3D modelling/programming boost tool and die

By introducing 3D technology - design modelling and programming - a UK tool and die maker said that these changes have developed the company's competitiveness in a very tough market.

A close partnership with a CAD/CAM supplier has enabled a UK tool and diemaker - FSG Tool and Die - to expand its business and relocate to new 4650m2 plant located in Llantrisant, South Wales.

FSG's managing director, Gareth Jenkins, said that all UK toolmakers find it hard to compete on price with competitors in low labour cost countries.

"To win business, we need to provide our customers with better service and higher quality; the commitment and support of our suppliers is crucial," he said.

Jenkins said that the major change at FSG during recent times had been the introduction of 3D design modelling and programming.

He added: "It has been a difficult learning curve and we have required considerable support to apply these applications to our processes.

We now know that these changes have developed our 'competitive edge'." FSG's CAD/CAM partner is Delcam, about which Jenkins commented: "The relationship with Delcam is all about people, there is a high level of mutual respect between both teams - we both feel that we are good at what we do.

Delcam staff regularly audit our progress to establish best practice and we like to think that we can influence the software development process." Jenkins underlined three other reasons for his company's continued progress, as follows.

* Diversity - FSG makes all types of tooling.

Main products are injection mould tools and press tools as well as thermoforming tools, and some prototyping and precision machining.

* Wide variety of customers - plastics packaging represents about a third of FSG turnover and metal packaging almost a further quarter.

The automotive industry provides just over a quarter of the business but is becoming overtaken by medical and pharmaceutical projects.

Recently, FSG gained aerospace work.

* Technological expertise - FSG concentrates on technically difficult projects tdemanding highest quality.

The company produces tooling to run 24h/day and seven days/week.

Such demanding work requires close collaboration with the product designer and the moulder - such liason is difficult twith an overseas toolmaker.

At the start of the development Delcam was not FSG's first choice.

"Our first experience with a CAM system was a disaster," related Jenkins.

"Until 2002, we had relied on manual programming at the machine tool control but we knew we needed to move to a CAM system as we were being challenged by more complex work.

We were using an alternative system for design so we chose a system that was built into that software but the results were extremely disappointing." Jenkins said that they had got to know of Delcam through the UK's Gauge and Tool Makers Association (GTMA).

"Delcam facilitated an excellent benchmarking exercise with assisted support to test PowerMILL on our applications.

We have never looked back.

We now use PowerMILL and PowerSHAPE for all the programs for our seven Bridgeports and two Matsuura machines, including our five-axis equipment." A very impotant factor in FSG's success has been a long-term commitment to training.

The company has employed apprentices since it was founded in 1961 and now has 12 apprentices in its workforce of 85.

This emphasis on training has won the company numerous awards, including the 2006 National Training Award and the Engineering Employers' Federation Apprentice of the Year.

Back to top