Advanced Manufacturing (Sheffield) Ltd (AML) is a sub-contract manufacturer that works mostly with major players in the aerospace industry, producing complex hard-metal parts. Formed in 2008, the company started by offering manufacturing, training and consultancy to aerospace companies and Tier One suppliers; in 2010, it extended its capabilities with its own manufacturing facility, producing critical parts such as blades, disks, blisks and combustion-casing components.

It is also a Tier Two member of the The University of Sheffield Advanced Manufacturing Research Centre with Boeing (AMRC) and benefits from a close technological relationship with that organisation, to continually enhance its machining capabilities.

AML managing director Gareth Morgan was one of the first 10 people to work at the AMRC when it was formed in 2001. However, the fact that it could not offer its customers commercial manufacturing led him to form AML to deliver this service.

By combining technology and experience from AMRC with machinery from Coventry-based DMG Mori Seiki UK Ltd (www.dmgmori.com), AML routinely offers its clients metal removal rates two- to three-times higher than could previously be achieved. “DMG Mori always came out high on the list for machine up-time, service, rigidity and repeatability; without these characteristics, it would be impossible for us to achieve the results we do.”

AML currently has six DMG Mori machines: one NT5400, two NT4300s, one NMV5000 and two NMV8000s. It also has a Mitutoyo CMM, Factory Master MRP, NX CAD/CAM and Vericut software. Dr Morgan adds: “We chose DMG Mori machines for their five-axis capabilities, as they give us maximum flexibility for the wide range of parts we produce.

In addition, my experience with these machines has given us an insight into ways of maximising their capabilities by optimising factors such as work-holding and cutting methods. Where necessary, we also have access directly to Japan through dedicated DMG Mori service personnel for more advanced technological questions.”

AML chairman Nigel Lane says: “For Tier One aerospace suppliers, stability of supply is a major factor, so avoiding problems during manufacture is key to a good relationship. The technology and equipment we use is aimed at eliminating uncertainty, shortening lead times and reducing cost. We are already well recognised in the industry for our advanced capabilities.

"Our relationship with the AMRC and DMG Mori gives us access to extra resources — both in machining capacity and in know-how — and we are currently developing plans for a 50% expansion in our manufacturing facility. The first stage is already underway with a new DMG Mori NMV8000.”