Measurement system retrofit reduces inspection times and gains new business for world-class manufacturer

Mike Sullivan founded Future Advanced Manufacture Ltd (Future AM) thirty years ago and realised immediately that competing on price was not the way forward: “There’s always a ‘Fred in the shed’ down the road who will offer to do any job cheaper,” he says. “From the beginning, we decided we had to position ourselves so ‘Fred’ couldn’t compete with us.” Mike’s solution was to focus on engineering work with specific attributes: high intellectual property (IP) values, safety critical applications and highly complex designs. “Put those three together and a buyer can’t simply opt for the cheapest provider because they are putting their reputation on the line – and possibly the lives of their customers.”

Future AM now specialises in precision engineering for clients in the medical, aeronautical, space and oilfield exploration sectors – some of the world’s most demanding industries with a need for ongoing research, development and testing. The firm’s managing director Craig Peterson, who is halfway through a five-year management buyout, explains: “Our clients demand excellence both in the accuracy of the design and build and also in the efficiency of the operation. Long-term success comes from continuous improvement in our systems and technology, and investment in highly skilled engineers. The acquisition of Renishaw’s REVO 5-axis system in July 2010 is just the latest example of that process.”

The firm has developed a particular expertise in the aerospace industry, gaining AS9100 certification towards the end of 2009 for its capabilities in producing ‘high complexity components and assemblies for aerospace applications'. “We are one of Europe’s leading designers and manufacturers of aerodynamic models used in wind-tunnel tests,” says Craig, “and we have worked with Airbus & The Aircraft Research Association in Bedford for a number of years.”

This world-class reputation helped the firm win its first significant contract in the US, in early 2010. “We can’t say much about it,” confides Craig, “except that making Titanium blades for a new propulsion system requires a very stringent validation process. Our existing metrology tools were not up to the job, so we turned to Renishaw and their REVO 5-axis system for help.”

REVO is a dynamic new measuring head and probe system, designed to maximise the throughput of new and existing coordinate measuring machines (CMMs) by providing greater accuracy, faster measurement, more automation and new capabilities. It uses synchronised motion and Renscan5™ measurement technology to minimise the dynamic effects of CMM motion at ultra high speeds. It also uses Renishaw’s new MODUS™ software (which works with standard industry programming languages) to take full advantage of CAD-driven programming.

“We chose Renishaw’s REVO and MODUS package,” says Mike, “because we were developing a Digital Product Definition (DPD) cycle based on the secure transfer of data using Dassault Systèmes’ CATIA®. This allows us to share information, including CAD files, with customers and suppliers quickly and safely. However you need a system that can pick up and directly interrogate the CATIA V5 files, so that you know you are working on the same CAD throughout the production process; MODUS does just that. We could also retro-fit the REVO head to our existing CMM, which speeded up the installation.”

At first, because of the tight project timings, Future AM used a REVO at Renishaw’s facility (also in Gloucestershire) to validate the work while they had their own system installed. “Renishaw were a great help,” says Craig. “We succeeded in getting every blade out on time, on budget and with no rejections; even the spare test blades were validated OK. As a result our US client is considering offering us further work. But, that’s not the only good thing to come out of this $250,000 project.”


Investing in the REVO and MODUS systems has paid dividends in other areas of the business already. “It has improved our metrology department’s final validation service by 80%,” says Craig. “For instance, to validate work on say a high precision imaging drum for our customer Highwater Products could take an hour on the old machine. Whereas the new REVO only takes about 10 minutes, and the Modus software has improved the accuracy of our post-machining operation because of the level of detail in its reports.”

This improvement in efficiency and accuracy has enabled the company to offer reverse engineering services. As Craig explains: “Customers often ask ‘Can you make this item when we have no CAD (usually because it was made pre-CAD)?’ Well, now we can. First we laser scan the component and turn the data into a point cloud, which we run through SolidWorks® & Visi Reverse software to create a virtual 3D surface. We then use the REVO to compare the new virtual surface with the original part to validate possible engineering processes before making the cloned parts.”

The new system is also helping Future AM keep ahead of its European competitors in aerodynamic testing. “You always run the risk of being left behind on technology,” observes Craig, “but the combination of REVO and MODUS is one of the most sophisticated reporting and validation systems available, so it provides good future proofing and makes more sense than copying the technology used by our competitors.

It enables us to produce inspection data by direct comparison with the original CAD model – both in tabular and visual reports that meet our clients demanding standards. These include complete sectional scans, surface waviness and slope criteria.”

The final surprise development has been a surge in demand from clients using Future AM as a sub-contractor for final inspection and validation, even when the firm hasn’t been involved in making the original products. “We’ve only had the REVO/MODUS system for a few months and hadn’t planned to market the fact until 2011 but, thanks to word of mouth, our existing clients are already aware of our new capabilities.

“They know that we don’t just do design and manufacturing but offer a comprehensive, ISO 9001:2008 or AS9100 certified service. They also like the fact that our team can integrate seamlessly with their own, using secure pathways for the transfer of original data, so providing a virtual in-house facility.” Although Craig is pleased that the REVO/MODUS investment has already made a significant contribution to the firm’s success, he is left with one problem: “We’re going to have to consider investing more in our metrology department in 2011, simply to cope with the new business!”

For further information on REVO visit www.renishaw.com/revo

Technology that's Watered down — but Never Weak

To dramatically oversimplify – Take the most abundant liquid on Earth, put it under high pressure, let it escape through a small hole, inject some sand into the stream, and you can cut anything. This is basically the outline of a modern waterjet machine tool. Granted that we are considering pressures that are greater than on the bottom of the deepest ocean and the sand is usually crushed garnet, but the concept is about right.


Waterjet cutting technology has matured from its very early days in the 1950s when it was initially studied for use in cutting lumber. Waterjet cutting technology, and if sand or crushed garnet is used, the process is called abrasive-waterjet, has many applications in the modern machine shop. Waterjet cutting processes are one of the most versatile and fastest growing machining operations in the world and 5-axis waterjet machines are currently available.

Very often waterjet processes can complement other manufacturing technologies as no noxious gases or liquids are used. Waterjets do not create hazardous materials or vapors, and they do not create heat-affected zones or mechanical stresses in the materials cut. In certain situations, waterjets can accomplish cutting tasks in less time than conventional technologies, and sometimes they can do things that other technologies cannot.

IMTS is this year’s preeminent location to see the latest developments from waterjet technology providers. No other place on Earth will bring the latest and greatest innovations and technology developments together in one place.

If you’re thinking about additional capabilities for your machine shop, waterjet operations should be on your list. Waterjet machine developers are continually upgrading and incorporating the latest research from both private-sector companies and universities. Many are expanding on their own capabilities by exploring the dynamics of cutting newer metals, ceramics, and various composites. Also, more recent research has focused on waterjet micro-machining. So this may also be an area worth exploring.

It is ironic that on your lookout for a competitive edge in the manufacturing environment, the answer may be a machine tool that has actually no cutting edge at all ... just a jet of water.

Ask for details at any number of companies that will be displaying in the North Building during IMTS.

Source: IMTS Insider Newsletter - Vol. 10

Aluminium helps cut greenhouse gas emissions

The aluminium industry can be CO2 positive in a decade’s time. Reduced emissions from recycling, as well as the use of aluminium in automotive, buildings and in solar energy, will more than offset CO2 emissions from primary aluminium production.

In his presentation to the international aluminium conference in Oslo Tuesday, Hydro President and CEO Svein Richard Brandtzæg explained how solutions based on aluminium can enhance energy efficiency and cut emissions in key areas of society, such as transport and buildings.

Brandtzæg made one of the keynote speeches at the 15th World Aluminium Conference organized by the independent business analysis and consultancy group CRU, organized in Oslo for the first time.


More than 250 participants from all over the world are in Oslo to listen to presentations and take part in discussions on trends in the aluminium industry, with energy and climate issues high on the agenda.

The conference was officially opened by Trond Giske, the Norwegian minister for trade and industry.
Aluminium is used by the automotive industry in order to achieve weight reductions. Energy consumption and greenhouse gas emissions from vehicles primarily result from the use, not its production. Lighter vehicles thus contribute to reduced energy consumption and emissions compared to heavier vehicles. Analyses show that 1 kg aluminium replacing about 2 kg steel or iron will cut CO2 emissions by 21 kg of CO2-equivalents over the lifespan of the car. Globally, this "lightweighting" can result in a reduction of some 500 million tonnes CO2-equivalents in 2020.
The bumper systems for the Reneault Megane are made from aluminium, allowing a weight reduction of 7 kg per car. With an annual production of this model of 800,000 cars, the bumper weight reduction alone contributes a reduction of 800,000 tonnes of CO2-equivalents. The reduced fuel consumption offsets some 13,000 gasoline trucks!
Car manufacturing is expected to grow significantly, at the same time as the amount of aluminium in each car is increasing. This is one of the strong drivers behind the expected increase in the world demand for aluminium. Brandtzæg referred to analysis pointing to an increase in the aluminium demand of 76 percent from 2010 to 2020, up to approximately 68 million tonnes. In the same time frame, because of its contribution to reduced CO2 emissions from the end users, the aluminium industry will reduce its carbon footprint and turn CO2 positive.
The buildings represent close to 40 percent of the total global energy consumption. New solutions allowing more energy-efficient buildings, can lead to significant reductions. Hydro provides solutions already now allowing buildings to be energy neutral, producing as much energy as they consume on average. Further, the expected increase in aluminium recycling, a process only requiring five percent of the energy that goes into primary aluminium production, add to energy efficiency.

The Hydro CEO also informed that Hydro is developing new technologies aimed at reducing energy consumption in primary aluminium production by 25 percent at the same time as the new technology will be ready to capture the CO2 emissions in order to store it and not release it at all.

Author: Thomas Knutzen

Ultimate surge protector

On Aug. 14, 2003, more than 40 million people were plunged into darkness when electrical service failed in large portions of the Northeastern and Midwestern United States and Ontario, Canada. Though many workplaces ceased functioning without electricity, New York City’s emergency medical services had to deal with a doubling of call volume during the 29-hour blackout, according to a 2006 report in Prehospital and Disaster Medicine.


Cardiac and respiratory complaints increased, likely due to commuters being left without subway transportation or elevators, according to the report.
Paramedics responded to a large number of heat-related medical calls because air conditioners could not function. Ambulances struggled to navigate streets that lacked functioning traffic signals and were crowded with commuters walking home.


The Department of Homeland Security (DHS) Science and Technology Directorate (S&T) is supporting a technological advance that could reduce the chances of similar blackouts occurring in the future. The Directorate’s Homeland Security Advanced Research Projects Agency (HSARPA) helped fund the development of an electrical cable that could be used to link substations, providing backup sources of electricity in the event part of the grid experiences an outage. The Resilient Electric Grid project will help ensure the nation’s utilities can withstand power surges that cause blackouts.

According to Sarah Mahmood, program manager for HSARPA, electric utilities have hesitated to connect substations in the past. Although one substation can compensate for another’s outage if the two are linked, there is a downside to building an interconnected grid. If an equipment failure, terrorist attack, or lightning strike causes a power surge, also known as a fault current, that fault current can cascade through the grid and knock out every substation and piece of equipment connected to the problem site. Part of the Resilient Electric Grid project is the development of a superconductor cable designed to suppress fault currents that can potentially cause permanent equipment damage. This technology will allow electric companies to link substations without running the risk of fault currents cascading through the electric grid. “This will help [first responders] by keeping that backbone [of the electric grid] up and running,” Mahmood said.

In 2007, HSARPA awarded a contract to American Superconductor Corporation to develop an inherently fault-current limiting high-temperature superconductor cable (IFCL-HTS), also known as Secure Super Grids, which was the first of its kind. A superconductor offers no resistance to electricity flowing through it, thus eliminating power loss incurred with regular wires. In order to do this, however, the superconductor must be super cooled to -460°F. According to Jason Fredette, director of corporate communications for American Superconductor, when a large fault current travels through the grid, the superconductor cable heats up and stops conducting, effectively suppressing the power surge. “The wire itself can act as a smart switch,” Fredette said.

What makes IFCL-HTS cable unique is that it operates at a higher temperature than traditional superconductors, -320°F, which makes it more practical for use. American Superconductor and its partner Southwire Company developed a 25-meter IFCL-HTS cable that was tested at Oak Ridge National Laboratory (ORNL) in 2009. According to Dr. Christopher Rey, senior staff scientist at ORNL, the lab plans to test an improved version in the near future.

In addition to preventing surges, the IFCL-HTS cable can improve electrical service to dense urban areas, according to David Lindsay, director for distribution engineering at Southwire Company. Superconductor cables can carry up to 10 times more electricity than a typical copper cable, and superconductor cables transmit electricity with near zero resistance. The added capacity and efficiency is useful for large cities such as New York, where electricity demand is rising and underground space to run additional cables is limited.

The fault current-limiting superconductor cables are best suited for urban markets, according to Lindsay. In rural areas, he explained, it would likely be more affordable to use overhead power lines and other solutions to suppress power surges. As developmental testing of the cable concludes, HSARPA will explore the possibility of installing the IFCL-HTS technology in a selected location in the electric grid for an operational demonstration, according to Mahmood.

Another aspect of DHS’s Resilient Electric Grid project focuses on developing a stand alone fault current-limiting device that can be installed anywhere on the existing electric grid, according to Mahmood. DHS is collaborating with Silicon Power to develop a Solid State Current Limiter. A semiconductor switch in the device suppresses power surges in electric cables. The technology would allow utilities to incorporate surge protector capabilities into the infrastructure without replacing current cables or existing protection schemes. DHS is scheduled to hold a demonstration of that technology’s key elements at the KEMA, Inc. testing facility in Chalfont, Penn. in the fall of 2010.

These solutions would protect critical infrastructure dependent on electrical power from blackouts that not only threaten safety, but commerce as well. Power outages cost the nation approximately $100 billion a year, according to HSARPA. Having a resilient electric grid will protect Wall Street and other financial centers from power outages, according to Fredette. “If New York City goes black, that damages our economy,” he said. “This project employs superconductor technology to protect our nation’s financial centers.”

For more information on HSARPA, visit www.dhs.gov/files/grants/gc_1247254578009.shtm. For more information on ORNL, visit http://www.ornl.gov/.

Delcam’s PartMaker makes aerospace company more productive

Since implementing Delcam’s PartMaker CAM software in 2002, C&A Tool has not only been able to cope with the increased complexity of the aerospace parts made on the company’s Swiss machines, it has also become appreciably more productive. The full story can be seen on Delcam TV at http://www.delcam.tv/delcam-video.asp?VideoId=109.

Founder and President Richard Conrow began his company 40 years ago in a garage in rural Indiana and grew it into a 530-employee organisation with 750,000 square feet of manufacturing space. A portion of the sophisticated manufacturing is carried out across a bank of twenty-seven state-of-the-art, multi-axis Star CNC Swiss-type lathes. The key to success in manufacturing highly complex, highly precise components on these machines is in developing NC programs for them quickly and efficiently. To this end, C&A Tool adopted PartMaker to automate its programming.

“We can take a complex part and have it programmed in a couple of hours. There is no way this could be done on the shop floor any more,” said Mark Simpson, Supervisor of C&A Tool’s Swiss machining area.
An important factor is the Full Machine Simulation function that allows C&A Tool’s programmers to simulate the machining of a part in a “virtual reality” environment on their PC away from the shop floor. The software allows them to see exactly how the part will look on an exact machine model, detecting any errors on the part or any collisions that may occur in the machine’s working envelope, before setting up a job.
“With PartMaker, we can do more with less. The more time you take with the software, running the collision detection, the less time you spend in set-up,” commented Nathan Esslinger, Manufacturing Engineer. “An extra twenty minutes on PartMaker can save eight hours in set up during the middle of the night when noone is here to help.”
“The best way to evaluate the improvement is to look at programming time. We have cut programming time in half, easily,” claimed Mr. Esslinger. “Now we’re doing parts that we would have turned away previously because the programming would have been too difficult or time-consuming.”

Nathan Esslinger from C&A Tool claims that PartMaker has cut his programming times in half

C&A Tool must not only be ultra-efficient in its programming but in its quoting process as well. By using PartMaker and by requesting solid models from customers rather than just part drawings, time cycles and quotations can be generated very quickly.

In the current tight economic environment, C&A Tool has seen a big increase in quoting as customers look to shop for the most competitive prices available for engineered aerospace components. “Especially in this economy, a lot of people are passing parts around to get quotes. When we get a solid model, with PartMaker, instead of taking hours, quoting takes minutes,” said Mr. Esslinger. This means C&A Tool can quote on more jobs and win more as well.