RP Tooling builds its business on Hurco machining centre technology

Founded by Brett Mitchell and Darren Withers, by September 2010, turnover had grown to the point where they were able to move out of a rented industrial unit in Halesowen and purchase a freehold property nearby. The two partners, who now employ 20 additional staff, put their success down to following the market and targeting industry sectors that are buoyant at any given time. For example, three years ago, a majority of work was for the aerospace industry, whereas presently, moulds for automotive customers account for half of throughput. Three of its Hurco machines, as well as a Mitutoyo CMM, were installed in summer 2009, right in the middle of the recession, underlining Mr Mitchell's opinion that regular investment in new plant is crucial for business expansion, even in difficult times. Of the choice of Hurco technology, Mr Withers comments: "We chose Hurco VMCs because their sturdy construction and build quality stood out from the rest. Compared with some of the machines we looked at, there was a big difference in robustness. "The Hurcos have also proved easy to use. Two days' training is provided with each machine, but we have not been on any of the courses. The engineer that commissioned the first machines showed us a little of how to program using the conversational control and we just took it from there." The company's next purchases will be a 5-axis Hurco machining centre to expand component manufacture and speed complex profiling jobs; and a much larger DCX22, with a 1.75 m Y-axis, to tackle larger moulds that the company is currently having to turn away. RP Tooling is not a typical user of Hurco VMCs, however. Hurco's Windows-based Ultimax control running proprietary WinMax shopfloor programming software is often the deciding factor for investors. For RP Tooling, it only comes into play for engraving part numbers around tools and for preparing programs for machining some components and fixtures. Invariably, mould design and programming are carried out off-line, using ZW3D (formerly VX) CAD and NCG CAM software, based on an imported solid model of the end product, supplied by the customer. A single post-processor is needed for downloading machine code to all seven Hurcos via DNC links. As the machines have similar sets of cutters resident in the tool magazines, jobs are freely interchangeable, providing production flexibility. "Although we do not use Ultimax for programming our tools, we do find the control's 'work offset' feature useful when running machines unattended overnight and at weekends, which we do regularly, "reports Mr Mitchell. "It means we can maximise productivity by fixturing multiple jobs on each machine table, as appropriate. We may import, say, three programs created on our CAD/CAM system and simply enter two additional G-codes to tell the spindle to 'redatum' automatically after each job has finished." RP Tooling specialises in short-lead-time design and manufacture of aluminium injection moulds for producing plastic prototypes and short batch runs, typically up to 5,000-off. Some smaller steel tools are machined for longer production runs. The firm also makes investment tooling for production of castings, destined mainly for export markets in Europe. Another facet of its business is low-volume machining of bespoke jigs and fixtures, as well as components in anything from resin board through plastics and aluminium to hardened steel, predominantly for Formula 1 teams and luxury car manufacturers.