Founded in 2003,
Friction Technology Ltd began manufacturing industrial brake and clutch components in the West Midlands. As demand grew and the original site reached capacity, the business relocated to the North Wales town of Caernarfon, which has a long history in this sector, having previously hosted the Ferodo factory for several decades. Friction Technology now operates from a modern facility there.
As requirements for precision and productivity increased, Friction Technology needed to upgrade its manual machining equipment and got in touch with
Haas Automation Ltd, Norwich, to explore various CNC options. Taking up the story, Gethin Magee — Friction Technology’s production manager — said: “I was new to the role at the time, so having the right support was crucial. Ian Lowe, the Haas sales manager for the region, took the time to understand what we were trying to achieve, then guided us through the selection process and recommended the machine that would best suit our applications and future plans.
“The discussions with Haas resulted in our first CNC investment — a Haas VF-2YT vertical machining centre (VMC) that was chosen for its extended Y-axis travel and 8,100rev/min direct-drive spindle. Moreover, the quality of the machine stood out straight away, plus we found it very user friendly; and because the control system is common across the range, investing in further Haas machines when we needed to increase capacity would be much easier.
“We have recently achieved EN9100 Aerospace and Military certification, which reflects the fact that the programmes we support require consistently high surface finishes and the tightest tolerances. Our Haas machinery delivers the precision, repeatability and finish quality required by aerospace and defence applications.”
Further installationsFriction Technology subsequently expanded its CNC machining capability with the addition of a VF-4 VMC and, most recently, a VF-4SS Super Speed VMC with a 12,000rev/min direct-drive spindle and a high speed 30+1 side-mounted tool changer. “The Super Speed machine has delivered a significant uplift in performance on demanding work. Indeed, we can really push the end mills to their limits, allowing us to cut our cycle times by 25% — and we make full use of the high-speed machining capability, which helps with toolpath motion through corners and improves both surface finish and overall part quality.
“Furthermore, the WIPS wireless probing system also makes a big difference, saving a lot of set-up time and ensuring our work is always accurate by allowing automated probing of tools and workpieces, thereby reducing manual intervention and helping maintain consistent accuracy across repeat production runs.”
Orders range from small batch quantities of around 10 components through to high-volume production runs of several thousand, supplying customers worldwide in sectors that including marine, wind energy, agriculture, and construction. The company supports customers at multiple stages of the manufacturing process, from initial concept through to finished parts.
Mr Magee continued: “We work directly from customer drawings but also offer a full in-house design service. Using Fusion 360 for CAD and CAM allows us to manage both design and machining within a single workflow. Moreover, we find it rewarding to be involved in a project from the very start and see it through to completion.”
Turning capacity was the next requirement for the workshop, and after reviewing pre-owned options Friction Technology again turned to Haas Automation UK. “We wanted peace of mind when buying pre-owned. With Haas, the machines are fully refurbished and supplied with a warranty, so you know you are getting something reliable.”
Productivity and consistencyThe company selected a TL-1 Toolroom Lathe, a CNC machine designed to replace traditional manual lathes while offering far greater productivity and consistency. “Programmed through the Haas control, the TL-1 provides a straightforward and accessible route into CNC turning, particularly for one-off work and small batch production.
“Furthermore, because this machine is fully guarded, the safety aspect of running a turning centre is taken care of, which gives me real peace of mind. It is also much faster than the machines we previously used; and because we can machine multiple operations in a single setup, our overall set-up time has been reduced.”
Following the success of the TL-1, Friction Technology next invested in a larger pre-owned turning centre, adding an ST-20Y (pictured right) with a Haas bar feeder that is interfaced directly with the Haas control. “With its Y-axis capability and a C-axis sub-spindle, the machine delivers a complete done-in-one machining solution. From bar feeding through to turning and milling, everything is completed in one cycle, with the parts catcher delivering the finished component. We are producing some very complex parts on this machine.
“One of our earlier VF-4 machines has now been dedicated to machining friction component production and is used exclusively for dry machining operations. For these, we not only developed a bespoke vacuum table to securely hold friction sheets during machining but also produce our own cutting tools in-house. Being able to design and make our own fixtures and tooling gives us complete autonomy over the process and the finished result, and that level of control is important to us.
“Ongoing support has also played a key role in the company’s long-term relationship with Haas Automation. We have been impressed with the after-sales service, and Richard Ratcliffe G — our Haas applications engineer — was thorough during our on-site training and is always available when we need support. We have stayed with Haas because the service has been second to none.”