Bristol-based MACH Machine Tools, a leading supplier of CNC and manual machines and machine shop equipment to UK and Irish component manufacturers, has recently supplied Hill Helicopters Ltd, a vertically-integrated manufacturer of luxury private helicopters, with two new manual machines.

Comprising a MACH VS-1SP (Super Precision) vertical turret-type mill and a MACH L-1340 lathe, the machines were installed at Hill’s modern 5,250ft² development centre in Rugeley, Staffordshire in May and October 2022, respectively.

The investment in both MACH models was made to increase the machining capacity and capabilities of the company’s newly-established toolroom and ‘free-up’ its advanced, production-led CNC machine tools from having to be available to undertake routine and less complex and critical machining operations.

Although only recently acquired, the two MACH machines have already proved their worth and are now an important part of the helicopter manufacturer’s in-house machining resource.

The two MACH machines, along with other manual equipment, have been installed in a specially-designated toolroom within Hill’s machine shop, which plays an important ‘supporting’ role in helping the company achieve its daily production targets. They are currently focused on designing, developing and machining high-precision prototypes and pre-production parts (and their attendant machining processes), for Hill’s HX 50 (private), and HC 50 (commercial), helicopter platforms.

To date, the MACH machines have been busy machining one-offs and small batch series as well as machining intricate features, including thread forms on shafts, on specific parts. The machines are also being used to manufacture a range of jigs and fixtures which, when completed, are transferred over to the production-oriented CNC machines in the machine shop.

Mark Webb, Hill Helicopter’s lead production engineer, said: “The MACH machines are accurate, fast, flexible and reliable, and are helping us improve our productivity and process efficiencies. Our toolroom facility acts like a ‘business within a business’. It exists to serve and support our wider machine shop needs and takes pressure off our production-oriented CNC machines which, to meet our tight deadlines, are always in high demand.”

The acquisition of the two MACH machines followed a chance meeting earlier in the year between Mark Webb and representatives of MACH Machine Tools at MACH 2022 in Birmingham.

Mr Webb said: “We attended MACH 2022 primarily to look at acquiring a range of ancillary machine shop equipment like wash tanks, welding kit, rumblers and polishers, for our machine shop.

“During our visit we came across MACH Machine Tool’s stand and there, in plain view, were a number of manual machines that I believed could do an important job for us. I met Dave Andrew from MACH Machine Tools to discuss our requirements and, after agreeing the scope and scale of the investment and finalising all the details, ordered a manual mill and a manual lathe there and then.”

With a VS-1 SP already in stock and available for immediate delivery, the decision was made by MACH Machine Tools to loan Hill Helicopters an ex-demo L-1340 lathe from its showroom until a new lathe could be delivered.

Mr Webb reflected: “We appreciated MACH’s flexible and proactive approach that would enable the mill and lathe to be delivered to us at the same time.”

Although MACH Machine Tools’ involvement with Hill Helicopters is currently limited to the supply of one manual mill and one manual lathe, this could dramatically change in the future. A planned move in 2024 to a brand new, 330,000ft² manufacturing facility in Stoke, to enable Hill Helicopters to ramp up production, presents opportunities for the relationship between the two companies to grow.

Mr Webb said: “We will be increasing our headcount from 40 to 400-plus in the next few years and, to help address future skills shortage issues and problems recruiting talented staff, will create an apprentice training school at the new facility.

“To ensure new apprentices learn basic and foundation level engineering and machining skills and competencies, it is our intention to invest in a number of additional manual machines to train them.”