Transferring Optical Technologies to Moulds for Mass Production

It is common knowledge that much of mass production has moved to the Far East, and to China in particular. The press has highlighted increasing dangers of out-sourcing of materials and components through complex and time-critical supply-chains. This is arising in a fast-changing world, due to factors such as shifting global-politics, Brexit, skills-shortages, and COVID-19 (with mutations and possible future pandemics). Prominent organisations, such as NatWest and the long established trade-association - GTMA - Gauge and Toolmakers Association, have called for 're-shoring' of manufacture - bringing back "making things" to the UK, with the prosperity and jobs that implies. Indeed, GTMA has established an organisation to promote precisely this - Reshoring-UK with some thirty trade association partners.

Interestingly, one commentator observed, 'reshoring manufacture must start with the mould and die sector', and that is precisely the sector on which this project is focussed. Moulds and dies are so important because they are the essential tooling needed to mass-produce a host of typically plastic components that surround us on every side - from car parts and household items, to medical components and mobile phones. These moulds and dies are usually thick, heavy, metal blocks, often of steel, which are machined into the complex 3D contours needed to mould the plastic components. The remarkable fact is that, in the 21st century, most of these machined blocks are still hand-finished by highly-skilled artisans with decades of experience - and they are retiring! Using hand tools and abrasives, they meticulously work surfaces, removing burrs and other defects, control contours in inaccessible nooks and crannies, and create what may be a requirement for uniformly-dull surfaces (to be imprinted on the plastic) or often, a highly polished finish. In the latter case, the detailed surface can be extremely critical, as tiny ripples or residual scratches or pits will imprint into the plastic, and can spoil the aesthetic appeal of the final component, or in the case of the medical sector, provide crevices to harbour germs.

Working with GTMA and Reshoring UK, this project aims to transfer a wealth of University expertise in the manufacture of lenses and mirrors for astronomy, into automating mould and die finishing. The lead partner is the Laboratory for Ultra-Precision Surfaces, which the University of Huddersfield has established at STFC's Daresbury Science and Innovation campus near Warrington. Dr Guoyu Yu, who leads the project, has extensive experience of automated polishing using CNC polishing machines from Zeeko Ltd, and robots from Fanuc robot. Dr Yu's team will use both types of machine to develop processes optimised for mould steels. Zeeko is joining the project as an industry partner, because it has a special interest in improving mould-polishing for its customers. Wayland Additive produces advanced electron-beam machines for 3D-printing of complex components, providing an attractive alternative to classical machining. Wayland is interested in diversifying into the mould and die sector. The consortium is rounded up by Arthur Jackson and Co, who is a mould manufacturer who wants to automate their manual processes.

The three industry partners will provide samples to be used for process development in the lab at Daresbury, and will help in assessing the results for their respective applications. We hope that what will emerge from the project is a joined-up automated manufacturing process for moulds and dies, starting with conventional milling or 3D-printing, and then proceeding through finishing process-steps to deliver defect-free and highly-polished components. This promises to bring new business to the partners, and we hope will help to stimulate a wider re-shoring - and indeed renaissance - in UK manufacturing.