Axes of power

Patterns & Moulds continues to invest for the future with the arrival of a brand new Breton Raptor 5-axis CNC machining centre. Mike Richardson catches up with the Leicestershire-based tooling experts to hear more about the progress the company is making in getting the Raptor up and running.

It’s been a busy few weeks at P&M with the installation of its new Breton Raptor CNC machining centre. The Breton team has made considerable progress in installing and commissioning the machine setup and it is now really starting to look like the finished product.

“As part of our plan to invest in the future, we took on more space mid-last year to enable the improvement of existing facilities, as well as make space for the new machine,” begins P&M managing director, Gary Lucas – who along with wife Kate, runs a family business that is never afraid to take on many of the weird and wonderful projects the various industries often throw at them.

P&M’s new 300m² unit comprises a dedicated spray and finishing department housing the company’s new Titan 10 x 6 x 4m spray/bake and curing booth. Alongside this is a new 250m² inspection and vacuum bag facility, complete with a training room for in-house training and development. Meanwhile, an extension is currently under build to one of the existing units of approximately 200m² as a dedicated stock build area to serve the CNC machines.

“We have increased our staffing numbers and we are delighted to have college leavers joining us, learning and developing in-house alongside our experienced team. We are also currently working towards Cyber Essentials plus (CE+) which will be fully rolled out in the first quarter of 2024, showing the commitment we make on cyber security.”

Let’s go large!

P&M supplies into all areas, including marine, automotive, construction, rail, aerospace, renewables, defence, and leisure - anywhere there is a need for a pattern or a mould, the company is prepared to take on most things. Its CNC capabilities enable large scale machining of single items up to 13 x 5 x 2.5m, and 6 x 4 x 2m on the Breton Raptor.

In terms of the types of performance demands placed on his company by today’s customers, price, quality and delivery are vitally important, but the personal touch, customer relationships, after sales support, and the willingness to help with a flexible approach, all help build long-term relationships. As a family business for 56 years, P&M is as invested in its employees as it is its clients.

“Our biggest assets are our team of employees,” states Lucas. “Mix their experience with the technology we have and, I feel we are unique in offering such varied skills through our motivated workforce with abilities to turn our hand to anything.

“Our long-standing partnerships - both with the client and supplier – are vital, and have brought huge benefits. Without a strong and robust supply chain, we cannot supply our customers with their tooling. Purchasing on availability and quality is just as important as price these days.”

A seamless process

I’m interested to know more about the purchase and installation of the Breton Raptor 5-axis CNC machining centre, which according to Lucas has been seamless and easy.

“Breton has been a delight to deal with from our initial enquiry, their knowledgeable approach has ensured the machine is precisely what we required. The Breton products are superb quality machines - its accuracy and surface finish quality will certainly improve the end product we offer our customers. We’ve found Breton to be honest and open and they have ensured the process has worked effortlessly.

“During installation, Breton worked professionally to get us up and running. From start to finish, it’s been an excellent experience. The installation of the Raptor meant that we first needed to relocate one of our other CNC machines. Then the excavation for the new foundations and the casting of a 120 tonne new slab could finally begin.”

The industry’s increasing use of latest large scale additive manufacturing (LSAM) technologies has not gone unnoticed by many of the UK’s leading composites manufacturers. So, what kinds of pattern & mould developments will we be seeing in the future?

“Large scale additive manufacturing (LSAM) is a very interesting technology, and one we are keeping a very close eye on,” notes Lucas. “Having installed a robotic 3D printing cell for polyurethane material a couple of years ago, we know the process and we are looking to further invest over the next 12 months. LSAM is fantastic technology that has proven to be the right way forward over and over again.”

Onwards and upwards

P&M is now looking to push into higher requirement marketplaces over the coming 12 months, particularly in the aerospace and defence sectors where tighter tolerances and engineering go into every package of work.

“After a year or two of growth and investment, we will use this year to stabilise and formalise our plans to be ready for the next chapter,” concludes Lucas. “Following the last two years of investment into our world class facilities, we have the facilities to be at the forefront of what we do - for decades to come. Meanwhile, we continue our relationships with customers that have been loyal to us for decades and also build on it by starting new partnerships.”

www.patternsandmoulds.co.uk