Since the hyperMILL® and hyperCAD® introduction the benefits are evident. The very first job produced internally was a 6 cylinder air-box epoxy male pattern that required a carbon mould tool. Then we fitted an oil mister system and progressed to machining alloy moulds these were previously manufactured externally with a lead-time of seven days per part with three parts completing the assembly (21 day total); Reverie wouldn’t have won the contract based on this time scale. By utilising hyperCAD® and hyperMILL®, the company completed all three components of the project in the seven day timescale, reducing lead times by 40%.
The ability to machine carbon fibre components to high tolerances in house has also been of huge benefit and again coupled to our Faro arm and inspection software allowed us to machine and produce and control components time and again to high tolerances.
On a project to reverse engineer in CAD here and produce an 18 foot skiff mast extension and spreader assemblies for a sailing boat, three parts were required and each needed a two-piece tool for production. Externally produced, each tool had a minimum lead-time of three days – a total of three female 2 piece tools. By conducting this project internally with hyperMILL® and its 5-axis machine, the entire contract was completed in 3 days.
As Mr Farren concludes: “Since acquiring the 5-axis router and the hyperCAD® and hyperMILL® packages, we have improved cycle times, product quality and reduced our overall lead-times. Most impressively, our capabilities have increased beyond recognition and this has enabled us to win new orders and bring in work previously outside our scope. This and the ability to develop and grow our own product completely in-house, are the underpinning factors in our turnover growing by over 30% in the last 12 months. Our world renowned product range includes carbon fibre steering wheels, seats, single and dual element wings, rear diffusers, lotus specific fitment parts, cam covers, air boxes, inlets, scoops ducts and filter kits, plus much more for the motorsport sector. Without the new machining capabilities and the OPEN MIND software, the company growth and the extensive product range wouldn’t have been possible.”