Founded in 2015, Coventry-based
Vigour Limited has grown from a single 5-axis machining centre in its workshop into a specialist manufacturer producing some of the industry's most demanding components. Central to that growth has been
Open Mind Technologies' hyperMILL CAM software, which has supported the company since day one.
Founder and managing director Ashley Hatton identified an opportunity early in his career working in subcontract machining and Formula One. While many subcontract manufacturers relied on 3-axis machining and manual programming at the machine control, Hatton saw the potential of advanced 5-axis machining combined with CAD/CAM software.
“Lots of subcontract manufacturers had 3-axis machining, and they were mostly programming at the control,” he says. “Adoption of 5-axis and CAD/CAM was barely in existence in the subcontract market.”
Rather than following the traditional route of starting with 3-axis capability and expanding later, Vigour was built around 5-axis machining from the outset. Today, the company operates four 5-axis machines, including three DMG Mori EVO50 machines equipped with automation, creating consistency across production.
hyperMILL from the startWhen selecting a CAM platform, Hatton's previous experience made the decision straightforward.
“I looked at one or two other CAM vendors at the time, but hyperMILL was the safe choice. I'd used it previously at Formula One teams, and it was very reliable,” he explains. “It's incredibly safe; the cycles are fast to calculate. It's reliable and robust.”
That reliability has become fundamental to the business. Vigour, which operates under ISO 9001 accreditation, now runs two hyperMILL seats with a full suite of additional modules.
“My business is built around hyperMILL; it's been a pillar of success for the company,” says Hatton. “It really is the backbone of the business.”
The software has become a key driver of productivity. Rather than programming an entire component before machining begins, Hatton typically creates roughing operations in around 15 minutes, loads the billet and starts machining. While the machine is cutting material, he programmes subsequent roughing and finishing operations, allowing spindle utilisation to remain high.
The process begins as soon as an enquiry is converted into an order. Automated workflows create the correct file structure, while hyperMILL imports the STEP model and quickly generates stock dimensions and workholding positions. Additional surfaces are also added to digital models to represent fixtures and vices, improving the accuracy of simulation.
Roughing operations are designed to establish reference surfaces before material removal continues. While these operations run, additional strategies are programmed using high-feed milling cutters and ball-nose tools to progressively refine the part.
Finishing programmes are then generated using hyperMILL's dedicated strategies for surface finishing, wall machining and pocket machining, all while machining continues in the background.
“The machine is always running in the background,” says Hatton.
A critical enabler of this approach is simulation technology. Vigour relies heavily on virtual verification rather than traditional prove-outs at the machine.
“There's no single-blocking or prove-outs anymore,” he explains. “We run the simulation in the software. Once it's gone through that with no collisions, it's on the machine and running.”
Feature Recognition further accelerates programming, automatically identifying holes and machinable features. “It all just takes two minutes,” says Hatton. “We couldn't imagine life without hyperMILL.”
Tackling challenging componentsVigour has built its reputation on taking on work that many manufacturers avoid. The company specialises in difficult materials, complex geometries and extremely demanding tolerance requirements.
“I want to do the parts that other people don't want to do,” says Hatton. “I see the company as an engineering solution provider, not a manufacturing business.”
The business has developed a strong position within the gas turbine sector, producing components including MAR-M247 cast turbine wheels and highly complex 17-4PH H900 compressor wheels for micro gas turbine applications. These assemblies demand exceptionally high levels of geometric accuracy, with shaft-to-wheel runout below five microns.
A notable example of Vigour's machining capability is a Formula Student car upright manufactured for Oxford Brookes University. Featuring angled holes, undercuts and tight dimensional requirements, the component required a combination of 5-axis Shape Finishing, ISO Machining and Automatic 5-axis Rest Machining strategies.
“hyperMILL makes sure the toolholder doesn't come into contact with the job, and the cutting edge is always in cut,” says Hatton. “So you don't get chatter, just sublime surface finishes.”
Alongside its manufacturing activities, Vigour has introduced its Roadmap to Employment and Alternative Route to University Programme in partnership with Solihull College. The four-year scheme provides apprentices with practical industrial experience while developing engineering and manufacturing skills.
Cutting cycle times and building partnershipsAmong the hyperMILL features that have had the greatest impact on productivity is Tangential Plane Machining using barrel tools.
“We were making a motorsport upright, and the part was taking eight hours,” recalls Hatton. “We introduced barrel tools and Tangential Plane Machining; it wiped out three hours of cycle time with exceptional surface finishes. We've been using it ever since.”
Hatton's relationship with Open MInd extends back to 2010, when he requested custom fields within the hyperMILL tool database while working in Formula One. The functionality was subsequently added and is still delivering value today.
Vigour now uses that custom data within its own in-house ERP system to track stock quantities, locations and costs.
“That's a real example of where they've taken on board what you've said and actually added functionality to the software, which I'm using today and really appreciate,” he says.
The company also benefits from responsive technical support.
“Within the hour I'll get an answer to a question. If I call up, quite often I'll get a response immediately.”
Reflecting on the role hyperMILL has played in the company's development, Hatton believes the software has been instrumental in Vigour's success.
“It's very difficult to say where Vigour would be today without hyperMILL,” he concludes, “but where it is today is a success due in large part to hyperMILL.”