KS Composites on Fast Track with hyperMILL®
Melton Mowbray, United Kingdom
Key Takeaway
KS Composites accelerates complex composite and multi-axis machining by using hyperMILL®’s modular CAD/CAM capabilities, achieving faster programming, consistent processes, and high-quality results for motorsport and advanced engineering projects.
Having formed many close relationships with some of the leading lights in design and consultancy through prototype and development projects, KS Composites offers design services, FEA, and CFD. This is complemented by a 48,000sq/ft manufacturing site that supports the design and consultancy services with everything from kit cutting, fitting and assembly to wet lay composites, autoclaves and ovens, a composite shop, machine shop and much more. Whether it’s the development of new lightweight wind turbines, the production of super-efficient alternative energy vehicles or the unique demands of the aviation and military industries, KS Composites approach all projects with the same enthusiasm and professionalism.
Exhibition car manufactured by KS Composites
“We are representing motorsport’s pinnacle- high-performance, high precision. So, when making the patterns for this vehicle, they had to be of the same quality - that is what we have achieved with hyperMILL®.”
Dan Johnston, Business Development Manager at KS Composites
Very modular licenses
Discussing the relationship with OPEN MIND Technologies, Justin Tallboys-Cotton from OPEN MIND adds: “KS Composites came to us because of their needs, which are not only metallic but also composite machining. This encompasses everything from 3-axis vertical machines to complex 5-axis gantry-style machines. One thing that KS Composites liked about hyperMILL® is that the licenses are very modular, so whilst they use the 5-axis licences that we are famed for worldwide, they don’t need all of it. So, KS Composites just chose the two or three modules needed to do their work. They know they can expand if needed, but they don’t need to invest in everything up front.”
Looking at a replica race car the company has manufactured, Dan Johnston adds: “On the vehicle itself, there is a multitude of things. We have carbon composite body panels and machined GRP and 3D printed elements. We are hitting on all our core services with this vehicle. One of the first things to come into our new building was CNC machines. At that point, we identified that we needed a CAM package that could get the most out of our machines. We went to the market and evaluated the options, and it was clear from the offset that hyperMILL® was the obvious choice.”
OPEN MIND's Justin Tallboys Cotton with KS Composites Dan Johnston
KS Composites are renowned experts in manufacturing lightweight motorsport components
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KS Composites are embracing the tools within hyperMILL®
Justin Tallboys-Cotton adds: “It makes me extremely proud to see how KS Composites are embracing the tools that we have within hyperMILL®. For example, they colour-code their components and use bookmarks and templates. What this is giving them as a company is consistency throughout the process, especially when different guys’ programs work in different ways. It also helps with time to market; KS Composites can reduce the programming time to a bare minimum, ultimately getting parts onto the machines quicker to keep their customers happy.”
In conclusion, Dan says: “hyperMILL® is making our life so much easier, especially when we are making things like a show vehicle. We are representing motorsport’s pinnacle- high-performance, high precision. So, when making the patterns for this vehicle, they had to be of the same quality - that is what we have achieved with hyperMILL®.”
A KS Composites programmer using OPEN MIND's hyperMILL®