Joining forces on making large plastics moulds

Discussions and machining collaboration with another sub-contract toolmaker helped a UK toolmaker deliver the largest plastics moulding tool it had ever made.

Weighing in at 7.5 tonnes, a boot liner tool for a UK executive car manufacturer was the largest ever produced by WHSmith and Sons (Tools) of Sutton Coldfield, UK.

However, with capacity stretched WHS required the services of DMS-Diemould, to ensure tight delivery deadlines were met.

Employing 370 people and 95 injection moulding machines across 24/7 operations, WHS is a leading player in the UK market for moulded plastics components.

It has a toolmaking capacity of GBP 6 million per annum with 21 people deployed across design and manufacturing disciplines within its tooling department.

However, when a prestige motor manufacturer approached WHS with an enquiry to produce boot liners, the company knew immediately that the tooling would be bigger and heavier than anything it had produced in its 60-year history.

"At 7.5 tonnes it was a big step up in weight for us," confirms toolroom and design manager, Richard Madeley.

"In fact we had to invest in larger CNC machining centres, EDM and wire erosion machines to cope with the project." Despite this investment strategy WHS still did not have enough capacity to meet the demanding delivery schedule set out by the customer.

It was during discussions with DMS-Diemould regarding a suitable multi point feed hot runner system, that the company discovered the capability for large 3D machining offered by the High Wycombe company.

"We had used DMS-Diemould many times for standard mould tool parts such as plates, pins, pillars, bushes and ejector pins, but not for anything on this scale," says Richard; "We had approached DMS-Diemould to quote for a hot runner system and it was then that we realised they could help further." After brief negotiations it was agreed that DMS-Diemould would undertake pre-machining on both the punch and die to within 1mm, as well as bolster machining (to a finish).

WHS would then provide finish machining of the punch and die at Sutton Coldfield.

As part of the agreement DMS-Diemould also supplied the hot runner system, described by WHS as integral to the whole project.

"It was a big, big tool for us," states Richard, "manufactured to very tight deadlines.

The project was extremely important for both the customer and ourselves.

There was plenty of risk involved but, thanks to the co-operation of DMS-Diemould, we were able to meet the schedule and keep the customer happy.

There was always a likelihood that the project would have been sourced overseas if our customer was not convinced we could meet the timescales involved." He adds that the scarcity of 'off the shelf' steel compounded the original problem, saying that the extra 'clout' of DMS-Diemould ensured enough steel could be purchased to complete the tooling.

Close liaison with DMS-Diemould was crucial," he concludes.

"Without their structured communication and attention things would have been difficult.

All of the key delivery dates required by WHS and quoted by DMS-Diemould were hit without problem." The mould tool for the boot liner was commissioned at the Sutton Coldfield facility of WHS approximately six months ago and is now in full production.

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