Large-Part investment delivers gains for Complete Engineering Services

A strategic investment in a large-capacity vertical machining centre is helping Carlisle-based Complete Engineering Services increase productivity, improve flexibility and strengthen its ability to machine large, high-precision components for customers across a range of demanding industries.

Supplied by Mills CNC, the new DN Solutions DNM 6700XL vertical machining centre was installed in June 2026 at the subcontract specialist’s 12,000ft² machining facility. Equipped with a Detron fourth-axis rotary table and Siemens 828D control with ShopMill conversational software, the machine is already producing complex parts for customers in sectors including motorsport, rail, power generation, renewables, timber processing, packaging and fluid sealing systems.

The investment forms part of the company's wider strategy to continually improve its manufacturing capabilities and provide customers with a comprehensive engineering service, from design support and prototyping through to machining, finishing and assembly.

Managing director Andrew Monkhouse says the business has focused on creating a true one-stop engineering resource.

He explains: “We provide customers with a one-stop engineering service that, through a range of integrated advanced technologies and the skill and experience of our staff, can deliver high-quality prototypes, pre-production and production parts from concept through to completion.”

Alongside its more traditional three- and four-axis milling and turning capabilities, Complete Engineering Services has invested heavily in advanced manufacturing technologies. These include simultaneous five-axis machining centres, wire EDM machines, 3D printing equipment, light fabrication facilities and comprehensive inspection systems. The company also manages secondary processes such as heat treatment, anodising and plating through approved partners.

This broad capability enables customers to source complete projects through a single supplier while benefiting from tighter quality control and streamlined project management.

Continuous investment
The latest investment reflects Complete Engineering Services’ long-standing commitment to upgrading its production equipment. Rather than simply increasing capacity, the company regularly replaces ageing machines with newer, more productive technologies capable of delivering higher-value work.

The DNM 6700XL is only the second machine tool purchased from Mills CNC during the company's 28-year history, following the installation of a DN Solutions Lynx 2600Y multitasking lathe in 2024.

That machine played an important role in transforming the company's small-part machining operations. Equipped with Y-axis capability, driven tooling and C-axis control, the lathe enabled turning, milling, drilling and tapping operations to be completed in a single set-up.

Prior to its arrival, components often required transfer between separate turning and milling machines, introducing inefficiencies and creating production bottlenecks.

“Prior to acquiring the lathe we were, on numerous jobs, having to perform first operations on an older lathe and then transfer parts to a machining centre for milling, drilling and tapping operations,” explains Mr Monkhouse.

“Such labour-intensive processes were inefficient, created production bottlenecks and affected our productivity.

“We needed to change things, and with the arrival of the Lynx 2600Y, with its integrated Y-axis, C-axis and driven tooling, we were able to transform our small parts processing operations.”

Floor space constraints prevented the installation of a conventional bar feeder, so the company specified a bar-puller system instead. This allows material to be automatically advanced through the spindle, enabling longer periods of unattended operation and improving productivity without consuming additional floor space.

The success of that investment, together with positive experiences working with Mills CNC, influenced the company when it came to replacing an ageing machining centre used for larger components.

Replacing an old workhorse
By late 2025, the company's existing large-capacity machining centre had been in service for around 15 years. Although still capable, the machine was becoming increasingly susceptible to breakdowns, while its dedicated operator was approaching retirement.

Rather than simply replacing like-for-like, Complete Engineering Services saw an opportunity to significantly enhance its large-part machining capabilities.

“The older machine was getting a bit long in the tooth, was more prone to breakdown and the operator dedicated to run it was about to retire,” recalls Mr Monkhouse.

“This set of circumstances provided the ideal opportunity to improve and increase our large machining capacity and capabilities by investing in a new machine.”

Having established a positive relationship through the Lynx lathe project, the company approached Mills CNC directly to discuss potential solutions.

Several key requirements were identified from the outset. First, the new machine had to feature a Siemens control system to maintain consistency across the shopfloor, where the majority of CNC equipment already uses Siemens controls and ShopMill or ShopTurn software. This would minimise training requirements and simplify program transfer between machines.

The company also wanted substantially larger travels and a bigger worktable to accommodate longer components than could be machined previously. A powerful spindle with through-spindle coolant was considered essential to maximise material removal rates during roughing operations, while a large-capacity automatic tool changer would support extended machining cycles and complex jobs requiring multiple tools.

A fourth-axis rotary table was another priority, enabling more complete machining in fewer set-ups while increasing flexibility for future work.

According to Mr Monkhouse, the DN Solutions DNM 6700XL met all of these requirements.
“The DNM 6700XL is an impressive machine and its technical specifications fitted the bill,” he says.

Delivering on the shopfloor
Part of DN Solutions’ established DNM machining centre range, the DNM 6700XL combines substantial capacity with high productivity. The machine supplied to Complete Engineering Services features 2,100mm, 670mm and 625mm travels in the X, Y and Z axes respectively, together with a 2,200mm-long table capable of supporting workpieces weighing up to 1,300kg.

An 18.5kW, 12,000rev/min spindle with 20 bar through-spindle coolant provides the power needed for demanding roughing and finishing operations, while rapid traverse rates of 30m/min help reduce non-cutting time. The machine is also equipped with a 40-position automatic tool changer, Renishaw tool and workpiece probing systems, a FilterMist extraction unit and a Detron GXA-255H rotary table fitted with a 10in chuck.

Since installation, the machine has quickly become a valuable production asset. It is currently being used to manufacture batches of stainless steel deadplates for food, beverage and packaging applications. Approximately 1.5m in length, the components require multiple machining operations, including precision holes, counterbores and chamfers, together with high-quality surface finishes.

The machine has also been used to process long shaft-type components and other complex workpieces that benefit from its extended travels and fourth-axis capability.

For Complete Engineering Services, the investment is already delivering measurable operational benefits. Faster cycle times, improved reliability, greater machining flexibility and increased capacity are helping the company respond more effectively to customer demand while positioning it for future growth.

The DNM 6700XL also reinforces the company's wider commitment to continuous improvement, ensuring it remains competitive in markets where tight tolerances, demanding lead times and high-quality finishes are increasingly expected.

Together with the previously installed Lynx 2600Y multitasking lathe, the new machining centre is helping Complete Engineering Services improve productivity, streamline workflows and enhance profitability. Just as importantly, the success of both projects has strengthened the company's relationship with Mills CNC, creating a partnership likely to support future investments as the business continues to expand its manufacturing capabilities.