Built to last

As Composites in Manufacturing discovers, a component is only as good as the pattern it is made from. And Buckinghamshire-based Freeform Technology should know – it has been manufacturing precision patterns and moulds for components since 2008.

 

Each possessing a background in precision machining gained from working within motorsport, Freeform Technology was founded by Fred Hutton and Simon Burchett. They noticed a shortfall of quality tooling within the composites sector and as a result, decided to set up Freeform Technology, bringing the accuracy from their background in precision machining into the manufacture of patterns and moulds for the composites industry.

The company has since grown to become a leading, ISO 9001 certified, 5-axis CNC machining supplier to many clients in many different sectors, including motorsport, automotive, marine, medical, prototyping and TV and film props. Freeform Technology provides epoxy and PU tooling, along with aluminium moulds and components and the recently introduced carbon insert machining.

Pattern machining still remains the largest proportion of its workload, with six machines with 5-axis machining capabilities catering for the requirements of the composites industry. The largest has a maximum working envelope of 4.8 x 1.8 x 1.2m, providing the ability to manufacture large-scale projects like automotive floors, bumpers, mock-ups, large marine projects, etc.

With a large presence within the Motorsport/Formula 1 sector, Freeform Technology says it is familiar with the demands that this industry can throw at you, such as high tolerances, quick turnaround and tight delivery timescales, for example.

The company also offers an array of services on top of its composite tooling manufacture, and having the ability to assist clients with improvement suggestions, advising on potential changes to save time and money for its tools, shows its continual effort in building quality relationships with customers. Freeform is able to offer tooling design to take the stress away from the customer by project managing the component, organising the sealing of the patterns and using a network of trusted, quality suppliers to manufacture the end product.

Invest in the best

Freeform Technology has made it a priority to only invest in the latest and best technology available on the market. This ensures that the 5-axis machining centres run with the highest precision to consistently machine quality tools every time.

Its CMS range of machines gives it the ability to accurately and consistently mill high quality, large-scale (maximum size working envelope of 4.8 x 1.8 x 1.2m) epoxy and PU tooling board patterns/moulds to its clients’ requirements. The CMS machines are checked weekly by in-house engineers to ensure that high quality and tolerances are met. The machine tools have a bi-annual service by CMS engineers and an annual laser calibration service.

Freeform Technology also has three DMG Mori machining centres, comprising a 100T, a 65 monoBLOCK and a 60 eVo Linear. These machines provide Freeform with the peace of mind knowing the part will be manufactured in a quick turnaround, along with the highest quality and consistently met tolerances required.

The DMU 65 monoBLOCK also provides Freeform Technology the capability to machine aluminium moulds, jigs and components, increasing its wide range of services, along with its patterns with aluminium inserts.

In the middle of 2016, Freeform Technology undertook a marketing survey to find out more from its customers to look into the expansion of the company. The results that came back from the survey showed a requirement for quality carbon fibre inserts.

From acquiring this information, the company set out to become a market leading insert provider, investing in a DMG Mori 60 eVo Linear machine to use for the machining, along with working with a key client to develop cutting strategies, tooling and internal processes.

It is now awaiting the arrival of its second machining centre and will be opening its doors to assist other clients with inserts manufacture. This success has led to the understanding that there is a requirement for Rohacell machining. Entering the final quarter of 2017, Freeform Technology is looking to invest in this technology and provide clients with a wider breadth of capability.

Elsewhere, Freeform Technology has invested in Siemens NX CAD software, alongside its seats of Vericut software to increase machining efficiency and decrease downtime. In addition to the CNC machine tools from CMS and DMG, it has invested in what it considers the best inspection equipment: Faro arms and Romer scanners.

Times are changing

In terms of the ease in doing business and keeping pace with changing trends, pricing, ISO/AS9100 accreditations and EC legislations within the UK composites industry, Freeform Technology says it is a booming market with many different areas that suit the company, such as medical, marine, motorsport, and gas and oil. This offers Freeform the ability to explore and understand where its strengths lie, and then work to introduce itself into new industry sectors.

The company decided to invest in the ISO 9001 certification back in late 2015 to streamline its in-house functions and increase efficiency. ISO 9001 has helped improve its processes and provide a leaner production line, which gives it the ability to tackle jobs quicker and improve on any injunctions on the journey to ensure they don’t reoccur.

Due to Freeform Technology’s continual effort to grow and expand within the composites industry, it is looking to adopt AS9100 certification to effectively work within the aerospace sector.

Freeform Technology builds long-lasting relationships with its clients; it is not ‘just another job’. This relationship mentality is said to ensure a quality service for its clients. By working with - not for the client, a thorough understanding of their needs and requirements is established, along with providing potential process improvements to save time and/or costs. Along with Freeform’s dedicated workforce hinged on quality and precision and a well-trusted and proven network of suppliers, it can take the customer’s CAD design to a quality, complete product.

www.freeformtechnology.co.uk