New machine delivers additional capacity, flexibility and process efficiencies

Rapid Precision Engineering, a leading aerospace component manufacturing and chemical processing subcontract specialist, has invested in a compact DN Solutions DEM 4000 vertical machining centre equipped with a 4th-axis unit from Mills CNC.

The investment has provided much-needed additional capacity, enabling the company to meet a significant rise in demand for small, complex and high-precision landing gear components from existing aerospace customers.

Mills CNC, exclusive distributor of DN Solutions and Zayer machine tools in the UK and Ireland, supplied the Fanuc-controlled DEM 4000, featuring a 7.5kW, 8,000rpm spindle, 20-tool ATC and Nikken CNC202 4th-axis rotary table. Installed at Rapid Precision's 15,000 sq ft Liverpool facility in July 2026, the machine is now producing thousands of high-precision landing gear fasteners alongside other aerospace components.

A rapid overview
Established in 1993, Rapid Precision initially served a broad range of industries before focusing on aerospace manufacture in 2003/04. The company specialises in machining, treating and supplying high-precision components to landing gear manufacturers.

Alongside a well-equipped machine shop, Rapid Precision has developed a range of in-house processes including NDT, painting, passivation and cadmium plating. The company is ISO 9001, AS9100 and NADCAP (Merit) accredited, with aerospace work now accounting for more than 95% of annual turnover.

DEM 4000 investment
Earlier this year, Rapid Precision was informed by key aerospace customers that production requirements would increase significantly.

Paul Brennan, owner and director, explains: “Earlier in 2026, a couple of our aerospace customers informed us of their intention to significantly ramp up their production requirements.
“We could see, straight away, that such an increase in volumes would put pressure on our existing machining resources - specifically on one of our vertical machining centres with 4th-axis processing capabilities.

“Having crunched the numbers, we made the decision to invest in a new machining centre with a 4th-axis rotary table as a route to improving throughput and avoiding production bottlenecks and potential disruptions to customer delivery schedules.”

Rapid Precision and Mills CNC
Rapid Precision has worked with Mills CNC since 2001 and, before purchasing the DEM 4000, had acquired five CNC lathes and three machining centres from the supplier.

Mr Brennan says: “We have a strong partnership with Mills CNC, and the machines they have supplied to us in the past are reliable and deliver excellent cutting performance, high precision and machining flexibility.

“We acquired our first three Puma multi-tasking lathes from Mills in 2001, 2004 and 2007, respectively, and all three are still going strong!

“As a consequence, whenever we are in the market for a new CNC lathe or machining centre we invariably make Mills CNC our first port of call.”

A DNM 4500 machining centre supplied in 2021, complete with a Nikken 4th-axis rotary table, had already demonstrated the productivity benefits of multi-sided machining in a single setup.

Why the DEM 4000?
After reviewing its requirements, Rapid Precision concluded it needed 4th-axis capability rather than the larger capacity offered by another DNM 4500.

“We needed the 4th-axis capability but didn’t need a machine with such a big table,” explains Mr Brennan.
“Because we had previously invested in a new DEM 4000 from Mills CNC in 2020, we already liked, and were well aware of, the machine’s capabilities.

“By investing in a second DEM 4000 and equipping it with a 4th-axis unit, we were confident that programs and processes that we had developed for machining small parts on the DNM 4500 could be transferred over and used on the DEM 4000.

“This solution would not only provide us with additional machining capabilities but would also help free-up capacity on the DNM 4500 - a real win:win situation.”

New DEM 4000 in action
Since installation, the machine has been used continuously to produce a range of small, high-precision components, particularly aerospace landing gear screws and fasteners.

Mr Brennan says: “We previously machined the screws on one of our older manual milling machines. This was achievable when the volumes required were relatively low but when the quantities required went from 3000-off to 15,000-off, we knew we had to think outside the box and develop a new approach.

“This increase in demand was one of the main catalysts driving the new DEM 4000 machine tool investment.”

The screws involve re-machining, modification, treatment and testing, including thread modifications, head alterations, drilling precision wire-locking holes, cadmium plating and NDT inspection. Custom fixtures mounted on the 4th-axis unit allow batches of parts to be completed in a single setup.

“This is a far more efficient and faster process than what we had before,” says Mr Brennan.
When not producing fasteners, the machine is used for other landing gear components, combining 4th-axis and conventional 3-axis machining.

Initial benefits
The DEM 4000 investment has enabled Rapid Precision to increase capacity, improve process efficiency and free up resources on its existing DNM 4500. Within weeks of installation, the machine had helped boost productivity, reduce backlogs and minimise the risk of production bottlenecks as aerospace demand continues to grow.