with passenger versions able to fly up to 9,700 nm / 18,000 km non-stop. Powered by latest generation Rolls-Royce engines, the airframe uses 70% advanced

Korean Air has become a new customer for the A350 Family following the signature of a firm order with Airbus for 33 aircraft. The order covers 27 A350-1000s and six A350-900s. Offering the longest range of any aircraft, the A350 will be able to operate any of the airline’s current intercontinental routes with a 25% reduction in fuel consumption and carbon emissions compared to previous generation aircraft. The additional range of the A350 will also enable the carrier to evaluate new long-haul destinations. “The A350’s exceptional range, fuel efficiency and passenger comfort make it a great fit for our global network, We are confident that the introduction of the A350 to our fleet will drive operational efficiencies and elevate the overall travel experience for our passengers.”

With polymer additive manufacturing technology, combined with 3D scanning and 3D modelling, it is possible to deliver creative solutions to complex engineering problems in the aviation and defence part market, including solutions for airframe tooling. This technology can also be adapted for other industries including space, nuclear, motorsport and rail. Recent projects undertaken by Airframe Designs include the design and manufacture of several 3D printed tooling fixtures to aid the installation of external sensors onto the fuselage of a special mission military aircraft and the integration of new systems into heavy lift drone platforms. The company has also been responsible for the conceptual design at a platform level for new uncrewed air-systems, test rig and tooling for electric vehicle propulsion systems and most recently the design and analysis of operator consoles for a special mission aircraft.

delivered at pace, whilst also helping to reduce carbon emissions and achieve Net Zero goals by 2050.” As part of its commitment to the development of additive manufacturing, Airframe Designs has recently invested in a second 3D printing machine, a state-of-the-art Stratasys Fortus 450, a new five-axis milling machine and new sophisticated resin printing technology to offer increased capability and quality of parts and tools for its increasing customer base. The AMUK has become part of the wider Manufacturing Technologies Association (MTA) cluster to lead the industry as it becomes an increasingly important part of the manufacturing drive. The services offered by Airframe Designs meet the demand from the aviation and defence sectors to create new parts or re-engineer obsolete parts in an agile, cost-effective, and sustainable manner.

Aerospace specialist Airframe Designs has joined Additive Manufacturing UK (AMUK), a national industry body, to help lead the development of additive manufacturing and 3D printing in the UK. The company has become a member of AMUK whose aim is to establish the UK as a world leader in the development and adoption of additive and 3D printing technology. Jerrod Hartley, CEO of Airframe Designs, said: “Joining the lead industry organisation will help raise awareness of the benefits of additive manufacturing technology and our own engineering excellence. “There is a revolution happening in UK manufacturing with the adoption of additive manufacturing and we want to help lead and build on these opportunities. “This technology enables us to produce lightweight, highly accurate, and robust airframe parts and tooling which are For more information contact Airframe Designs, tel 01253 400320 or visit the Airframe Designs website.

Find out more

Aerospace leader joins UCLan Former BAE Systems Director Andrew Schofield awarded Honorary Professorship is currently the Chair of the North West Aerospace Alliance, a member of a number of UK advisory groups and director of his consultancy business. Andrew said: “I am delighted to have been awarded this honorary position at UCLan. achievement of being awarded an Honorary Professorship at ULCan. This is a testament to Andy’s unparalleled dedication, expertise, and significant contributions to our industry.”

Find out more

The University has invested heavily in its engineering provision in recent years, most notably through its £35 million Engineering and Innovation Centre (EIC) that is home to state-of-the-art aerospace technology including cutting-edge software tools, flight simulators and unmanned air vehicles (UAVs).

The work the University does is having a significant impact on the success and prominence in the North West across the aerospace and space sectors. I am looking forward to supporting the drive to ensure that the region remains at the forefront of innovation and continues to provide the talent pipeline required to succeed.” UCLan Pro-Vice Chancellor Professor St John Crean added: “Andy is an incredibly experienced leader in the aerospace industry, and we are delighted that he is willing to share the decades of experience with our students who will benefit immensely.” Paula Gill, CEO of NWAA, said “We are very proud of our Chairman, and I want to take a moment to extend my heartfelt congratulations on this outstanding

An aerospace expert with more than 40 years’ industry experience has been awarded an Honorary Professorship at the University of Central Lancashire (UCLan). Andrew Schofield, who worked for BAE Systems for more than 40 years, has joined the School of Engineering and Computing, where he will be involved in student engagement and providing industrial support as the University develops its provision in air and space engineering. Andrew began his engineering career with BAE Systems in 1979 as a Technologist Apprentice, rising through the ranks to when he left the company in 2022 as Director of Programme Technology Integration. He

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

Bowers Group triumph at MACH Exhibition 2024

Plotting a course: how businesses can tap into international talent pools With skilled workers in increasingly short supply, Ikram Malik, Partner at Brabners, highlights how business immigration can help the North West’s aerospace sector develop a healthy talent pipeline, and the key legal considerations for businesses looking to do so.

WYLER, and Gagemaker. Attendees also got a glimpse of Bowers’ new surface form and geometry machinery, offering precise measurements of contours and roundness. To mark the event, the Bowers team took the opportunity to stage a number of informative demonstrations of a range of its products live at the event, which are now available to watch on the company’s YouTube channel and across its social media platforms. These demonstrations offer valuable insights into its innovative metrology solutions, highlighting their capabilities and benefits for those who couldn’t attend the show.

At the exhibition, Bowers Group unveiled its latest products and measurement solutions, including the brand new Baty Venture FV series. Visitors to the stand had the exclusive opportunity to experience live demonstrations of the field of view machine, seeing firsthand its capabilities in providing fast and accurate measurements of multiple parts. This innovative field of view machine offers impressive accuracy and efficiency, enabling users to conduct precise measurements across various applications. With features such as its simple user interface, automatic measuring and dimensioning, and ultra-fast reporting, the Baty Venture FV streamlines inspection processes and boosts productivity. Alongside the Baty Venture FV series, Bowers Group displayed a diverse range of metrology instruments, hand tools, and vision systems from its brands and trusted partners such as Moore & Wright, Trimos, Sylvac,

Bowers Group is celebrating its most successful showcase to date at this year’s MACH Exhibition. Held at the NEC in Birmingham, the event marked a significant milestone for the company, highlighting its commitment to innovation and excellence in the field of metrology. “We’re absolutely delighted with the fantastic response we received at MACH Exhibition,” said Martin Hawkins, Managing Director at Bowers Group. “Our meticulous planning for our largest event to date truly paid off. With our bigger-than- ever stand, we were able to showcase our latest innovations and demonstrated our prowess in delivering efficient metrology solutions. It proved to be our busiest exhibition to date, allowing us to engage with a wealth of industry professionals and explore collaboration opportunities. We’re excited about the upcoming weeks as we reconnect with visitors and start putting plans into action for them.” For more information about Bowers Group and its range of metrology solutions, visit www.bowersgroup.co.uk

Proactively plotting a course Those businesses that are prospering are taking a proactive approach of having business immigration embedded into their talent strategy, creating an alternative recruitment lane they can tap into whenever it’s appropriate. A key reason why employers may be reluctant to engage with the sponsorship route is the compliance burden it brings. Employers are required to familiarise themselves with sponsor duties and report change of circumstances for the organisation or the sponsored worker in a timely manner. Our specialist immigration team at Brabners work with our clients to advise on all aspects of economic migration to ensure their organisation is compliant with immigration and employment law requirements. As the skills gap continues to persist, successfully navigating the UK’s immigration regime is becoming increasingly business- critical for many organisations. Yet, by taking a proactive approach and identifying the benefits it can bring early, it can also be a catalyst for the sector’s continued evolution.

International talent Despite Home Office statistics showing a fall in business immigration for the first quarter of 2024, it’s important that management teams remain alive to the benefits that business immigration - especially through the Skilled Worker Visa route - can bring. Being an approved sponsor licence holder with the Home Office grants businesses access to a much broader talent pool comprising qualified, experienced candidates from across the globe. This is particularly beneficial for those operating in advanced manufacturing sub-sectors, who often require applicants with specialised skillsets that can be costly to develop through training. In a similar vein, the route allows businesses to tap into the UK’s extensive pool of international graduates actively seeking employment following the completion of their course.

The skills gap facing UK industry continues to represent one of the most pressing economic challenges of our time, so it was encouraging to connect with so many of the North West’s aerospace industry at our recent NWAA partner event which explored the sector’s response.

Be it through engagement with local schools and universities to help build

interest in careers in STEM or outreach into underrepresented communities, the good news is that major aerospace organisations across the North West are utilising a range of tools to develop a strong pipeline of regional talent. BAE Systems’ FOCUS scheme, which provides mentoring for students looking to pursue a career in engineering, is a great example of this in action. Developing a pipeline for the future takes time though, with the return on investment often taking years to materialise. And with new technologies such as AI becoming more prevalent, the need for experienced, skilled workers able to utilise these tools means that tackling the skills gap remains very much as an issue for the here and now. Business immigration is high amongst employer considerations. For more information on how business immigration can benefit your business, contact Ikram.Malik@Brabners.com.

or view the product demos now at www.youtube.com/@BowersGroupUK

Find out more

Green Shield Group announces appointment on New Century Foods

The group, which boasts an impressive client roster, has supported businesses and brands with their solar installations, working with brands such as Dakota Hotels, Sandal BMW, AMRC, Soper BMW, Burnley College, UCLAN and Eric Wright Group with several upcoming projects in the pipeline. Green Shield Group is also now a member of the British Franchise Association and recently attained an elite-level CHAS qualification for methodology and project delivery standards.

Chris Ridehalgh, Green Shield Group said: “It’s been great to work with New Century Foods on their renewable energy solution. “We enjoy working within the food manufacturing industry because solar PV is almost a guaranteed game-changer. The solution provided to New Century will significantly reduce their grid dependency and save the business over 150,000 kg CO2 in the first year of installation.” Green Shield Group specialises in delivering carbon reduction strategies for businesses across the UK. The business operates across a multitude of sectors, including manufacturing, automotive, aerospace, leisure, education, and local authorities. It simplifies the transition to sustainable solutions for clients while providing operational cost reduction.

Lancashire-based Green Shield Group have been appointed to deliver a 339.33 kWp solar PV system for New Century Foods in Scunthorpe. The bespoke system will save New Century Foods almost £40,000 in the first year of business and represent a return on investment within five years with an 82% self-consumption rate. The new solar PV installation spread across two buildings will save the business almost 150,000 kg of CO2 in Year One. New Century Foods is located in Scunthorpe. Its 26,000 sq ft factory has been purpose- built to the highest standard, and it employs over 100 full-time staff members, from office workers to butchers, packers, and delivery drivers.

Find out more

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

Machining super alloys, whilst keeping it cool

Precising cooling that’s out of this world One example displaying the power of 3D-printed solutions and additive

Maximized service life

When machining heat-resistant materials, such as titanium and other super alloys, two factors play an especially crucial role in controlling temperature and maximizing service life downtimes: top-quality tools and a targeted coolant supply. The additively manufactured MaxiMill – 211-DC indexable insert milling system showcases how proper nozzle positioning can be a true difference maker. As anyone in the business of machining titanium parts and super alloys can attest, there’s no getting around using improvised strategies aimed at cutting costs and time. Despite high-speed machining, these incredibly tough materials simply make it difficult to ensure process reliability. “If these processes are to be carried out in an even remotely financially viable manner, professionals often at times have to deviate from the proven “roadmap” and be open to trying out new strategies. It’s for such stubborn instances that we developed our 3D-printed indexable insert milling system MaxiMill – 211-DC.” says Robert Frei, Product Manager at CERATIZIT. 3D-printed and precision-cooling Optimised coolant is essential for achieving top quality results, especially when machining titanium and other heat-resistant materials. And it’s here where the patented shoulder mill from CERATIZIT shines, thanks to precision coolant placement on the milling indexable insert flanks. “Additive manufacturing processes are no longer mere nice-to-haves. They are essential to achieving results that would be impossible with conventional strategies. A prime example is our indexable insert milling system, the additively manufactured MaxiMill – 211-DC,” says Frei. CERATIZIT recognized early on that 3D-printed solutions could go beyond the limits of traditional manufacturing processes and deliver viable alternatives. Developed in-house and tailored to meet individual needs, these specially designed tools are manufactured additively.

To see where the MaxiMill – 211-DC with direct cooling really proves its value, just take a look at its service life compared to tools with standard cooling: 60% longer service life. “This additional surplus of service life makes for fluid machining of titanium and super alloys, while delivering the benefits of secure manufacturing processes and minimizing tool use,” says Robert Freis about using the MaxiMill – 211-DC.

manufacturing is the base body of the milling cutter on the MaxiMill – 211-DC. CERATIZIT’s team of engineers sought to optimise the flank cooling process that is essential for machining titanium. “Our objective was to funnel the maximum amount of coolant directly on the flank, which sounds straight-forward enough. However, pulling it off required a very complex construction process, which was only made possible by additive manufacturing Thus, we were able to create the perfect combination of geometric and functional properties, including the ideal nozzle position and an insert geometry precisely tailored for cooling. In doing so, we are able to guarantee full coverage wetting of the coolant on the indexable insert cutting surface. Despite the complexity of the numerous coolant holes present inside the tool body, the MaxiMill –211-DC is compatible with standard adapters with thro’ coolant supply, without requiring any standard coolant on the chip breaker. Moreover, it provides the same performance and advantages as using direct cooling for turning tools.

Find out more

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

INGMETAL choose independent NC code checking software

Delkia welcomes 14 new staff to support rapid growth

Delkia has also invested in future development with two new research, technology and innovation engineers joining the R&D team: Alasdair Regan who has a PhD in electrical and electronic engineering and is working on the command and control of remote systems, e.g. unmanned air vehicles. Paul Broadley holds a PhD in aerospace engineering and is working on air systems. Delkia’s growth is good news for job hunters and the company is still recruiting for roles in Cumbria, Preston and across the UK. Current vacancies are at www.Delkia.uk/careers

Delkia Aerospace welcomes three new experienced members of staff: John Brindle - Senior Avionics Systems Engineer, John Green – Senior Systems Design Engineer, Flight Systems, and Lyndon Herbert - Senior Avionics Equipment Engineer. Maritime sector hires include Tim Moore - Programme Engineering Manager; Peter Brown - Deputy Programme Engineering Manager; Paul Weaver - Design Engineer, and Josh Myers - Business and Technical Administrator who said: ‘Colleagues know you by your name at Delkia, you aren’t just a number.’ The team has been further strengthened by Maritime Project Manager Joe Pruden, who joined Delkia as it is: ‘A great place develop my own skills going forward.’ Support roles have also been augmented with a new Information Security Engineer, Curtis Dowdle. Tendering Manger Laura Connor said: “The positive reputation of the company and the investment put into the staff is impressive. To support further recruitment, two new talent acquisition specialists have been appointed, Gareth Sharp and Victoria Armstrong.

Due to a large volume of contract wins across all sectors, engineering and technology specialist Delkia has employed 14 new staff. These new team members are working across the entire organisation to support projects, the team and customer needs in the company, a leader in safety-related and mission-critical systems in aerospace, clean energy, and maritime sectors. “Delkia has enjoyed massive success in winning new contracts across aerospace, clean energy, and maritime sectors in the early part of 2024, leading to the creation of many new jobs across the UK. We’re delighted to welcome our new recruits in the last few months and are still actively recruiting. The company is going from strength to strength as we move towards our vision to be the UK’s leading engineering and technology partner for safety-related and mission-critical systems.”

VERICUT force optimisation The next logical step for INGMETAL was to purchase the VERICUT Force module, which analyses the NC code to further optimise machining processes, resulting in significant time savings and improved tool life. VERICUT Force is a physics-based software module for optimising NC programs. It is used to analyse the cutting conditions during the entire NC program operation. In particular, the maximum reliable feed rate for a given cutting condition is determined based on the load on the cutting edge, spindle power and the maximum chip thickness. Martin Stredňák confirms, “this allows us to speed up or smooth the toolpath and thus reduce the machining time.” Over a period of 2 years of using VERICUT Force, INGMETAL has seen a saving in machining time of between 15 and 25% depending on the produced part complexity. Martin Stredňák concludes, “Thanks to innovation and continuous improvement in the technological production of moulds for EPS and EPP moulding and shape complex parts, we are recognised players on the European and world market. We owe our innovation to VERICUT, which is the key to our fast and reliable machining of parts”.

added Martin Stredňák. “We wanted an independent NC code checking software.” After looking to the market and attending presentations and trainings in two different software companies, INGEMETAL ultimately selected VERICUT CNC simulation, verification and optimisation software. In 2021 they engaged AXIOM TECH (VERICUT reseller) to acquire and install VERICUT into the machining processes for NC code simulation and verification. VERICUT simulation and verification VERICUT software detects errors, possible collisions, and potential inefficiencies in CNC machining. Unlike CAM simulation, which only simulates the toolpaths and not the actual NC data, VERICUT checks the actual NC code that is running the machines, giving a true virtual machine and a 3D machining digital twin. VERICUT can simulate any CNC machine, regardless of manufacturer and can seamlessly integrate with all CAM systems. Interfaces ensure that VERICUT integrates into the customer’s specific software manufacturing environment. The simulation software is completely independent of the controller, CAM system and CNC machine used.

INGMETAL s.r.o. is a dynamically developing company, which since its establishment in 1990 has been engaged in mechanical engineering production with a focus on complex and precision parts. As a member of the HIRSCH servo Group, INGMETAL employs 79 people, including 25 designers and technologists, and specialises in the production of expanded polystyrene and polypropylene moulds. Martin Stredňák, Programmer at INGMETAL confirms, “Our company officially became a member of HIRSCH Servo Group in April 2022 and our customers are companies such as HIRSCH group, Synprodo, HSV, Izoblok, Schaumaplast Germany, Grupor, JAS plastic.” In its 1700m² production facility located in Petrovany, Slovakia, INGMETAL operates 6 modern milling centers and produces an average of 200 moulds per year. The technology department consists of a team of 10 technicians who work with 3 different CAM systems to produce NC code for the machine tools. In the past, the machine shop had suffered machine collisions, downtime, and re- machining of pieces due to the complexity and variety of the parts being produced. “So, we started looking for a solution”

John Green

Lyndon Herbert John Brindle

Find out more

Kurt Canfield

CEO

Find out more

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

ELE Advanced Technologies makes change possible today for the benefit of tomorrow Engineering solutions provider ELE Advanced Technologies (ELE) has achieved its initial scope one and two sustainability objectives and is now working towards scope three targets.

Why digital transformation is important in the race to net zero

of collating that data, analysing and tracking progress to Net Zero will be key. At Gradient , we’ve always known that robust and accurate data is critical for successful ERP projects. This is why we are partnering with YuzeData , bringing their Data Automation platform to SMEs. As Elizabeth Mills from YuzeData said to us recently... “Supply chain is poised to make a significant contribution to Net Zero over the coming years. We are very happy to see the collaboration amongst suppliers at all levels to support global brands in their Net Zero ambitions. YuzeData and Gradient have the opportunity to support these clients by making a Net Zero strategy a sustainable business imperative”. For all businesses, digital transformation is a business imperative and extending it to address climate change is a moral obligation. So, the question can no longer be where you start; it has to be when will you start your digital transformation journey?

impact on sustainability and the race towards Net Zero. The World Economic Forum has stated that 20 per cent of the cut in GHG emissions will come from digital technologies in four key ways: • Foundational technologies – using functionality within ERP systems to drive operational efficiencies, improve planning, enable supply-chain collaboration, reduce wastage and monitor costs. • Sensing & control technologies – using monitors to track energy consumption, enabling real-time adjustments and intervention. • Decision making technologies – using AI to predict maintenance needs, reducing down-time and resource waste. • Enabling technologies – using cloud- based tools to facilitate remote working and on-line meetings. Digital transformation is no longer just about staying competitive, it is an essential enabler to the achievement of a sustainable future. Businesses benefit from reduced costs, reduced risks, improved supply chain and customer relationships as well as demonstrating a commitment to achieving Net Zero. However, and we know there’s always a “however”, these technologies gather data, but a Net Zero strategy requires targets, measures, performance and reporting. Digital transformation incorporates data from many different sources, not just ERP, so ways

If someone was to ask you – do you want to help save the world, I’m guessing most of us would say “yes”! But ask managers of SMEs, operating within the current economic challenges of cost increases, consumer confidence decreases and conflict impacts, then the answer is more likely to be a “maybe, but…” Where do I start?

chain as a result of our operations.

David Stanley, CEO of ELE Advanced Technologies, said: “Our customers may be some of the biggest blue-chip companies in the world, but they still have a steep journey ahead of them in achieving net zero by 2050 – through what they make and how they make it. “We may have gone early in terms of leading the way for the rest of the supply chain, however we believe this is the right thing to do and our customers value our responsible and collaborative approach.” A key aspect of ELE’s drive to be an early adopter of the most sustainable approaches and techniques in advanced manufacturing is its formation of a Sustainability Committee. Led by David and tasked with driving forward environmental, social and governance aims, the committee engages with employees from all areas of the business and will now work towards the next phase of the business’ journey to net zero. David said: “Scope three now involves us looking into how we can support reduction of carbon emissions generated by our supply

It’s original goal of reducing scope one and two carbon emissions by 80 per cent by minimising energy usage and sourcing energy from renewable sources, was achieved at the end of 2023. Lancashire-based ELE, which produces complex, high-integrity components for some of the biggest original equipment manufacturers in the world, introduced an energy optimisation programme utilising digital diagnostic tools to reduce the energy needed to power its machining tools by 20pc. The business, which provides engineering solutions in the aerospace, power generation and automotive sectors, also installed photovoltaic solar panels to enable it to generate up to 37pc of its own clean energy, with the remaining energy used on site coming from alternative renewable sources. Its new state-of-the-art manufacturing facility site features electric vehicle charging points free to use for all employees. A streamlined waste management system has also reduced the level of waste produced and increased repurposing and recycling rates so that 88pc of the waste it produces now avoids landfill. The final step of this initial phase will involve ELE reducing carbon emissions resulting from its heating requirements by exploring potential heat recovery options within its manufacturing operations. Heat recovery is now in place, heating a new extension recently built for a highly specialised application.

“This will undoubtedly be the most challenging aspect of our sustainability journey. However, ELE already has excellent working relationships with its supply chain, so we’re already one step ahead than most, and look forward to working with our suppliers to explore the difference we can make together.” To start, ELE aims to reduce carbon emissions produced by its commuting and courier services by 25pc and then intends to achieve a further 25pc reduction from working with the remainder of its supply chain, by the end of 2024. Sustainability improvements achieved by ELE Advanced Technologies to date have recently been recognised by an external party that independently assesses progress being made. Having been benchmarked in 2022 the assessment improved again in 2023 with an overall score of 68% and is considered ‘Advanced’ in the framework. David Stanley added: “ELE’s culture is one of ‘making things possible’; this ethos will ensure we continue to make a difference in advancing technology for the benefit of future generations.”

This is where digital transformation comes in.

20 per cent of emissions reductions come from Digital Transformation (Source World Economic Forum) . Digital transformation is the incorporation of computer-based technologies into business processes in order to realise operational efficiency, cost optimisation, customer and supply chain engagement. In other words, it’s about using systems to deliver new products and services, to improve existing ones, to streamline processes, to gather business-critical data and respond to customer demands. But, as with any change, people are critical to the success of digital transformation. Businesses need to become more agile, accepting uncertainty and ultimately seeing it as an opportunity to thrive. It requires a shift away from traditional thinking and toward a more collaborative, experimental approach. Whilst digital transformation is about resilience and innovation, there is a further significant bonus from this journey – a positive

Find out more

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Member News

Matrix have been designing and manufacturing machine tools in Coventry in the UK since 1913

The devil is in the detail

All of these disasters could have been avoided if the manual had been written correctly!

he suggests that the document needed interpreting into plain English. The technical content, although correct was not easy to read and understand, contributing to the crash where just two passengers miraculously survived. Arguably, if a professional technical author had written the Service Bulletin the disaster could have been avoided. Often, AD’s are written by engineers’ who have a different skill set from that of a professional technical author/ illustrator.

trim tab components. According to the (NTSB) report the manufacturer says that the installation figure is correct but it is viewed from the back of the aircraft (opposite of what the mechanic would see when installing the system). Additionally, the fact that the technical content is questionable suggests that it is not ‘clear, concise and unambiguous’, resulting in the death of 2 crew and 8 passengers.

CARGO OPERATIONS MANUAL WRONG!

2024 sees Matrix join the North West Aerospace Alliance and we look forward to a long and mutually beneficial relationship and we are honoured to serve the UK Aerospace tradition.

The Matrix thread grinders have undergone much development over the years and are now available with full Siemens CNC and our own user-friendly software. Development has been made for some of the machines to use a stable stone base as opposed to the traditional cast iron. Our Gear production machines have innovative software with simple easy to use menus and the machine can generate NC programmes automatically through input parameters. The contact surface can be adjusted very easily within the programmes. Looking forward, Matrix will continue to innovate and fine tune our existing machine tools and develop new solutions where we believe them to be the most beneficial to our clients. Matrix Machines are hand built at our state of the art facility in Coventry. Where possible Matrix can offer turnkey packages with bespoke features for the clients benefit. Customers are always welcome to visit our facility and see the machines being built.

As original innovators of thread grinding machines, Matrix has sold thousands of machines worldwide. Very many of these machines are still in use as manual thread grinders producing components from thread gauges and to ring gauges. Some of the machines are in excess of 60 years old and are still accurate and running strongly. As Matrix moved in to the 21st century a decision was made to return to gear manufacture, a technology that goes hand in hand with producing worm shafts. As a result, Matrix now has a range of precision CNC gear cutting and grinding machines to add to our portfolio of thread grinders. Typically, these are targeted at the user for small to medium accurate batch work. However, if required Matrix can adapt for more focused production targets. Our machines are used within the aerospace industry leading and trailing edge screw actuation manufacture, aircraft/space transmission systems, helical landing gear components, main rotor and tail rotor gear for helicopters, space attitude control and deployment of solar panels and antennae.

The National Airlines crash was the result of an individual making significant changes to technical publications outside of any formal process, and without cooperation with other stakeholders. Although the Chief Loadmaster had good intentions, he lacked the skills of a professional technical communicator and simply ‘got it very wrong’, resulting in the death of 7 crew. AIRCRAFT MAINTENANCE MANUAL WRONG! The Beechcraft Maintenance manual illustration incorrectly depicted the elevator

SERVICE BULLETIN MISINTERPRETED

Clear, concise and unambiguous instructions could have prevented the disaster. Greg Feith comments (below) about the complexity of the Airworthiness Directive (AD) in this case a Service Bulletin, where

PROFESSIONAL TECHNICAL AUTHORSHIP IS CRUCIAL TO SAFETY & CONTINUED AIRWORTHINESS

Find out more

Neil Langridge (Director) TechWriterUK (Trading name of Liberty360 Limited | 12th May 2024

The role of a professional technical author/illustrator extends far from the edge of the page. Writing clear, concise and unambiguous technical instructions is only the first crucial step towards safety and continued airworthiness. There is a whole bigger picture around the cultural change that is ‘technical authorship’.

technical documentation including the review and approval process.

The accidents described in this article are the worst possible outcomes, however it is a frightening thought that many ‘near misses’ are not reported. The technical authorship/illustration

The crucial first step must be supported by robust review, approval and quality management processes where responsibilities are defined from the c-suite to the mechanic at the end of the line. What might seem to be a few small errors in a procedure can culminate and result in disaster. Individuals can and are, being held accountable for errors in technical content. Where accountability is clearly established the punishment can result in a custodial sentence.

Find out more

that we see on a regular basis is often ‘inexact and subject to misinterpretation’.

Join our webinar series where we will be showcasing technical authorship/illustration methods and practices and discussing how to best produce clear, concise and unambiguous

plane talk summer 2024

www.aerospace.co.uk

@NWAerospace

plane talk summer 2024

Page 1 Page 2-3 Page 4-5 Page 6-7 Page 8-9 Page 10-11 Page 12-13 Page 14-15 Page 16-17 Page 18-19 Page 20-21 Page 22-23 Page 24

Made with FlippingBook Digital Publishing Software