Mike Richardson catches up with Alex White, managing director of flatbed cutting machine specialists, Blackman & White to hear how the company is staying at the cutting edge of an increasingly competitive industry.
Using a process that is traditionally done by hand, the composites industry cuts shapes from rolls of material which are then laid up in moulds. Cutting prepreg materials on a flatbed cutting machine is much faster, more accurate and the material can be utilised much better. Additionally, companies can save money on installing material into moulds because they get a more accurate fit due to highly precise cutting, making layup far quicker and easier for operators to handle.
Founded in 1964 by engineers Les White and Jack Blackman, Blackman & White has a proud heritage which has seen it create a range of high quality machinery with longevity. The company first developed its machines for the sail making industry in the 1980s, and has gone on to pioneer multi-tool laser cutters within the textile world and launched specialist cutting tools for the filtration and graphics industries.
To satisfy the types of demands placed on the company by its customers, Alex White, managing director of flatbed cutting machine specialists, Blackman & White says that in today’s competitive market, customers are looking firstly for a machine that will give the required return on investment.
“It is not sensible to invest in a machine from a distant overseas supplier if you are not certain that the support and backup will be there when you need it,” he begins. “Cost is often the most important factor in making a decision but this clearly should not be the only consideration. The development of Blackman & White cutting solutions has shown that as a company we listen to our customers’ requirements and implement new features in order to meet production requirements.”
Automate to innovate
In terms of the latest trends driving flatbed cutting machine technology, White points to a clear trend in the industry toward automation.
“Blackman & White is working with several customers on supplying machines to work within a production cell. With the use of high-speed robotics, it’s possible to fully-automate a cell from material supplied from a roll to finished part without any manual intervention. This level of integration will drive the market for our machines in the future as high production demands from automotive and aerospace push forward.
“Feeder solutions are available for both dry and prepreg material that are supplied with the machine. Customers often require edge sensing and powered un-roll for the large sized rolls of material. Blackman & White can supply feeders for applications across the range of fabrics and sizes.”
Blackman & White produces a machine designed for the composite industry, however just cutting dry prepreg is often not the only material to be processed.
“The machines we produce now are able to cut 2-inch core material with both oscillating blade and high-speed milling spindle. We’re now fitting our machines with the choice of a 5kw spindle that is IP 55 rated specifically for processing composite materials. Dry carbon and glass fibre is also commonly cut on the system, and for this we recommend the high-powered driven wheel. The fully-automated knife depth station makes it quick and easy to change between cutting tools.”
A system of systems
White adds that most customers already have well-developed CAD systems. Catia is often used, but lower-cost alternatives exist, such as SolidWorks and Rhino. Indeed, some customers still only require 2D software and are content to use traditional manual patterning techniques for developing the shape profiles.
“The nesting software that we recommend is the CutFab solution. This has been developed to interface projection with the cutting process, so that part identification is enabled. Inkjet systems are also available to mark at high-speed complex text strings onto the material.
“The cutting systems are available with a range of sizes with high speed and also economic entry level solutions for the market. Blackman & White has the most comprehensive range, including the options of laser cutting on the same platform. Automation within cutting cells even supports 24-hour production that is leading the way for the future of composite manufacture. Training on software is quick and painless and often completed, either on site or at a training day at Blackman & White. The safe use of the machine is important and this is achieved by both onsite supervision and also a two-day training course at the Blackman & White factory.
“The range of machines is suitable for most composite manufacturing plants. It’s still often the case that companies are cutting material by hand. With nesting software and high speed cutting all our customers see a rapid return on investment and regret not making the investment sooner.”
Blackman & White has supplied many machines to customers that produce fabrics across the range of composite manufacture and vacuum bagging films.
“We are proud to have supplied machines to leading companies, such as TenCate and Toray, along with manufacturers such as Hope Technology and Surrey Satellite Technology Limited,” he adds.
Driven by experience
White believes that it is the experience of Blackman & White that really sets it apart from the competition. For him, the development of the company’s machines and integration with complex production workflow is unrivalled.
“The company remains family-owned and at its heart is driven by management to ensure customer satisfaction. Whilst we are not the largest manufacturer of cutting solutions, it is a proud fact that not only do we produce machines that integrate into challenging applications, we also ensure our customers recommend us to other companies. It’s no surprise that close to 50% of our customers own more than one of our machines.”
I’m interested to know how White sees the future of the UK’s composites manufacturing industry - and particularly subcontract kit cutting evolving in the future?
“It is certainly true that we are increasingly supplying machines for companies that then supply kit cutting services to composite manufacturers. It is impossible for some customers to work this way as the cure time and requirement for cut panels just prohibits the outsourcing of the cutting. However, it certainly makes sense for customers that are already outsourcing the vacuum bagging to also have delivered cut components.”
White concludes: “As the future of composites develop, it is likely that manufacturing techniques will change and it will make the cutting of fabric unnecessary. In fact, for the composite industry to reach its full potential and penetrate markets, such as automotive electric cars, there will have to be lower costs and higher speed composite production solutions. Perhaps this will come from improved 3D printing techniques that will enable raw material to be processed directly into finished parts.”
