An injection mould tool manufacturer that has recently seen a resurgence of tool-making in its native Ireland says ‘state of the art’ software helped the company through the recession by giving it the competitive edge that enabled it to work in ‘high end’ markets.

Alpha Precision, based in Tubbercurry (County Sligo), operates an almost full suite of VISI modules (www.visicadcam.com), which director Brendan Feely (pictured above) describes as a ‘seamless communication tool’.

He says: “Several years ago, Ireland experienced an exodus of tool-making contracts, as work went overseas — particularly to China.

“At the same time, VISI CAD/CAM software for the mould-and-die industry was developing rapidly and adding new features. Even companies that weren’t computer-literate were investing in the technology to survive.

“The software had a huge effect on the tool-making industry, giving us a competitive advantage to weather the storm. It promotes a more automated process, and our staff have developed the new skill sets needed to use VISI to its full potential.”

Explaining why he feels VISI is the “seamless communication tool that acts as the glue in the complete tool-making environment”, Mr Feely says he likens his tool-room to a football team: “We need our goalkeeper, defenders, midfielders and strikers.

"We have a variety of different machines doing different jobs, so our operators have different skills. The software is applied on the back of the machining; and because there are several disciplines — such as design, milling, wire and spark eroding — the software fits naturally into each given area.

“The operator in that area is trained only on use of the appropriate VISI module.

“Another slant on the ‘team’ analogy is likening the tool-room to a group of people from different countries, with none of them speaking a language other than their own.

"One language is design, with others including flow analysis, milling, wire eroding and spark erosion. VISI is the common language that unites all processes, ensuring that everything moves ‘fluently’ through the tool-room from one discipline to another.”

Alpha Precision has 12 employees and produces about 40 tools a year, ranging in size from 100 x 100 x 100mm up to 600 x 1,000mm — mainly for the automotive, medical, packaging and electronics industries.

Current projects include: producing tools with a large number of cavities for one of Alpha Precision’s many medical customers; and a contract for two-shot plastic injection tools that involve ‘over-moulding’.

Mr Feely says: “Although two-shot production adds another element by involving a second material and process, VISI keeps it simple and efficient.”

Medical challenges

Mr Feely says that with VISI programs running the company’s high-speed milling on Röder and Makino machining centres, the micron levels of accuracy and finish required by the medical industry are readily achieved.

“We use a 42,000rev/min spindle speed for finishing very fine details, and we generally machine our electrodes on a Makino F3, with particularly high-definition electrode work done on a Makino F5.

“Using VISI Machining, we can quickly produce a highly polished medical part with fine detail, a milled finish and a split line within micron accuracy. VISI also powers our Charmilles spark eroding machines and Mitsubishi wire eroders.”

Mr Feely says that with Alpha Precision having invested in many VISI modules — including Modelling, Analysis, Flow, Mould, Progress, the wire cutting and electrode systems, along with 2-D Milling, 3-D Milling and High Speed Milling — the software is used at every stage of the tool-making process, beginning with providing an accurate quotation for the customer.

“When an order has been placed, we work closely with our customer’s moulders on the design concept, including flow analysis and tool layout.

“Once the 2-D design is broken down and we have the tooling in full 3-D, we begin to see the full capability of VISI, which controls everything from design, through milling to EDM in one environment.”

Although injection mould tools form the core of Alpha Precision’s business, the company also provides tools for blow moulding and forming; it also has experience in specialised press tooling.

It is currently embarking on what Mr Feely describes as “an exciting new journey, working closely with one of our major customers on injection moulding rubber”.