Every second counts at CA Models

Stirling-based www.camodels.co.uk CA Models, a specialist in high-quality, fast-turnaround additive manufacturing (AM) components, is using two cutting-edge Sodick wire-erosion machines supplied by Sodi-Tech EDM to optimise the process of removing 3-D printed parts from their build platforms. With sectors such as Formula One (F1) developing cars for the 2023 season, the new Sodick machines are making a real difference to operational efficiency at this progressive and highly successful company.

Established in 1983, CA Models sets the standard for excellence in rapid prototyping. Providing a varied, extensive and streamlined service to meet the challenges and demands of a growing market, the company has five different AM departments, including metal laser sintering. This process allows components to be 3-D printed in aluminium, titanium and steel. The 35-employee company can also provide both finishing and optional post-machining services.

Clark Campbell, CA Models founder and managing director, said: “We had two Sodick wire EDM machines that were still running well but getting on in years, so I felt it was the right time to bring in some new technology for the next decade. The latest Sodick machines are even more accurate and faster and as we are in the ‘quick’ business, where just about every client wants their parts yesterday, the new machines are already making a significant difference. Every time we have a really complex, accurate part to produce — the clock is ticking.”

With two Sodick machines already in-situ and proving their worth over many years, the company had no hesitation in selecting Sodi-Tech EDM to upgrade the existing equipment.

Mr Campbell added: “I think Sodick technology is brilliant and the reliability of the machines warrants some loyalty in my opinion. I went to an Open Day at Sodi-Tech EDM’s Warwick facility and was really impressed when I saw the latest generation machines, and I am certain they will have a big part to play over the coming years.”

Installed in September 2022, the new Sodick ALC600G and ALC800G wire EDM machines are already very busy. Mr Campbell continued: “For example, take a titanium build platform with 14 motorsport components on the base — when the 3-D printing process is complete, the entire platform goes into our furnace for heat treatment for 24hr, after which we wire-off all the components from the base plate using our Sodick technology, and as the wire cuts so finely we do not lose any dimensional accuracy.

“Furthermore, the machines wire so quickly that we get a head start in finishing the components. Although this process is the underlying reason behind our investment, we also get many sub-contract CNC machining projects, some of which lend themselves to wire EDM. It is great to have that flexibility, particularly for complex, intricate parts required by sectors like F1.”

Performance boosting technologies
The ALC600G is a rigid linear motor driven wire EDM machine that offers features such as Sodick’s next-generation SPW control with Smart Pulse Generator and other performance boosting technologies. While offering X, Y and Z axis travels of 600 x 400 x 350mm, CA Models thought it prudent to also invest in the larger Sodick ALC800G wire EDM, which provides 800 x 600 x 500mm (Z-axis option of 800mm).

Mr Campbell explained: “As far as wire EDM is concerned it is nice to also have a larger machine as we sometimes get large or unusual requests. I think we are the only company in the UK to have the ALC800G model.”

Without the Sodick wire EDMs, CA Models would have to remove AM parts from base plates using its large bandsaw, which is far from ideal. He added: “It is something we have done before, but it always feels a little unsafe and not exactly best-practice in my opinion. Wire EDM is far more practical, efficient and effective. Furthermore, once finished, the support plate looks brand new and ready to use again, which is really helpful.”

Although CA Models serves clients across a host of industries including aerospace, defence, medical and energy, motorsport is among the busiest, particularly F1, where teams are designing and manufacturing parts for next year’s cars.

“I think we could be particularly busy this time around as F1 currently has one dominant team, so the others are very keen to make up ground — we received a nice order last week from a team towards the back of the grid, who should really be towards the front.

“These are aerodynamic body parts made from aluminium that we will additively manufacture and finish in-house. Undoubtedly, the parts will end up on the Sodick machines for base plate removal — it is something we now rely on.”