Birds Precision flying high with Sodick wire EDM

Nuneaton-based Birds Precision Engineering has recently invested in a refurbished Sodick AG 600L wire erosion machine supplied by Sodi-Tech UK, marking a significant advance in the company's capabilities and service offerings. This latest investment represents the next chapter in the evolution of a business that has been growing steadily since its inception over three decades ago.

The story of Birds Precision Engineering, a sub-contract CNC machine shop began in 1991 when Chris Bird established B&C Engineering in Nuneaton. What started as a sole trader operation quickly expanded, necessitating a move to larger premises. As demand grew, the business relocated and the name was changed to Birds Precision Engineering Ltd. Chris's son, Tom Bird, joined the company and immersed himself in all aspects of the operation, eventually becoming the managing director in 2023.

The latest advancement came earlier this year with the acquisition of a Sodick AG 600L wire erosion machine from Warwick-based Sodi-Tech EDM Ltd. This investment was driven by practical business considerations, as Tom Bird explained: “We are predominantly a sub-contract CNC machine shop, and we focus mainly on the special-purpose machine tool industry. We invested in the wire eroder because, in the tooling industry, there are a lot of complex components with tight tolerances.”

Before this investment, Birds Precision had outsourced wire EDM work to local companies, which created bottlenecks in their production schedules. Tom Bird continued: “We were subbing a lot of the work out to a couple of companies in the local area, but it created bottlenecks with our schedules, so we decided to bring it in-house to control it a little bit better.” This decision to bring wire EDM capabilities in-house has proven to be transformative, enabling the company to have complete control over its production process, from start to finish, while eradicating sub-contract EDM costs.

The Sodick AG 600L is a high-precision, linear motor-driven die-sink EDM machine renowned for its accuracy, speed, and superior finishing capabilities. For Birds Precision, this machine has been a gamechanger, offering several key benefits.

Remarkable precision
The AG 600L utilises advanced linear motor technology to achieve remarkable precision, with accuracy on all axes (X, Y, Z, U, W) of +/-0.001mm. This level of precision is crucial for Birds Precision, as Tom Bird notes: “Customers are always after accuracy. The components that we are machining are getting tighter and tighter on tolerances every time we see the drawings. It is a major factor, and this machine helps to set us apart as we always guarantee to hit those tolerances for our customers.”

The Sodick AG 600L machine features a linear drive system that ensures swift axis movement and immediate response, optimising spark gaps and enhancing cutting performance. The wire erosion machine can produce fine finishes, including satin and mirror finishes, thereby expanding Birds Precision’s service offerings. “It is a great machine that can be set up and left to run. Operators can then go and carry on with other jobs that need doing. So for me, being in and out of the office, I can set it up and then go and do my office work.”

Tom Bird’s enthusiasm for the machine’s capabilities is evident: “When you see the precision this machine delivers consistently, it is a game-changer. What used to be our most challenging work is now just another day. That is the difference quality equipment makes.”

This efficiency has helped Birds Precision meet delivery dates more consistently and has opened up possibilities for expanding into new sectors within the industry. The new EDM technology enables Birds Precision to achieve extremely tight tolerances across a wide range of materials, including hardened tool steels.

Tom Bird said: “For us, our tolerance demands from customers are probably in the 15 to 20µm realm, and this machine doesn't even think about it; it hits tolerance every time. In fact, we haven't had a part come off that hasn’t been right yet.”

This capability allows Birds Precision to produce complex components for various industries, including aerospace, medical, special-purpose machine tools, and the nuclear sectors. What makes this investment particularly noteworthy is that Birds Precision opted for a refurbished Sodick machine instead of a new one.

Practical considerations
This decision was driven by practical considerations, as Tom Bird pointed out: “For us, not being as big as some of the other companies out there, we don't have as big a budget. This machine has opened the door to us having access to an in-house wire eroder because it is refurbished. It was significantly cheaper than a brand new one, yet for the accuracy we were after, it has been brilliant.”

Contrary to what some might assume, the refurbished machine from Sodi-Tech is far from merely a cosmetically refreshed unit. Sodi-Tech restores each refurbished machine to factory standards through a meticulous full specification check. Tom Bird added: “All the parts of the refurbishment are genuine Sodi-Tech parts, and they were all kept at a facility in Warwick, so it was a quick turnround on the refurb. I haven't told any of my customers that it is a refurb. I have told them all that it is brand new, because it looks brand new."

Beyond the machine, Birds Precision has been impressed with the service provided by Sodi-Tech. The machine tool supplier’s reputation in the industry influenced the decision to choose Sodi-Tech. Tom stated: “The reason we chose Sodi-Tech was their brand, their reputation in the industry for EDM machining and customer service, which I can't fault. It's been brilliant.”

The training provided by Sodi-Tech was particularly valuable, featuring trainers who ‘knew exactly what they were doing’ and understood Birds Precision’s need to get the machine operational quickly. "They trained us on the parts that we were cutting. So, the afternoon they left, we were already cutting parts that needed to go out in the next couple of days.”

This practical approach to training, combined with the 12-month warranty on the refurbished machine, has given Birds Precision complete confidence in their investment.

For Birds Precision Engineering, the investment in the Sodick AG 600L wire erosion machine represents more than just an addition to their plant list. It is a strategic enhancement of their capabilities that positions them for future growth. Tom Bird continued: “Right now, it has ensured that we can keep hitting production times and delivery dates, but going forward, it will open up more doors for us into different sectors within the industry.”

When asked about the impact on his business, he concluded: “This machine doesn't just cut metal — it cuts through barriers. We are now competing for work we could not even quote on before. In this industry, you are only as good as your tools, and with this Sodick machine, we are better than we have ever been.”