Precision Manufacturing Centre · 4 Precision Manufacturing Centre nottingham.ac.uk/pmc 5 Foreword The Precision Manufacturing Centre is a world-leading centre of research expertise

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


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


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.


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


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


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


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


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


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


Micro Wire EDM

Sodick AP200L


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


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


Y = 120mm

Z = 200mm


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


MEMS packaging


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



Wire EDM System

Sodick AQ750L


Y = 500mm

Z = 400mm


Machining accuracy±30° taper

<5µm part feature repeatability

Typical applicationsMedical implants – device manufacture

Aerospace – critical fine tolerance parts


Precision electromagnetic components

Machine tool parts


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


Micro Coordinate Measurement MachineZeiss F25


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


Multi-Sensor Measurement MachineZeiss O-Inspect


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


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


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:

[email protected]

+44 115 748 6717

@UoNPMC

Documents

Precision Manufacturing Centre · 4 Precision Manufacturing Centre nottingham.ac.uk/pmc 5 Foreword The Precision Manufacturing Centre is a world-leading centre of research expertise