Strategic relationships with OEMs sustain and inspire Radshape Sheet Metal’s success

The name of Morgan is synonymous with traditional British craftsmanship but it is also believed to be one of four automotive companies in the world to embrace the concept of a bonded chassis. Radshape produced its first 200 bonded chassis for the Morgan Aero 8 in 1999 and the growing number of units helped to support it when the demand for Rolls Royce and Bentley cars suffered in the 2009 recession. Today, however, Radshape's sales figures are setting new records and it supplies Morgan not only with chassis but also other panels, grilles, bumpers, cowls, wind and side screens. A specially built production cell at Radshape's Birmingham factory manufactures the Morgan bonded chassis. Crucial to the process are its Trumpf TruPunch 5000 and two TruBend 5130 press brakes. Manufacturing tolerance on the chassis is 0.25 mm – this is even more rigorous than the 0.5 mm standard required by Morgan. Radshape bonding engineer John Harper comments: "We've used Trumpf machines right from the start of this project. The chassis is self-jigging, there are no fixtures involved, so we have nothing to rely on but the accuracy of the machines. "The TruTops CADCAM software has proved a particularly good investment for us. It's easy to use and has radically changed how we make the tub [the chassis assembly]. In the early days, we spent days working out the correct profile. Now we can do it in an hour or so." The 2.5 mm aluminium chassis parts are punched, then formed on press brakes, and transferred into the bonding cell for wet-build and curing in the oven. "Originally, we were simply responsible for the chassis up to the bulkhead, but now we build up the front end, too, and install sound-deadening material," says Radshape managing director Keith Chadwick. He adds: "Over the years we have suggested around 600 ideas for improvement to customers and two out of three have been taken up." One of these was the development of the universal tub to replace left- or right-hand drive versions. It's this high level of customer service that has proved such an important element in Radshape attracting more business from the prestige automotive sector. Its relationship with Bentley now accounts for 35% of Radshape's revenue and this includes the stainless steel and electro-polished grille for the new Bentley Mulsanne, elements of which lock together like an egg box. This prestige component is produced on a Trumpf TruLaser 5030 to a manufacturing tolerance of ±0.05 mm. Both John Harper of Morgan and Keith Chadwick of Radshape have worked their way up their corporate ladders through apprenticeships. The Radshape managing director continued to take on apprentices even when sales were not so buoyant and believes this depth of knowledge and experience gives Radshape an important edge in its dealings with OEMs. "How can anyone talk about how much a job will cost if they don't know how to make it?" he asks? Mr Chadwick names two apprentices, Jamie Sproson and Tom Gwynn who have moved from the shopfloor to the sales office as commercial engineers. He says: "These lads have the experience to look at a drawing and point out, for example, that the design would present a problem and recommend solutions to resolve it based on the knowledge they have attained during their apprenticeship." In common with many UK automotive suppliers, Radshape is seeking to diversify to safeguard its business. Rail, aerospace, commercial vehicles and nuclear sectors are all playing their part, but it's another take on 'automotive' that is poised to boost growth in the coming years. Radshape is now making its mark on the radio-controlled race car market. This initiative came from Radshape business development director Chris Dickinson, and it has spawned a thriving new division of the company. RadshapeRC produces aftermarket metal spares on its Trumpf machines to strengthen, modify and enhance various brands of RC cars. "We're the only company making metal parts and they have proved immensely popular with hobbyists," Mr Dickinson explains. "Within just four months, RadshapeRC trademarked spare parts are selling to 24 countries across the world and we just developed our own, as yet unnamed, RC vehicle." First published online