Engineering start-up invests in a new MACH MDS 845-8T milling machine equipped with the advanced DynaPath Control and experiences significant productivity and process efficiency gains.

MACH Machine Tools, a leading supplier of CNC and manual machine tools and machine shop equipment to UK and Irish component manufacturers, and part of the Vigilance Group, has recently supplied PMR Developments & Engineering Ltd., a precision subcontract specialist start-up, based in Hereford, with a new toolroom mill.

The machine, a 3-axis MACH MDS 845-8T, equipped with the advanced DynaPath WinDelta CNC control system, was initially installed at the company’s recently vacated 350sq. ft. machine shop facility in Ledbury back in June 2022.

Following PMR’s recent relocation to larger premises, completed in March 2023, the MDS 845-8T machine has now been re-installed, in double quick-time, at the company’s new 1,200sq. ft. facility in Hereford, with a little help from MACH Machine Tools’ service engineers.

Increased machining capacity and capabilities

The MDS 845-8T is the most recent machine tool investment made by PMR in its three-year history and has taken its place alongside a new mini mill and a pre-owned 2-axis lathe both acquired by the company in 2021.

Since being acquired, the MDS 845-8T has been put though its paces machining a range of precision components including injection mould tool inserts and associated parts for a number of customers in the automotive and medical sectors, as well as new and replacement industrial equipment parts.

These parts, typically machined in small volumes from a range of different materials, are characterised by their tight geometric and dimensional tolerances and their high surface finishes.

To meet customers’ lead times and ensure that machining contract requirements are achieved on time and in budget, PMR regularly pushes the MDS 845-8T’s capabilities to the limit in order to reduce part cycle times.

Where feasible, high material removal rates (MMR) involving extended depths of cut (DOC) and optimised speeds and feeds are employed – all to good effect.

Says William Homes, PMR’s owner and director:

“The investment in the new MDS 845-8T has significantly increased our machining capacity and improved our capabilities.

“The machine’s rigid design and build, powerful spindle technology, large worktable and eight-position ATC mean we can machine a range of precision parts quickly and efficiently – meeting customers’ stringent lead times and part quality requirements.

“The MDS 845-8T is powerful, fast, accurate and flexible and, although classified as a ‘toolroom mill’, such is its technical specification and processing capabilities, that it is much more a production-oriented rather than toolroom machine.”

Investment rationale and decision

PMR’s decision to invest in a new MDS 845-8T was made for a number of reasons.

As with all new engineering business start-ups, an imperative for PMS was the need to quickly establish its name, raise awareness about its capabilities and build a solid reputation as a reliable supplier of high-quality, competitively-priced machined components - delivered on-time, every time.

To help generate and secure new machining contracts and to strengthen its position within new and existing customers’ supply chains, the company made the decision, in early 2022, to ‘beef-up’ its in-house milling capabilities.

Explains William Homes:

“You simply can’t afford to promise to meet customers’ machining and production needs and requirements if you don’t have the necessary resources at your fingertips.

“It can take years to build a reputation and only minutes to lose it.”

To avoid these pitfalls and help the company improve its output and production efficiencies, PMR made the decision to invest in a new milling machine.

Continues William Homes:

“From a reliability perspective we decided to go for a new (as opposed to a used) machine and, having already established good relationships with the Vigilance Group, through its Machine Tool Sales Online (MTSO) operation, approached them with our requirements.”

As part of the company’s decision-making process and to help it narrow down its investment choice, PMR visited MACH Machine Tools’ showroom in Bristol to see a new, recently-introduced MACH MDS 845-8T in action.

“I liked what I saw”, remembers William Homes. “The MDS 845-8T’s impressive technical specification that includes a 5.5kW/8,000rpm direct-drive spindle, an 850mm x 420mm worktable with a 220kg maximum load, and an 8-position ATC - plus the machine’s competitive price and quick availability, made the decision a ‘no brainer’”.

The DynaPath Control

An integral part of the MDS 845-8T machine tool demonstration given to PMR included an in-depth presentation and appraisal of the DynaPath CNC Control system – a key and differentiating feature on all new MACH machine tools.

Continues William Homes:

“The versatility and flexibility of the DynaPath control system are impressive.

“Straight-off-the-bat, we liked the control’s large 15.6” LED touchscreen, its clear and logical navigation and its simple-to-use and understand menus and operation screens which all help reduce set-up times and prevent input errors.

“But what really clinched the deal, was the DynaPath control’s on-board features that I knew would make us more efficient and our life easier.”

Specific strengths and advantages of the DynaPath control, from PMR’s perspective, included:

1) The control’s ability to accept multiple program formats via its in-built USB, ethernet and wireless interfaces.

The MDS 845-8T’s post-processor technology is sophisticated and adaptable and allows us to run multiple different posts from other machines”, explains William Homes.

2) The control’s inherent flexibility that allows it to use ISO and Conversational programming on the same platform.

“I use ISO programming whereas my father is more comfortable with conversational programming. The MACH MDS 845-8T caters for both approaches”, says William Homes.

3) The control’s 1000 block look-ahead capability allows the machine to ‘look-ahead’ in the toolpath and anticipate future moves in advance, resulting in fast, accurate and smooth machining.

“Machining mould tools and inserts etc., means that we need this capability”, explains William Homes.

4) The control’s Wi-Fi enabled, remote 24/7 service facility delivers real time technical and applications’ assistance and support to customers.

“It’s really important, especially with a new machine, to have this level of support”, says William Homes.

Efficiency and productivity are critical for every manufacturing company – possibly more so with a new start-up trying to make its mark.

Concludes William Homes:

“The DynaPath control has helped us significantly reduce job set-up times and to respond quickly and decisively to customers’, often last minute, critical part machining requirements.

“The MDS 845-8T mill with the DynaPath control has already proved its worth on many occasions, and the continued after-sales support provided by MACH Machine Tools has been exemplary.”

About PMR

Established in 2020, PMR is a precision subcontractor specialising in the design and manufacture of prototypes and the machining of one-offs and small batch series.

The company, through the owner and director’s tooling and moulding background and experience, provides a range of integrated services to mould tool (injection moulding) manufacturers, serving and operating in the automotive and medical sectors.

These services include:

a) Design for Manufacture (DfM), reverse engineering and technical consultancy including Mould Flow Analysis (MFA)

b) The design, manufacture and testing of new mould tools, mould inserts and associated tooling

c) The design and manufacture of jigs and fixtures

d) Mould tool repair, refurbishment and modification.