Formaplex is a dynamic manufacturing group using innovative processes and state-of-the-art manufacturing techniques to deliver cost-effective, superior tooling and component solutions to customers across many demanding sectors. Here, an ONA bridge-type EDM machine is supporting the company’s moulding and tooling operation.
Formaplex has been working with many Formula 1, motorsport and aerospace customers since its foundation in 2001. The company operates 24/7 to provide the manufacture of master patterns, components, tooling for composite part manufacture, and finish machined composite parts in-line with the demanding requirements from these high-tech industry sectors.
As a Tier 1 supplier to low‐medium volume automotive customers, including demanding prestige brands and sports cars, Formaplex provides integrated services including design support and advice, manufacture tooling, and supply injection moulded plastic parts and composite parts to meet delivery schedules. Parts are supplied as individual items, complete assemblies, and where required, are finished and painted.
Formaplex operates from three sites on the South Coast which collectively span over 140,000 ft2, The company also designs and manufactures injection mould tooling for many of the components required by most of the high volume car manufacturers. Operations Director, Chris Carter, comments: “With extensive capabilities and a very experienced team we are a preferred supplier for the design and manufacture of injection-mould tooling for key Tier 1 companies supporting the high volume automotive industry throughout Europe.”
The toolroom at Havant produces new mould tools for low volume production and also modifies tooling, where manufacture is outsourced to global partners. “I’ve been in this business over 30 years. Most tools will require minor modifications between design and production, it’s the nature of our business. Once tooling goes into operation, quality control will identify any glitches and the necessary changes can then be made says Chris Carter.
Growing demand for Formaplex’s services highlighted the need for a large EDM machine, as the volume of this work was increasing. By mid-2014 the decision to invest was taken, as Chris Carter explains: “My experience with ONA EDM machinery goes back more than two decades, and I have purchased a number of the company’s EDM die sinkers from UK agent, Warwick Machine Tools (WMT), over the years. I have always had professional service and support from WMT, the machines themselves are very durable, robust and reliable. With ONA we are buying quality machinery that we can depend upon to meets our requirements and to perform under extensive operation.”
For ease of access to load and unload the large mould tool components, Formaplex wanted a bridge-type machine. Although this specification was not available, ONA had a suitable machine that could be rebuilt and retro fitted with completely new components. Other than the cast structure the ONA PX S1 installed at Formaplex is completely new, with a new table, motors, scales and generator, as well as the latest ONA NX CNC system.
“With axis travels of 1,500 mm in X, 1,000 mm in Y and 400 mm in Z, the price was very competitive, and there’s not really another machine manufacturer offering bridge-type machines now. ONA EDM generators are very good, and the front end is not as complicated as other systems,” states Chris Carter.
While ONA die sinkers are designed to operate around-the-clock, the requirement at Formaplex is very demanding.The machine can be running for 3 or 4 days continuously.. Chris Carter recalls: “When we first set up we considered engineering a method of cutting thin, deep rib sections on a CNC miller rather than putting it on a die sinker. This was not a cost-effective or time efficient process to get a finish in the cavity. It became apparent that we could not achieve the same results with a milling machine as you can with a spark eroder, it’s also faster to die sink to our tolerances and geometric form requirements.”
The toolroom at Havant produces the tools used in the large mould machines. At 3,500 tonne and 1,500 tonne, these machines produce large single piece components, such as bumpers, facia and engine trays for the automotive industry. With a large 2,000 by 1,180 mm worktable capable of accepting workpieces up to 10,000 kg the machine can easily accommodate the company’s mould tool components.
Formaplex also project manages its overseas manufacturing operations, performing rigorous tests on the tooling manufactured by global partners. This ensures that when the tooling arrives in the UK at Formaplex, any set-up time and work prior to production is kept to a minimum. This is vital when working on approximately 120 large tools per year, weighing up to 25 tonne or more.
“We have extensive tool making expertise and state-of-the-art-technology to produce superior quality tools. Continuous investment is paramount, and we will consider further ONA bridge-type machinery in the future. Our experience working with WMT has also been exceptional,” concludes Chris Carter.
