Laser cutting machine is equipped with a high performance 5.2kW system that is capable of increasing and decreasing its power precisely at the desired point and without delay.

Bystronic UK exhibited at the MACH exhibition for the first time under the Bystronic name since the combining of the Pullmax and Edwards Pearson companies at the beginning of 2006. Visitors to the stand were able to view a wide range of products from across the company's comprehensive portfolio. Laser cutting was represented by the successful Byspeed 3015 equipped with the high performance Bylaser 5200 ARC.

This laser source is capable of increasing and decreasing its power precisely at the desired point and without delay, and with a constant output power of no less than 5.2kW permits the processing of steel sheets up to 25mm in thickness consistently, accurately and quickly.

The Adaptive Radius Control (ARC) technology ensures that the diameter of the laser beam remains constant over the whole cutting area.

The Byjet 3015 waterjet system to be shown will feature two shuttle tables (all Bystronic waterjet systems are equipped with the additional shuttle table as standard) and automatic swivel load/unload.

The twin shuttle tables increase productivity by up to 30% and allow for further automation.

In addition the machine is equipped with two parallel High Precision Tool (HTP) cutting heads which work with even greater precision and faster repositioning times.

The Bypump APC high pressure pump, with active pressure control, incorporates an extensive and automatic diagnostic system that monitors and displays more than 20 signals.

* press brakes - Bystronic offers a wide range of press brakes from the Hammerle 3P range to the Beyeler PR range to the AFM EP series to ensure customers choose the correct machine to meet their bending needs.

Two Beyeler machines were on show at MACH.

The first machine has a bending length of three meters and a pressing power of 100 tonf (100kN).

It also features the award winning Integrated Process Control (IPC).

IPC controls the bending angle without the use of mechanical measuring equipment and without intervention in the control or the need to change parameters.

The second Beyeler PR machine featured an ABB industrial robot to form a highly efficient bending cell.

This cell produces a high quality product that is independent of an operator as well as increased productivity of up to 42% and requires the minimum of space.

The AFM EP series press brake to be shown fulfils the highest demands placed on process reliability by users.

When this is paired with a comparably low purchase price, this machine represents, for individual users, an extremely cost effective, reliable machine with the support and backup of the Bystronic organisation.

The bending and mechanical sector of the Bystronic stand also features a ByShear VR which produces a consistently high quality cut.

The incorporated VR technology allows automatic setting of the cutting angle and cutting slot and is suitable for cutting both thin and thick sheets of materials, in various types.

Bystronic also demonstrated various software programs including the new ByVision and the successful BySoft.

Both the laser systems and waterjet machine on show will be controlled by ByVision.

Visitors were able to learn more about the software available by participating in the software forums.

As well as its own products Bystronic UK also supplies, in the UK, the Pullmax range of CNC punching machines and the Virtek LaserQC measuring systems and examples of these were on show.

* CNC punching - flexibility, increased efficiency and the highest level of precision for punching are provided by the latest Pullmax punching machines and the Pullmatic 520 FC is the perfect illustration of this.

Not only does the customer get a punching machine when he invests in this machine he also gets the opportunity of turning it into a press brake, making it possible to finish complex parts in one set-up.

The punching and and profiling machine shown features this new tooling option which has been developed in conjunction with Wilson Tools.

This optional six-station tapping unit allows folds of up to 50mm long x 70mm high to be bent making the machine more versatile and allowing increased profits per part.

The machine is also equipped with a fabrication centre (FC) for the automatic loading and unloading of sheets for lights out or un-supervised operation.

Also to be seen on show was the successful and versatile Virtek Laser QC.

The system provides a unique method of rapidly inspecting 2D parts and reverse engineering and offers customers the opportunity to monitor their process through SPC charts easily generated by the Laser QC software.

Subcontractor purchased a nitrogen generator to replace an expensive manifold cylinder pack supply and has had no customer complaints due to edge quality, no breakdowns, or 'gas-outs'.

Martin Cook of Cutting technologies said: 'We purchased a nitrogen generator from MSS in November 2005'. 'We were previously running on MCP's (manifold cylinder packs), the most expensive option of nitrogen supply, but were struggling to get our Landlord's approval for external bulk storage. As an example of the high cost, we had to charge £80.00 per hour just for nitrogen when cutting 12mm stainless.' He explained: 'We only run two lasers, but we run them long and hard and a high percentage of our work is decorative stainless, aluminium and brass, up to 15mm thick in stainless steel, 10mm in aluminium and 6mm in brass.

We are currently running the generator at 90ppm oxygen impurity and achieving a flow-rate in excess of 70m3 per hour.' Prior to purchase the company carried out numerous trials at different ppm oxygen levels and showed the results to the most critical clients.

The company reports that it had had no negative feedback at levels below 150ppm, so proceeded with the installation.

Cook said: 'We chose a generator that would cope with 80% of our work and expected to have to supplement its output occasionally with MCPs.

We have run solely on the generator since November 2005 and have had no customer complaints due to edge quality, no breakdowns, no 'gas-outs' and never had to supplement the generator output with bottled nitrogen.' He added: 'In other words, the generator has done exactly what it 'says on the tin.

The most it has coped with across the two machines has been 10mm stainless on one and 5mm aluminium on the second machine, again with no issues and the generator was filling the tank quicker than we were emptying it.' The company has negotiated a five year maintenance contract, which is next to nothing per month, efficiency has improved dramatically through not having to constantly change MCPs, the factory is a much safer place because as it is not constantly moving the MCPs around and, said Cook: 'We dare not print how much we are saving per month on the nitrogen.

We are really pleased the landlord stopped us installing external bulk storage, he's saved us a fortune.' Nitrogen represents a significant percentage of a laser company's costs and anything a factory can do to reduce this is beneficial to its profitability and its competitiveness against other processes.

Prima Industrie beat off stiff competition from other leading machine tool manufacturers to win the Best Metal Forming / Fabrication Machine category in this year's Metalworking Production awards.

Prima Industrie beat off stiff competition from several other leading machine tool manufacturers to win the Best metal forming / Fabrication Machine category in this year's Metalworking Production awards, held at the Hilton Birmingham Metropole Hotel on 16th May. The company's new Syncrono machine - exhibited for the first time in the UK on Prima's stand at the MACH '06 show - won the judge's decision on the strength of its innovative design, which dramatically reduces cycle times and piece part production costs. Claimed to be the world's fastest 2D laser cutting machine, the Syncrono achieves a maximum head acceleration of more than 6g, twice that of previous benchmark machines, enabling it to produce over 1000 holes per minute in light gauge sheet metal applications.

Its ability to double the performance of other high speed laser machines is due to a number of key design features.

In effect, the new model is two machines in one - a larger unit with a 3000 x 1500 mm processing area, combined with a compact, short stroke, high dynamic head.

Both elements move independently, but are fully synchronised using patented control algorithms - allowing the machine to achieve extremely high cutting rates throughout a large machining envelope.

The parallel kinematics of the Syncrono's head and main carriage are optimised for minimum cycle times, with the required cutting trajectory generated automatically from standard machine G-code, without the need for any operator intervention.

Through increasing productivity by as much as 50% on components up to 3 mm thick, the Syncrono challenges the speeds of many CNC punch presses, while eliminating the need for costly tooling, cutter refurbishment, setting-up and change-over times.

The new machine's dynamically-balanced, low mass head incorporates advanced control features to eliminate vibration and maximise both machining accuracy and repeatability.

The Syncrono also utilises a high performance Prima CP4000 laser unit and is equipped with interchangeable optics to accommodate materials up to 20 mm thick.

Further features include simple installation and commissioning, constant laser beam length over the complete machining area, fibre-optic linked digital servo drives and intuitive operation using the system's 15 inch flat touch screen interface.

Prima's Syncrono is available with optional laser piercing monitoring for optimising the processing of heavy gauge materials, and a number of automatic work handling solutions for maximising production throughput.

As part of a strategy to create a production facility separate to its prototype shop, Coventry-based DCM has opened a new high productivity fabrication centre at Warwick.

As part of a strategy to create a production facility separate to its prototype shop, Coventry-based DCM has opened a new high productivity fabrication centre at Warwick. Forming the centrepiece of the new facility is a Trumpf L2510 flatbed laser and two TrumaBend V500 CNC press brakes, which produce small batch production components on a rapid turnaround Kanban system for a number of high profile automotive OEM and Tier 1 companies. 'We wanted to create a different philosophy at our new site,' explains Managing Director Nigel Stokes, 'one of lean manufacture and Kanban operation - hence the machines we selected were vital to its success.' Although DCM has been a Trumpf user since the early 1980s, the company had a long look at the marketplace before making its final decision.

'We certainly considered others but as always the price/quality ratio of Trumpf won out.' DCM's new Warwick facility opened in January complete with an L2510 flatbed laser and two TrumaBend V500 press brakes.

'Warwick is now our production centre,' continues Mr Stokes.

'All 14 staff at this facility are new recruits as we wanted to start with an open approach to the new methodology we were looking to impart.' Operating for automotive customers, as well as other clients in the aerospace, telecommunications and construction sectors, means DCM has had to gear up for Kanban deliveries.

The company's prestigious clients supply an empty storage box to DCM once a week to be filled with components of the correct quality and quantity.

Batch sizes are typically in the region of 25-50 a week - the largest batch is around 200.

DCM processes parts ranging in thickness from 0.9 to 10mm, mostly from mild steel material.

'We have designed the whole process to be ultra lean,' says Mr Stokes, 'which means having flexible machines that can be set-up as quickly as possible - one of the key reasons we selected Trumpf.

The L2510 laser has a self-loader, which is one of the best purchases we have ever made - automation is absolutely crucial to compete with manufacturers based overseas in economies with a low cost base.' Formed nearly 50 years ago, DCM continues to be a leader in its field.

The company's headquarters remain at Coventry, where 70 staff are based, although the facility only produces prototypes since the opening of the Warwick scheduled production centre.

Mr Stokes says that it is the balance of quality, flexibility and price that sets DCM apart from its competitors, as well as one other key factor: process repeatability.

'When we load a program and press the start button we need to feel confident that the part will come off correct - we get that with Trumpf.'

The most recent addition to ESAB Automation's plasma cutting range is the Suprarex SXE-P.

The most recent addition to ESAB Automation's plasma cutting range is the Suprarex SXE-P. It delivers high cuttings speeds, low running costs and requires minimum service. It combines a rugged heavy duty portal beam and rail system with extremely precise, maintenance free, dynamic AC drives and guiding systems.

Advanced, easy to use CNC controls with colour graphics are also included.

The Suprarex SXE-P can be supplied with a variety of precision plasma systems for cutting and marking to cover plate thicknesses from 1 mm to 40 mm.

The performance of the Suprarex SXE-P is further enhanced by high cutting and positional accuracy.

This is achieved through the double side rack and pinion longitudinal drive and rack and pinion transverse drive with optional linear guide.

The CNC cutting database control is intelligent and easy to use.

Collision protection on plasma torch is provided to avoid damage and there is also enhanced collision protection.

Cutting and positioning can be carried out at 24000 m/min.

Optional cutting tools including additional plasma and oxy-propane torches as well as optional plasma bevel cutting.

High precision laser cutting system profiles medical implants such as stents or other precision components and speeds are ten times higher than with the first machines.

Rofin / Baasel Lasertech presents the new StarCut Tube - a high precision laser cutting system for profiling medical implants such as stents or other precision components. State-of-the-art technology allows cutting a coronary stent of 8mm length in less than 1 min. A stent is a device which is surgically inserted into blood- or air-ways and expanded to hold a passage open to facilitate free flow.

Coronary stents are typically of order of 1mm diameter metal tubes which are inserted inside arteries as an alternative to heart bypass operations, for example.

Over 10 years ago the first such tube cutters were sold for making stents.

These had a gear driven rotary axis, an open work station and a separate supply unit for the laser source.

Today, after several hundred successfully installed systems, the fifth generation of StarCut Tube operates at up to ten times faster than the original launch machine.

The basis for the enormous increase in productivity is the state-of-the-art motion system based on linear motor technology and the direct drive rotary axis.

The sophisticated control unit of the laser adjusts all performance parameters of the laser source optimally to the travel speed of the motion system.

Even smallest radii pose no problem.

The actual contour trajectory can be viewed on the large TFT monitor at any time.

With the proven massive granite set-up, a dimansional tolerance of only a few microns can be achieved - and with high long term stability.

Another benefit the new StarCut Tube offers is the possibility to choose between several available sources: the proven StarCut 18 laser with a power range of 7 to 25W achieves 'kerf' (the width of the laser cut) widths of 18-20 microns.

The new StarCut12fm, a fundamental mode laser with 12 W makes kerf widths smaller than 15 micron.

Finally, state-of-the-art fiber laser technology: the Star-Cut Tube Fiber with maximum 20W power can also achieve kerf widths below 15 micron in suitable materials with high productivity.

Laser source, control, drives with supply modules and the automatic tube loading are integrated into the compact and ergonomic housing.

Rofin/Baasel Lasertech paid particular attention to ensuring easy access to the components, for set up, loaning and unloading.

Operation and the loading and unloading of tubes is done from the side.

A high quality stereo microscope or, as an option, a camera allows process viewing.

The StarCut Tube is configured to use a variety of process gases with a pressure of up to 25 bar.

The StarCut Tube wet cutting option allows cutting with liquid flushing inside the tube.

The optional 4-axis version allows non-radial cuts which opens up the possibility of cutting hole contours as produced by mechanical milling or eroding.

In this way novel geometries can be created to optimize the flexibility of stents even further.

For cutting of high precision flat sheet components, a cutting support box is available.

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS), 10 a.m.-6 p.m., Sept 6-13, at McCormick Place in Chicago.

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS), 10 a.m.-6 p.m., Sept 6-13, at McCormick Place in Chicago. During IMTS, Jet Edge sales engineers will conduct live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System utilizing the high-powered iP60-60 intensifier pump, AquaVision Di motion controller, and the new digital readout for Multi Head Positioning. Look for Jet Edge in booth #B-6252.

Jet Edge's waterjet-cutting systems cut nearly any material, from food products to hardened tool steel to titanium.

The company's systems are being used by the world's leading airlines, automotive and aerospace manufacturers as well as industrial manufacturing companies and machine and job shops around the world.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

'Our cutting systems have many advantages,' said David Dumas, Jet Edge sales director.

'We are known for our very large work areas and accuracy.

We can hold an accuracy of 0.005 inch with a repeatability of 0.001 inch over the entire work envelope.

Our cutting systems are powered by hydraulic intensifier pumps that can offer 15,000 to 30,000-plus hours of operation on the hydraulic pump, depending on the model.

This, of course, means greater productivity and lower operating costs.

The cutting systems are controlled by a state-of-the-art AquaVision Di motion controller that guides users through the project step-by-step.' During IMTS, show participants can see for themselves the remarkable versatility and speed of Jet Edge's High Rail Gantry System.

They also can see Jet Edge's new iP60-50 intensifier pump in action.

The 'heart and soul' of the Jet Edge waterjet cutting system, the iP60-50 intensifier pump is rated for 60,000 psi and features an extended-life hydraulic system.

The iP60-50 intensifier pump provides easy access for all service and maintenance.

It features non-threaded high-pressure components in the high-pressure cylinder, an improved performance check valve, and low torque values.

The Jet Edge iP60-50 intensifier pump leads the industry with ease of operation and low operating cost.

It requires very few tools to maintain.

The cutting system is controlled by the AquaVision Di motion controller that guides users through the process from job set-up to production.

With the AquaVision Di, single parts, part arrays, mirroring, scaling, rotation, and plate alignment are right at users' fingertips.

The AquaVision Di is fully networkable, allowing part programs to be generated offline and easily transferred to the system's hard drive for production.

Feed rate and acceleration are automatically varied, based on known features of a specific job.

Dynamic tool offset, or 'cutter compensation,' is employed real-time, and an optional real-time pump control allows remote starting and stopping of the pump, dual pressure set points for piercing hard-to-pierce materials, and unlimited data logging of every process parameter imaginable.

The AquaVision Di includes a full-featured hand-held pendant that allows feed rate override, return-to-path, program zero set points, and XYZ axis control.

Show participants are sure to be impressed by Jet Edge's new Digital Readout for Multi Head Positioning, which improves productivity by reducing setup time.

The Digital Readout for Multi Head Positioning digitally displays cutting head positions, eliminating manual measurement.

It is an excellent addition to your Jet Edge waterjet cutting system.

Supplier of composite components to the Formula One and motor racing industries has expanded its waterjet cutting service by adding a 50HP intensifier to an existing cutting table.

For the highly competitive Formula One and motor racing industries, the delivery of critical components and assemblies on time, every time is absolutely critical. Panther Composites' waterjet cutting division is a major supplier to this market and has now upgraded its waterjet cutting service by adding a new KMT Waterjet Cutting Systems Streamline Classic 50HP intensifier to its existing Powerjet Systems cutting table. This installation is already paying dividends with the company now able to take on more and varied cutting tasks from both the motor racing sector and other general sub-contract engineering customers.

Panther Composites was originally founded by a management team with extensive Formula One engineering experience with the Williams team.

When Paul Bowen joined the company to establish the waterjet cutting services division over two years ago, he too had a wealth of experience in the motor racing sector.

'There is no leeway for lateness on delivery to customers in this sector and the ability to be able to cut a variety of materials is also critical,' he said.

To provide the type of service required, Panther invested in a Powerjet Cutting Systems 3.0m x 1.5m waterjet cutting table.

In the last two years this has provided Panther with excellent service.

For its many different customers involved in motor racing, Panther uses the abrasive waterjet cutting process to cut materials as tough and varied as aluminium, titanium, Inconel, tungsten as well as rubber components.

'There is no material that our customers need that we cannot cut,' said Bowen.

The decision to invest in 2005 in a new KMT Waterjet Systems Streamline Classic 50HP intensifier and Abrasive Management System to use alongside the Powerjet Systems cutting table was made in order to give the company even greater opportunities to provide services both to the motor racing and general engineering sub-contract services sector.

'We now have a world class waterjet cutting facility, combining the Powerjet table with the KMT intensifier,' said Bowen.

The investment has given Panther Composites the ability to take on extra work with confidence, including the cutting of heavier materials.

The company's customer base now also includes building industry clients where the ability to cut ceramics and stone with high accuracy is important.

The 37kW Classic pump has represented a highly cost-effective investment for Panther and includes advanced features such as Soft Start which can give up to 20% energy savings when the pump is first switched on.

The Hard Seal End Cap topwork design reduces both consumable costs and downtime.

The AMS I Abrasive Management System is helping to automate the cutting process.

It starts with the Abraline III abrasive transfer system that monitors abrasive availability and ensures sufficient quantities throughout the cutting process.

The Feedline III abrasive metering system accurately controls the flow rate of abrasive to the Autoline abrasive cutting head which gives a consistently high quality of cut.

Off-line programming for cutting any components helps to speed Panther's production process with cutting programmes downloaded directly to the Powerjet Systems cutting table.

Bowen concluded, 'There is no question that the waterjet cutting process is highly versatile and has opened the door to new customers for Panther Composites.

The KMT installation is proving highly reliable and efficient.

In combination with the Powerjet Systems cutting table, it is allowing us to give out customers a first class sub-contract service.'

A powerful off-line drawing, editing and nesting software for CNC profiling machines allows drawing, nesting and cutting operations to be performed quickly off-line, without fuss.

ESAB Automation's new powerful off-line drawing, editing and nesting software for CNC Profiling machines is ideal for all sizes of fabricators. It allows drawing, nesting and cutting operations to be performed quickly off-line, without fuss. Interactive nesting for improved plate utilisation is offered together with cutter path definition, marking tool definition and post processing for all CNC controls.

Using this software, the operator can develop just about anything for plate and sheet fabrication including 2D + 3D DXF and marking, forming and costing details.

The software also offers a range of productivity options.

The profile quoter defines shape, specifies plate/process details, nests and calculates the cost.

The scanned outline facility converts scanned images into vectored outlines ready to cut.

It supports BMP, TIF and other formats and can output DXF and CAM files.

The font generator turns windows text into NC code, whilst the 3D development option ensures fast and simple plate development.

Other options include a remnant plate tracer which is a unique graphic remnant tracing software.

It is very simple to operate either standalone or as part of an integrated system.

The automatic nesting feature maximises plate usage, optimises machine time and minimises programming time.

Sheet metal working subcontractor has replaced a CNC punching machine with a flat bed laser, resulting in in 24h of minimally supervised work against a former 8h of manned production.

A UK subcontract manufacturer, Saint Ann's Sheet Metal Company, is replacing an existing punching machine with a new Trumpf Trumatic L2510 flatbed laser and in so doing swapping 8h of manned production for 24h of minimally supervised and 'lights out' production. 'The growth potential this machine offers us is huge,' explained managing director Dave Bloomer as he confirmed the company's order at MACH 2006. 'But it is not just productivity of the machine that is important to us, it is also the superb quality of its output.' Saint Ann's is taking delivery of the L2510 that appeared on the Trumpf stand at the show, a machine that attracted considerable interest thanks to its built-in automation.

'Nothing compares with the L2510 for its small footprint,' Bloomer added.

'Our factory is in a residential area and space is limited.

Being able to get significantly greater productivity from such a compact machine is great for us.

Our location also requires us to keep close control of our noise levels and the laser will certainly help to create better neighbour relations.' The L2510 is Saint Ann's first Trumpf machine and an important reason for its choice is to eliminate the need for deburring.

The majority of work produced on its existing punching machines needs secondary finishing, a time-consuming and costly addition.

With customers seeking significantly shorter lead times and competitive costs, methods need to be continually improving these days.

An existing job for 20,000 parts per annum for the electronics industry will immediately benefit from the new acquisition.

'We will make substantial productivity gains as the L2510 will take cycle times down by 10 seconds per part,' Bloomer continued.

'And of course there will be no need to deburr.' The company also cites Trumpf's Telepresence as an important feature in minimising potential downtime through on-line problem diagnosis.

As well as being able to provide a better service to its established automotive, shop fitting, H and V and marine engineering markets Saint Ann's is confident that the L2510 will greatly extend its scope.

'This is a highly flexible machine that will also allow us to include working with tube as part of our services,' Bloomer concluded.

'Installation started on 24th May and we are expecting great things from this machine.

We have an excellent team of men at Saint Ann's and I am positive that they will make very good use of this super laser to take the company to its next phase.'

The addition of a 2D system with a flatbed laser will enable a subcontract fabricator to undertake the machining of tube, profiles and box sections - for which demand in the UK is increasing.

From its origins as the provider of laser cutting services to other companies in the WEC Group, Laser Engineering has emerged as a major player in the laser- subcontracting field. Its impressive growth has been secured by continued investment in the latest technology but the company's latest acquisition will do more than simply increase capacity. Laser Engineering has just ordered a Trumatic L3050 flatbed laser machine from Trumpf with its sights firmly set on adding tube and box section cutting to its portfolio of services.

The machine is equipped with a Rotalas system, consisting of a NC rotary axis fixed to the machine frame for machining pipes and profiles.

A flexible support system guarantees that a wide variety of tube is guided securely.

The WEC Group now comprises four separate and complementary divisions - WEC providing camera-mounting solutions, welding engineering, architectural fabricator M-TEC and Laser Engineering.

It employs around 200 people.

The divisions serve all manufacturing industries from automotive, construction and transport through to pharmaceutical and catering, covering the full spectrum of heavy to light fabrication work.

Laser Engineering already has three Trumpf flatbed laser machines with 4, 5 and 6kW power with a bed size up to 4m x 2m.

They allow the processing of aluminium, mild and stainless steel from 0.5mm to 25mm.

Despite being a long term Trumpf customer however, Laser Engineering did not automatically 'plump' for another Trumatic.

The company wanted to assess thoroughly all other options to ensure it had the best machine for its needs in relation to both cost and performance.

In the final analysis however it was the Trumpf L3050 that met all Laser Engineering's purchasing criteria.

This latest addition to its range will have the same capacity as the existing Trumpf flatbeds but will be equipped with a series of optional features to increase its capability.

The addition of RotoLas in particular will enable Laser Engineering to undertake the machining of tube, profiles and box sections.

The demand for this type of work is indeed on the ascendancy and the company wanted to ensure that it was able to anticipate its customers' needs in this regard.

'We operate very tight lead times and needed the L3050 to guarantee fast turn round of our increasing workload,' explained general manager Wayne Wild.

'For us the L3050 offered the quality we needed at a price and with running costs that would prove most economical over a five year period.' Laser Engineering's new L3050 is due for installation at the company's factory in Darwen, Lancashire, UK, during the summer.

'Its extra capacity will enhance our Gold Same Day and Silver Next Day services,' Wild concluded.

A versatile water jet cutting machine has helped a gasket manufacturer increase productivity by eliminating the need for tooling for short and long-term jobs and prototypes.

During economic downturns, many businesses rein in their spending and hope merely to stay afloat until the storm passes. Others seize the opportunity to lunge ahead of their retreating competition by reinvesting in their business and increasing their productivity. This is a story of a gutsy gasket company that never stopped investing in its business and continues to grow as a result of its bold initiative.

Located in historic Haverhill, Massachusetts, New England, USA, Die Cutting is a rapidly growing gasket fabricator that serves the military, electronics, medical, and commercial industries.

With capabilities including die cutting, laser cutting, waterjet cutting and CNC drilling and routing of plastics, NEDC manufactures products from a wide range of materials, including elastomer, sponge, foams, films, extrusions, EMI shielding and thermal interface materials.

Business has been very good for this ISO 9001:2000-certified company, which is quickly transitioning from a small job shop to a true manufacturer.

In fact, NEDC recently moved into a new 18,000ft2 building, a huge step forward from its humble beginnings in 1982, when husband and wife David and Kim Abare opened the business at a former shoe factory on Haverhill's River Street.

In March 2005, NEDC received its 'Woman Owned' certification from the Women's Business Enterprise National Council, an important accomplishment for a company whose primary clients are defense contractors who are asked to place 23% of their dollars with certain small business categories.

In May 2005, NEDC received a US$40,000 grant from the Commonwealth of Massachusetts' Work Force Training Fund to implement lean manufacturing, and in spring 2006, the company received its Small Business Association 8(a) certification.

Over the years, NEDC has developed premier partnerships with Parker Chomerics, Laird, Thermagon, MTI, Grondyke, Bergquist, 3M, St.

Gobain and Rogers.

NEDC president Kim Abare attributes her company's phenomenal growth to continued reinvestment in the business despite economic downturns.

'Most companies feel a temptation to stop spending on advertising, marketing and new equipment when the economy takes a downturn,' Abare stated in the October 2005 'Gateway' magazine.

'You must always keep reinvesting in the business in order to stay ahead of the competition.' Despite its growth, NEDC retains the hospitality of a family-owned business.

NEDC's staff of 28 provides the quality products and service you would expect in this enterprising New England river town.

During the past two years, NEDC has made a number of its own enterprising moves, including adding abrasive waterjet cutting services to its lengthy list of capabilities.

In 2004, NEDC acquired a Jet Edge abrasive waterjet cutting system, which it uses to cut numerous types of material including metal, plastic, rubber, resin composites, tile, and glass.

Manufactured by Jet Edge, of St.

Michael, Minnesota, the abrasive waterjet system can cut through any material utilizing water that is pressurized up to 55,000 lb/in2 with a Jet Edge intensifier pump.

Abrasive garnet is added to the water to increase cutting speed through hard materials.

NEDC's Jet Edge system is capable of cutting sheets that are as big as 5ft by 10ft.

The machine is powered by Jet Edge's 50HP 55-50C intensifier pump and controlled by Jet Edge's PC-based AquaVision interface featuring SigmaNest software and automated features including 'Automatic Trueshape Nesting', 'Automatic Feedrate' generation and corner ramping, graphical and/or G and M code display, plate alignment, remote pendant, real-time cutter compensation, point and click start/stop points and more.

NEDC could have bought their waterjet system from a number of manufacturers, but they chose Jet Edge primarily because it is American made, Kim Abare said.

'We have lost so much business overseas, that to us, it is paramount that we invest in American-made equipment,' she explained.

'Beyond this reason, Jet Edge's sales director David Dumas specifically flew out to our facility, 1,500 miles away, to ask for our business, making us feel like we are an important customer.' NEDC vice president David Abare said he has been very satisfied with Jet Edge's equipment and customer service.

'First and foremost, compared to other equipment, it almost never goes down,' David Abare said.

'It is the most reliable piece of equipment we've ever invested in.

It's a versatile machine, meaning that it can cut anything, anyway, anytime.

By far, Jet Edge has done everything they said they would.

Their service has been fabulous.

Their sales guy is welcome here, and stops in from time-to-time, buying pizza for our shop.' The Jet Edge waterjet cutting system has helped NEDC increase productivity by eliminating the need for tooling for short and long-term jobs and prototypes, he noted.

'The part can be cut instantly using a DXF/IGES,' he said.

'We have one customer that requested an intricate part that would have cost US$8,000 to tool.' 'We were able to save that customer that money and cut a prototype, allowing him to make additional changes.' In addition to saving production time, the Jet Edge system also saves NEDC material costs by giving them the ability to tightly nest parts, David Abare noted.

Asked if he would recommend Jet Edge to other businesses, David Abare responded: 'Absolutely.' * About New England Die Cutting - call 001 978-374-0789, visit http://www.nedc.com or e-mail sales@nedc.com.

* About Jet Edge - Jet Edge is a global designer and manufacturer of ultra-high pressure waterjet systems for precision cutting, surface preparation, coating removal, and hydro demolition.

Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

* Advantages of Jet Edge Waterjets - Jet Edge waterjets offer many productivity and flexibility advantages over traditional cutting methods including: no sharpening and no burrs requiring secondary finishing.

Waterjets completely eliminate heat-affected zones, toxic fumes, recast layers, work hardening, and thermal stress, and offer a hygienic method for cutting food.

Jet Edge waterjets can hold a positional accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope.

They have been known to cut materials up to 15in thick.

Waterjets are environmentally friendly and produce no hazardous waste, reducing waste disposal costs.

They can cut off large pieces of reusable scrap material that might have been lost using traditional cutting methods, parts can be closely nested to maximize material use, and the waterjet saves material by creating very little kerf.

Waterjets use very little water (a half gallon to approximately one gallon per minute depending on cutting head orifice size), and the water that is used can be recycled using a closed-looped system.

Waste water usually is clean enough to filter and dispose of down a drain.

The garnet abrasive is a non-toxic natural substance that can be recycled for repeated use.

Garnet usually can be disposed of in a landfill.

A low cost, compact portal cutting machine will appeal to small and medium sized companies looking for a competitively priced cutting system that optimises quality, productivity and efficiency.

ESAB Automation has introduced the new Falcon low cost, compact portal cutting machine. It will appeal to small and medium sized companies looking for a competitively priced cutting solution that optimises quality, productivity and efficiency of production. The standard Falcon is an oxy-fuel cutting machine package with two torches.

It is also possible to up-grade to plasma-arc or indeed a combination of plasma-arc and oxy-fuel gas cutting.

Each cutting torch has automatic height adjustment to ensure that the cutting torch head is always at the correct distance from the workpiece.

The Falcon can be used to cut on all steels, aluminium and alloyed steels.

Depending on the torch used, metals up to a maximum thickness of 150mm can be cut.

The cutting width is 2.70m, the maximum cutting length 15m.

Following a serious fire, a CNC laser profiling machine company ordered a replacement laser resonator from Germany for a damaged, resited machine, and it was installed by next day.

On the face of it the loss of its manufacturing facility in the UK's Buncefield Oil Depot blaze in December 2005 could have been completely ruinous for subcontractor PCD. However with the support of suppliers, fellow traders and its insurer, PCD was up and running again within a matter of days. Furthermore, the disaster has given the company the opportunity to review its business and to re-establish itself with a greater range of manufacturing services in purpose designed premises.

Although its building was deemed unsafe after the blast PCD was fortunate not to suffer significant equipment loss.

Its powder-coating line and a graining and deburring machine were irreparable as was the laser resonator on a machine that is central to its production, the Trumpf L2530 flatbed laser.

Otherwise everything remained operable and in the immediate aftermath the PCD team simply donned hard hats and continued manufacturing as best they could.

Thanks to the swift work of insurers however PCD soon found temporary accommodation in the old Aquascutum factory in Hemel Hempstead.

Within a matter of days the company had re-located the lion's share of its production facility.

In addition to its Trumpf flatbed, PCD also has two Trumatic punching machines and chairman, Phil Cutts is quick to commend Trumpf's speed and efficiency in getting these important machines up and running again.

He explained, 'Having installed the L2530 at the new site Trumpf ordered a replacement laser resonator from Germany at 3.30pm the same afternoon.

When I arrived at the factory at 8.30am the following day it was already on the machine.

Trumpf really did us proud.' Within weeks a new powder coating line had been ordered and installation completed by April '06.

The grainer was ordered, installed and is now fully operational.

'By comparison with last year's trading figures in February '06 we were at 65% and by March, 80%,' explained David Stoneham, managing director.

'And by April we expect to resume the monthly business growth that prevailed before the fire.

Everyone has worked extremely hard to secure this recovery.' PCD is a BS EN ISO 9001:2000 certified subcontractor specialising in precision sheet metalwork, finishing and assembly.

It serves a wide customer base encompassing the telecoms, datacoms, audio, electronic and lighting industries.

During its 24-year history the company has steadily grown, introducing additional services such as powder coating and silk screening.

The original factory, destroyed by the blast, reflected this organic growth.

Although a devastating experience, the fire has presented PCD with the opportunity to plan a new factory layout that really is fit-for-purpose with flexibility for expansion.

Furthermore, it has allowed Phil Cutts and his team to look at the business and make it even better.

'We have invested in flexible, automated processes to enable us to undertake a broad variety of work economically,' Cutts explained.

The Trumpf TC5000R is equipped with automatic loading and the software is installed on PCD's latest acquisition, the TC3000R to provide a similar degree of automation.

'We are running both lights-out with minimal manning, specialising in close limit work such as chassis, panel work and enclosures.' PCD sees an expanding need for this type of cost-conscious, quality manufacturing and is now seeking to add value to the business by augmenting its growing sheet metalworking operation with other in-house machining services.

'Currently we outsource any machining element a job may require,' added Cutts.

'Having turning and milling in-house will allow us to provide customers with the complete manufacturing package and give us full control of scheduling and quality.' Plans for PCD's new factory on the original site have now been finalised.