Switzerland-based GF Machining Solutions (GFMS), the milling, EDM, laser and additive manufacturing (AM) machine tool manufacturer and automation and tooling systems’ specialist, has recently supplied a new ‘state of the art’ wire EDM machine to Mechlam Precision Tooling Ltd, a precision mould tool, fixturing and sub-contract manufacturing specialist based in Haydock.

The machine, an AgieCharmilles CUT P 350 Pro, was installed at the company’s 8,000ft² facility in October 2022 and is now being used to machine a range of high-precision components, that include complex and highly-accurate mould tools, inserts and associated parts, for the company’s growing customer base. The acquisition of the machine has significantly increased, and improved, Mechlam Precision’s wire EDM capacity and capabilities.

The machine’s ultra-fast processing speeds combined with quick and easy job preparation and set-up, plus its ability to consistently hit tight, tied-up geometric and dimensional tolerances, have been more than instrumental in helping the company secure more high-value work from new and existing customers, and strengthen its position within many customers’ supply chains.

Mechlam’s managing director Martin Atherton said: “We are always looking to improve and, as such, regularly invest in advanced manufacturing technologies to help make us more productive, more efficient and more competitive. Our new CUT P 350 Pro is a case in point and has helped transform our wire EDM operations enabling us to make precision parts faster, better and more economically than before.”

With business from many of Mechlam’s customers, specifically in the automotive, aerospace and medical sectors, returning to pre-pandemic levels, the company needed to act quickly and decisively to meet the upturn in demand for its high-quality machining services.

Mr Atherton added: “Our existing wire EDM resource, specifically an older machine that we had acquired some years earlier, was becoming unreliable and was creating production bottlenecks and pinch-points that, if left unchecked, would have impacted on our ability to meet customers’ lead times.”

To overcome the issue, Mechlam decided to upgrade its wire EDM capabilities and approached a number of machine tool suppliers with its plans. Although Mechlam has a good, long-standing relationship with GFMS, having invested in a number of its milling and EDM machines in the past, the decision was made to invite three wire EDM machine tool manufacturers to present their ideas and take part in a test cut to prove the efficacy of their proposals and demonstrate the performance of their machines.

Mr Atherton continued: “The part selected for the trial cut was an existing mould tool insert that we have machined in the past, and that we knew inside-out. We were particularly interested in how the machines proposed by each manufacturer would meet the high accuracy and surface requirements as well as the total processing time (from set up through to machining) involved to complete the part.”

GFMS’ CUT P 350 Pro machine used for the test cut came out ‘head and shoulders’ above the other two machines in terms of speed (set up and part cycle time) and precision. Mr Atherton said: “The test cut results plus GF Machining Solutions’ industry-leading back-up and support were major factors in us placing the order.”

Since being installed, back in October 2022, Mechlam has been ‘blown away’ by the CUT P 350 machine’s continued performance, flexibility, reliability and efficiency.

Unrivalled stability
The CUT P 350 Pro is a high-end wire EDM machine that features a number of market-leading and proprietary technological innovations. The machine is compact and features X-, Y- and Z-axis travels of 350 x 250 x 220mm respectively and can handle workpieces up to 1,000 x 550 x 220mm in size and up to 750kg in weight. It has a rigid design and build, and is equipped with GFMS’ Quadrax system which delivers unrivalled stability (and therefore accuracy) during machining operations.

Mr Atherton explained: “The mould tools, mould inserts and precision parts we machine are characterised by their high accuracies (+/-2µm) and surface finishes (Ra 0.08µm). The machine’s Quadrax system ensures we are able to meet these stringent quality requirements, even during long machining runs.”

The CUT P 350 Pro features GFMS’ Spark Track and digital generator technology — both designed to improve customers’ productivity, performance and process reliability.

Mr Atherton said: “The machine is equipped with ISPS (intelligent spark protection system) and iWire: together they have had, and continue to have, a significant impact on our performance.” ISPS monitors the spark environment in real time, adjusting the spark intensity according to individual part characteristics and features. This technological innovation reduces the potential for wire breakage during machining operations — ensuring machine uptime and optimised production.

He added: “ISPS helps reduce wire breakages that can be caused by poor flushing and/or unstable machining conditions. As a consequence, machining operations do not need to be stopped to allow for wire re-threading and our production schedules are uninterrupted.”

ISPS is particularly beneficial during lights-out, unattended operations where wire breakages can severely disrupt and compromise production planning and manufacturing output.

Running in conjunction with ISPS is the machine’s iWire innovation which, adjusts wire speeds (feed rates) according to individual part characteristics. The bottom line with iWire is that less wire is used to machine complex parts — and this delivers real consumables’ savings to the customer.

Another innovation, available on all new GFMS’ machine tools, is rConnect — a remote and secure diagnostic and trouble-shooting facility, that provides customers with instant and secure assistance in real time.

Since being acquired, Mechlam’s new CUT P 350 Pro has been operating around the clock. The machine is helping the company secure new, high-value machining contracts and is a key component in its drive and ambition to create a truly world-class machining resource and become a ‘preferred partner’ with many of its customers.