1 nottingham.ac.uk/pmc Precision Manufacturing Centre Providing integrated solutions for industry nottingham.ac.uk/pmc @UoNPMC
1nottingham.ac.uk/pmc
Precision Manufacturing CentreProviding integrated solutions for industry
nottingham.ac.uk/pmc
@UoNPMC
2 3Precision Manufacturing Centre nottingham.ac.uk/pmc
ContentsForeword 4An Introduction to the Precision Manufacturing Centre 5Services for business 6Services for small and medium businesses 7Facilities 8Equipment 10Precision Micro Machining Centre 12Precision Milling Machine 13CNC Machining Centre 14Ultra-Precision Lathe 15Micro Injection Moulding 16Prototyping 17Micro Precision Spark Erosion EDM System 18Micro Wire EDM 19Wire EDM System 20Micro Coordinate Measurement Machine 21Multi-Sensor Measurement Machine 22Non-Contact, White Light Optical Profiler 23Scanning Electron Microscopy 24Optical Microscopy 25Case studies 26Testimonials 27
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ForewordThe Precision Manufacturing Centre is a world-leading centre of research expertise. Our world-class facilities have some of the most uniquely accurate machines in the world. We have state-of-the-art, high and ultra-precision manufacturing equipment and unrivalled engineering expertise. These hold the key to solving the most rigorous and complex engineering challenges.Our centre supports the complete manufacturing lifecycle including digital engineering, component manufacture, high precision assembly, verification and inspection. You are welcome to visit the Precision Manufacturing Centre situated in the state-of-the-art Advanced Manufacturing Building at the University of Nottingham, to take a good look at our facilities and to discuss your advanced manufacturing requirements.
Professor Svetan Ratchev Director of the Precision Manufacturing Centre
IntroductionThe Precision Manufacturing Centre (PMC) was established in 2003 and provides a range of world-class services to industry.
These services range from the development of new product designs and manufacturing techniques to pilot production of low-volume, high-value products, as well as specialist training. The centre was upgraded in January 2018 when it moved from University Park to Jubilee Campus, where it now resides in the state-of-the-art £24m Advanced Manufacturing Building at the University of Nottingham.
Mission statementTo sustain and further establish the University of Nottingham as the leading international research centre and preferred supplier to industry of research and innovation products in advanced manufacturing technology.
World-leading research and development (R&D)The Precision Manufacturing Centre has an international reputation for research, from concept, design and simulation to manufacturing technologies and processes. It is supported by a wide range of stakeholders from major funding bodies to commercial companies of all sizes.
World-class facilitiesWe have some of the most advanced precision manufacturing machines in the world managed by a team of expert engineers. Our skilled technicians have a wealth of experience of taking customer specifications and delivering high quality, completed components to the required deadline. Companies can now have affordable access to tomorrow's technologies.
World-class servicesOur team can help you gain competitive advantage. We have unrivalled expertise in product design and engineering, contract manufacturing and bespoke tooling development and support our customers with training and after care.
All work is carried out under our ISO9001:2015 Quality Management System and managed according to PRINCE2® Project Management.
The PMC has worked with businesses and provided knowledge and support services to critical industrial sectors:
■ Aerospace
■ Automotive
■ Biomedical
■ Defence
■ Energy
■ Medical
■ Micro-assembly
■ Consumer products
■ Nano-technology
And we are always looking to expand and apply our expertise in new sectors.
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Services for businessManufacturing services
■ Manufacture of product prototypes
■ Small batch manufacture of products
■ Development and building of new manufacturing systems/processes
■ Improvement of current machines/processes through the integration of new sensors, process control intelligence and interface to PLM
■ Development of integrated manufacturing systems
Verification and validation
■ Contract measurement services for example part geometry, part features and others
■ Expert witness services – assurance on product/process quality
■ Scanning Electron Microscopy with natural state capability
Consultancy ■ Evaluation and optimisation of
current manufacturing processes
■ Product redesign for cost-effective manufacture
■ Manufacturing systems redesign for optimised performance
■ Development and testing of prototype manufacturing systems/processes
■ Development of specific manufacturing process know-how and the transfer of this know-how through training and staff development programmes
■ Development/optimisation/verification of CAD/CAM models
■ FEA modelling and simulation of specific manufacturing processes
Product development
■ Product design optimisation for improved manufacturability
■ Product redesign for cost-effective micro-manufacturing by reducing the number of sub-components
■ Product design and performance analysis
■ Small batch product prototyping
Collaborative research and development
■ Funding through UK and EU funding mechanisms
■ Contract-based/Project-based R&D work
Training and staff development
■ Training on the use of specific machines
■ Training of manufacturing process-specific know-how
■ Awareness courses on advanced manufacturing technologies and its implications
Services for small and medium businesses The Precision Manufacturing Centre (PMC) is offering free technology consultancy and development for small and medium enterprises (SMEs) through the European Regional Development Fund (ERDF) Enabling Innovation programme. It is aimed to help businesses develop new products and processes, and to expand their existing internal and external supply chain capabilities.
The PMC is part of the Institute for Advanced Manufacturing at the University of Nottingham, and has some of the most advanced precision manufacturing machines in the world managed by a team of highly skilled and dedicated expert technicians.
The ERDF programme is open to businesses who:
■ employ fewer than 250 employees
■ no more than 25% of the business is owned by another business that itself is not an SME
■ have an annual turnover not exceeding €50m OR an Annual Balance Sheet not exceeding €43m
■ have a registered business address based in the D2N2 (Derby, Derbyshire, Nottingham and Nottinghamshire) Local Enterprise Partnership area
If you are an eligible SME based in the D2N2 area we can offer you two days of FREE support under the Enabling Innovation programme. This support provides access to the latest manufacturing technology and expertise including:
■ confidential advice on product design and manufacturing process improvement
■ access to try out state-of-the-art manufacturing equipment supported by expert engineers
■ support for securing further funding for design and development
The ERDF programmes give SMEs affordable access tomorrow’s technologies.
The PMC provides world class expertise and cutting-edge technologies to help businesses create, develop and produce high-value, high-quality pioneering products. We can assist in a large variety of industries and projects, using our expertise in areas such as:
■ Ultra-Precision Complex Engineering – 3, 4, 5 Axis Milling, Turning & EDM
■ Mould Tool Design
■ Rapid Prototyping
■ Precision Engineering
■ Toolmaking – Mould and Press
■ CNC Programming
■ Ultra-Precision Metrology
■ Automated Assembly
■ Product Design
■ Design for Manufacture
■ Measurement Reporting
■ Microscopy – Optical/SEM
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Facilities
Precision ManufacturingPrecision Micro Machining Centre
Precision Milling Machine
CNC Machining Centre
Ultra-Precision Lathe
Micro Injection Moulding
Prototyping
Micro Precision Spark Erosion EDM System
Micro Wire EDM
Wire EDM System
Precision VerificationMicro Coordinate Measurement Machine
Multi-Sensor Measurement System Non-Contact, White Light Optical Profiler
Scanning Electron Microscopy
Optical Microscopy
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Equipment
EDM Systems – Sodick AP1L, AP200L, AQ750LProvides solutions to ultra-precision machining requirements based on achieved superiority in mini and microscopic machining, resulting in high quality surface finishes on components.
Micro Coordinate and Sensor Measuring Machines – Zeiss F25 and O-InspectThe Carl Zeiss CMMs – F25 and O-Inspect, offer nano and micro level accuracy, respectively. The F25 is the first machine of its kind in the UK and is currently the most accurate CMM. The O-Inspect was initially launched at the Precision Manufacturing Centre.
Non-Contact, White Light Optical Profiler – Veeco NP FLEX™ 3D Metrology SystemIdeal for characterising surfaces previously too difficult to measure due to size or part orientation. The NP FLEX combines the industry-leading performance of Veeco’s non-contact, white light optical profilers with a unique open-access design to enable rapid, three-dimensional data analysis.
Scanning Electron Microscopy – Hitachi S2600NThe Hitachi SEM enables us to provide product inspection and evaluation utilising up to the 300,000 times magnification and ‘natural state’ capabilities e.g. non-conductive parts.
Optical Microscopy – Olympus DSX110The unique combination of optics and today’s newest digital imaging technology integrated in the DSX110, delivers accurate colour reproduction, and eliminates flare and distortion. Every sample is reproduced with accurate and efficient observation, more intuitive magnifying operation, and a variety of observation methods.
Optical Microscopy – Zeiss Stemi-2000This high quality stereo-microscope, linked to a PC via a dedicated CCD camera, enables us to provide quick and accurate first-stage analysis of products and components.
Precision Micro Machining Centre – Kern EvoThe Kern Evo provides the capability to produce micro scale features using conventional machining methods combined with high precision tooling and linear actuation.
Precision Milling Machine – Hermle C20U Ideal for producing smaller, complex components requiring full 5-axis interpolative metal cutting.
CNC Machining Centre – Hurco VM1High accuracy, 3-axis machining centre with CNC, which is ideal for small batch production of components. Its large working area allows machining of samples larger than the working area.
Ultra-Precision Lathe – Spinner PD-CNCCapable of micro turning in the sub-micron range, the Spinner enables high accuracy and repeatability.
Micro Injection Moulding – Battenfeld Microsystem 50The Battenfeld enables us to produce high precision injection moulded parts, down to 1mg in weight, and to use a large range of materials, including some not conventionally used in injection moulding. The integrated quality inspection camera and robot handling ensures compliance of parts.
Prototyping – EnvisionTec PerfactoryBased on the principle of photo polymerisation, the EnvisionTec Perfactory system creates precision micro 3D complex components.
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Precision Micro Machining CentreKern Evo
Machining accuracyExcellent surface quality Ra ≤ 0.1µm
Digital direct-feed motors with positioning accuracy ±0.5µm
5-Axis simultaneous operation
Typical applicationsMedical Implants – device manufacture
Aerospace – Critical fine tolerance parts
Calibration artefacts
Precision manufacture of high tolerance components for example mechanical watch gears
Working EnvelopeX = 300mm
Y = 280mm
Z = 250mm
4th Axis 360° continuous rotary
5th Axis swivelling -10° to +100°
500–50,000 RPM max spindle speed
Max. weight = 50kg
Tools Ø30µm to Ø10mm
Solid carbide, HSS, Indexable carbide
Automatic tool-changer 30 tools
Blum Automatic laser-tool measurement system
Spindle probe system
MaterialsFerrous, non–ferrous, ceramic, hard steel, materials up to 70 HRC
Cooling unitOil mist or compressed air
ClampingCollet chuck, Vice, 3R Macro Nano or bespoke fixture to suit part being machined
Precision Milling MachineHermle C20U
High productivity 6m/s2 acceleration to 45m/min in all linear axes
4.5 second chip – chip tool change
Feed Force = 7000N
MaterialsFerrous, Non-ferrous, ceramic, hard steel, materials up to 70 HRC
Machining accuracyExcellent surface finish Ra ≤ 0.1µm
5-axis simultaneous operation
Positional Tolerances see’s x, y, z in accordance with VDI/DGQ = ±0.8µm
Working EnvelopeX = 600mm
Y = 450mm
Z = 450mm
4th axis – 360o Continuous Rotary
5th axis – Swivelling -115o to 115o
Max. Weight = 300kg
HSK 40 Spindle
20-40,000 RPM Max. Spindle Speed
ToolsØ0.03mm to 80mm
Material: Solid Carbide, HSS, Indexable Carbide
Automatic Tool Changer up to 30 Tools
Blum Automatic laser-tool measurement system
Renishaw spindle probe
CoolantSoluble Oil
ClampingCollet chuck, Vice or bespoke fixture to suit part being machined.
3R Macro System
Image with kind permission of KERN MicrotechnikImage with kind permission of Hermle AG
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CNC Machining Centre Hurco VM1
High productivityTable Working Surface Area = 762mm x 406mm
Spindle Nose Distance to Table = 100m to 610mm
Spindle Taper = CAT40
Max. Cutting Feed Rate = 7.62m/min
MaterialsFerrous, Non-ferrous, ceramic, hard steel, materials up to 70 HRC
Machining accuracyMinimum Command Increments = 2.5µm
Positional Accuracy = ±5µm
Repeatability = ±2.5µm
Working EnvelopeX = 660mm
Y = 406mm
Z = 508mm
Max. Weight = 340kg
Max. Spindle Speed = 8000 RPM
ToolsØ0.5mm to 100mm
Material: Solid Carbide, HSS, Indexable Carbide
Automatic Tool Changer up to 20 Tools
CoolantSoluble Oil
ClampingCollet chuck, Vice or bespoke fixture to suit part being machined.
3R Macro System
Ultra-Precision Lathe
Spinner PD-CNC (Siemens 840D)
MaterialsFerrous
Non-ferrous
Ceramic
Hard steel
Materials up to 70 HRC
ApplicationsFine Mechanics
Optics
Hydraulics & Pneumatics
Medical Technologies
Electronics
Motorsport & Aircraft Industries
Bearing Manufacture
Tool Making
Mould Making
Working EnvelopeMax. X stroke = 400mm
Max. Z stoke = 400mm
Max. Speed X/Z = 12m/min
Total Turret Positions = 16
Max. Weight (@5000 RPM) = 1.25kg
Max. Weight (@8000 RPM) = 0.625kg
Spindle 1Max. Speed = 5000/8000 RPM
Bar Capacity (collet) = Ø32mm
Chuck
3R System
Spindle 2Max. Speed = 8000 RPM
Bar Capacity (collet) = Ø32mm
CoolantSoluble Oil
Image with kind permission of Hurco Europe (UK)
Image with kind permission of SPINNER
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Micro Injection MouldingBattenfeld MicroSystem50
Working EnvelopeMould plate size: 240mm x 400mm
Mould height: 100mm–220mm
Theoretical max. shot volume: 1.2cm3
SpecificationIntegrated handling and quality control vision system
Fast cycle times 2.6s to 6.0s
Positioning precision 0.01mm
Typical applicationsDesigned and optimised for part weights below 100mg
Highly suitable for sensors, medical, telecommunication, electronics type applications
ToolsFour-level servo-electrical and mechanical combination
Dosing screw diameter: 14mm
Clamping force 50kN
MaterialsStandard (PP, PE, PS)
Technical (POM, PA, ABS, PBT,
PPS, LCP, PEEK, ETFE)
Elastomer (TPE, TPU)
Optical (PC, PMMA, COC, PSU, SAN, PETG)
Powder (MIM, CIM)
Medical (PDLL)
Image with kind permission of Wittmann Group
Prototyping
EnvisionTec Perfactory
Working EnvelopeX = 10mm
Y = 14mm
Z = 230mm
3D build technologyBuilds solid 3D objects using a DLP® projector
Projects sequential voxel planes into liquid resin
Resin cures from liquid to solid
Each voxel plane made up of voxels as small as 15μm x 15μm x 15μm in X, Y and Z direction
Typical applicationsMedical Devices
3D Complex Microproducts
MaterialPhotopolymers
Voxel size XY15µm (XY Resolution)
Layer thickness15–50µm (Z Build Thickness)
Photo curable resinsR11, R5 Acrylate resins: Chemical resistance and good mechanical properties
NanoCure RC25: strong, stiff, high temperature resistant composite parts
Image with kind permission of EnvisionTEC Limited
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Micro Wire EDM
Sodick AP200L
Working EnvelopeX = 220mm
Y = 150mm
Z = 120mm
Max. work piece weight 50kg
WS4P Rotary axis
Typical applicationsManufacture of dies and mould tools
Medical implants – device manufacture
Aerospace – critical tolerance parts
Calibration artefacts
High tolerance components
Machining accuracyCan machine up to ±7° taper
<5µm part feature repeatability
ToolsWire diameter 100µm standard
30µm to 200µm optional
3R Macro Nano work holding on WS4P
3R Vice & Rail Part work holding
DielectricOil
MaterialsHard conductive materials including; ferrous, non-ferrous and hard steels
Image with kind permission of Sodi-Tech EDM Limited
Micro Precision Spark Erosion EDM SystemSodick AP1L
Working EnvelopeX = 200mm
Y = 120mm
Z = 200mm
Max. work piece weight 25kg
Machining accuracyCapable of producing parts with features as small as 100µm to 150µm. On part accuracy sub 10µm
Typical applicationsManufacture of dies and mould tools
Medical implants – device manufacture
Aerospace-critical fine tolerance parts
Calibration artefacts
MEMS packaging
High tolerance components
ToolsMaster electrode up to 5kg, machined as required within workspace envelope
Integrated spindle capable of rotational speeds up to 2000 RPM
3 R Macro Nano work/electrode work holding
MaterialsHard conductive materials including ferrous, non-ferrous and hard steels
Image with kind permission of Sodi-Tech EDM Limited
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Wire EDM System
Sodick AQ750L
Working EnvelopeX = 750mm
Y = 500mm
Z = 400mm
Max. work piece weight 1500kg
Machining accuracy±30° taper
<5µm part feature repeatability
Typical applicationsMedical implants – device manufacture
Aerospace – critical fine tolerance parts
Calibration artefacts
Precision electromagnetic components
Machine tool parts
High tolerance components
ToolsWire diameter 250µm standard
150µm to 330µm optional
3R Vice & Rail Part work holding
DielectricDe Ionised Water
MaterialsHard conductive materials including ferrous, non-ferrous and hard steels
Image with kind permission of Sodi-Tech EDM Limited
Micro Coordinate Measurement MachineZeiss F25
Working EnvelopeX = 100mm
Y = 100mm
Z = 100mm
Max. work piece weight up to 5kg
Probing uncertainty<0.25µm
Optical uncertainty0.4µm
Typical applicationsDimensional measurement of medical implants, motorsport and aerospace components
Calibration of measurement artefacts
Production process and manufacturing quality
SoftwareCalypso, Free Form surface, Curve
Tactile sensorProbe diameter : 120µm, 300µm
Probe length : 2mm, 4mm
Probing force : 0.5mN
Optical sensor10x Carl Zeiss optics
Image with kind permission of Carl Zeiss Limited
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Multi-Sensor Measurement MachineZeiss O-Inspect
Working EnvelopeX = 400mm
Y = 400mm
Z = 200mm
ApplicationsComponent Verification
Calibration of Measurement Artefacts
Production Process Control and Manufacturing Quality
Aerospace, Motorsport & Medical Technologies - Dimensional Analysis
Precision accuracyProbing Uncertainty = 1.7µm
Optical Uncertainty = 1.7µm
SoftwareCalypso, Free Form Surface, Curve
Tactile sensorProbe Diameters = 0.25mm–5mm
Probe Lengths = 4mm–50mm
Optical sensorVariable up 6.5x Carl Zeiss Optics
Image with kind permission of Carl Zeiss Limited
Non-Contact, White Light Optical ProfilerBruker NP FLEX 3D
Working EnvelopeH = 350mm (249mm with automated stage)
D = 304mm
W = 304mm
Vertical resolution<0.15nm
RMS repeatability0.03nm
Lateral spatial sampling0.1μm to 13.2μm
Typical applicationsMedical implant R&D – surface condition
Aerospace – critical fine tolerance parts
Failure analysis – nanometre resolution
Production process control and manufacturing quality
White light interferometry3D areal information with sub-nanometere vertical resolution at every pixel
Measurement capabilityNon-contact, three dimensional, surface roughness, critical dimension, film thickness, tribology
Stage weight load capacity Up to 50kg
Image with kind permission of Bruker Corporation
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Scanning Electron MicroscopyHitachi S2600N SEM & EDX
Working EnvelopeX = Max. 20mm
Y = Max. 10mm
Z = Max. 35mm
Tilt Angle = -20o to +70o
Rotation Angle = 360o
Acceleration voltage0.5V up to approx. 30,000V
ApplicationsInspection of Components
Failure Analysis
Compositional Analysis
Cross-Sectional Analysis
Magnification40x up to approx. 300,000x
ResolutionSecondary Electron = 4.0nm
Backscattered Electron = 5.0nm
SoftwareQuartz Imaging System XOne Software
Image resolution640 x 480
1280 x 960
2560 x 1920
Optical Microscopy
Olympus DSX110
Working EnvelopeStandard Maximum Height : 80mm
To ensure U-centric operation in tilted operation : 50mm
Stage Dimensions : 100mm x 100mm
Load Capacity : 1kg
Zoom ratioOptical Zoom : 1x – 16x
Digital Zoom : 17x – 30x
Image sizeNormal : 1194 x 1194 (1:1)/1592 x 1194 (4:3)
Fine : 1194 x 1194 (1:1)/1592 x 1194 (4:3)
Super fine : 3594 x 3594 (1:1)/4792 x 3594 (4:3)
Image sensor1/1.8 inch, 2.01 megapixels, colour CCD (total pixels: 2.10 megapixels)
Total pixels : 1688 (H) x 1248 (V)
Available pixels : 1628 (H) x 1236 (V)
Effective pixels : 1600 (H) x 1200 (V)
Fine focusing (motorised)Stroke : 34mm
Resolution : 0.4µm
Course Focusing (Manual)
Stroke : 50mm
Tilt mechanismType : Manual, lock/release handle
Tilt angle : Left/Right 45°
Frame rate15 fps/27 fps with binning mode
Course focusing (Manual)Stroke : 50mm
Image with kind permission of Hitachi GroupImage with kind permission of KeyMed Limited
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Case studies Milek & Co LimitedThe owner is starting up their business as a luxury watch manufacturer. They approached the PMC for assistance due to the high complexity and high precision required on the watch components. Through our ERDF programme, the PMC were able to provide free technical work on some of the most complex components, moving the owner closer to creating their first prototype.
Flix Buckle LimitedThe owner of this business, spotted a gap in the market of horse blanket buckles. Traditionally made from metals, the use of a plastic buckle could provide more flexibility with the blanket. They approached the PMC looking for assistance with a mould tool design. Our expert team produced a mould tool design and manufactured a mould tool for free through our ERDF programme, which will enable the client to start manufacturing the buckle in large volumes.
Spaghetti Maths LimitedThe business creates innovative maths educational activities for children, and approached the PMC for support around the design and manufacture of connectors for producing platonic solids with straws. Through consultation, the PMC were able to suitably design a range of connectors for the business, and provide them with prototypes, before they moved towards producing them through mass manufacture.
BarmiesThe owner produces a food snack from the by-product of beer brewing. This dough-like product was initially rolled and cut by hand before cooking, which was very time consuming. They approached the PMC looking for assistance with this problem, and through our ERDF programme, the PMC were able to design and manufacture a bespoke delivery mechanism for a food slicer which has drastically improved productivity.
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Testimonials Calon Cardio
For over 6 years the PMC have been the main supplier of the very challenging, high precision titanium components used in our device. During this period, they have played a vital role in assisting us with the design for manufacture input and by supplying high quality components that other suppliers have even considered as ‘unmanufacturable using conventional machining techniques’. I would have no hesitation recommending PMC as a supplier, particularly where attention to detail, high precision and surface condition is critical.
Unicorn Metals
I would like to thank everyone at PMC for their excellent work, professionalism, kindness and understanding, especially towards someone such as me who has little understanding of engineered parts. Their help and guidance was brilliant and the finished parts were excellent and worked perfectly. I look forward to working with them again and would recommend PMC services to everyone.
WTF Wrench
As a local SME, having access to experts at the University, with state of the art equipment, is a real benefit for us. We have used the PMC for development work with a new product concept. They prepared the drawings, and made a 3D model, and input some good ideas. Dan, Mark, Jeremy and the team were a pleasure to work with – thank you. The 3D model allowed us to show a couple of customers, and we have procured an indicative order, which justifies the tooling cost, and initial production run. So, commercially, a real success story.
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This publication is available in alternative formats: +44 (0)115 951 5559
Precision Manufacturing CentreProviding integrated solutions for industry
nottingham.ac.uk/pmc
Printed July 2018.
The University of Nottingham has made every effort to ensure that the information in this brochure was accurate when published. Please note, however, that the nature of this content means that it is subject to change, therefore consider it to be guiding rather than definitive.
© The University of Nottingham 2018. All rights reserved.
We welcome the opportunity to talk to you about your business and how we can work together.For further information please contact:
+44 115 748 6717
@UoNPMC