Holes down to 0.25mm diameter can be produced and for larger electrode applications a component size of up to 600mm x 700mm can be accommodated. Using specialised equipment developed and produced internally, fan shaped holes commonly used for cooling holes on aerospace components can be produced.  For complex die sinking operations, (e.g. production of seal slots in Nozzle Guide Vanes), electrodes can be manufactured in house using both the Wire EDM and conventional CNC facilities. These facilities are supported by AutoCAD and XCAD CAD/CAM software meaning component information in electronic formats can be accepted and processed directly to the machines.

All of the Wire Erosion machines have APTII software installed for gear cutting, top and bottom different shapes and automatic wire threading.  The ability to run unattended for extended periods means that this process can show considerable savings over conventional techniques.  Again both machines are interfaced to the CAD/CAM system allowing for DNC links.

The three axis EDM Ring Drilling machine is of a type commonly used by aero engine manufacturers for the production of combuster cooling rings.  This machine has been comprehensively upgraded to include full 3-axis CNC control and modern generator technology.  Components up to 1000 mm in diameter can be processed and the operations range from single features up to multiple holes produced in one pass.  Tooling for the machine is produced in house and includes electrode holders, component fixtures and nose guides (including low cost moulded items).

This facility was specifically developed for the final machining and shaping of honeycomb structures after brazing into finished components.  By final machining as an assembly either as a complete ring or in segments machined simultaneously an accurate finished size can be achieved without the machining and deburring problems associated with conventional techniques.  Components up to 1000mm in diameter can be accommodated and complex forms can be machined in one cycle.  Electrodes are produced by CNC machining and therefore can be produced directly from data supplied in electronic formats.  For smaller, segmented parts, which do not require radial processing we have developed specialised techniques which utilise die sinking operations to produce the final shape and size.

One of the latest developments in the EDM process High Speed EDM utilises de-ionised water as the dielectric medium.  As a process it has significant advantages over conventional EDM both in terms of speed, depth to diameter ratios and environmental impact and is therefore utilised on components where conventional EDM would be impractical. Alongside the 4-axis CNC vertical machine is a HSW Ring Drilling machine capable of handling cooling rings of up to 2 meters diameter utilising the techniques and tooling previously developed.  High quality water of less than 0.5ms is provided by a Kinetico water processing plant which also supplies water for the Wire EDM and Nuclear Clean Room.       

Incorporated as part of the non-conventional machining cell are a 5 axis YAG Laser and a 2.5Kw CO2 Laser. The YAG Laser is mainly used for high speed production of cooling holes in fabricated and sheet metal parts and the CO2 for profiling of sheet metal items up to 8mm thickness. As with all special processes both are controlled by written procedures and data cards and supported by a range of post processing treatments to ensure the quality of the finished part.