Sodick machine brings wire EDM in-house at automotive toolmaker

Warwickshire-based 2G Tooling, a specialist in precision press tooling for the automotive industry, is leveraging the benefits of a Sodick VL400Q from Sodi-Tech EDM to bring in-house previously outsourced wire-erosion capabilities. As well as the savings this strategy has delivered, the investment is also allowing the company to reduce lead times and impart greater control over important business functions such as scheduling and quality.

Based in Southam, close to the heart of the UK’s automotive sector, 2G Tooling is building on an impressive start to life after the company was founded by brothers Chris and Jon Peters in 2013. Although Jon is a silent partner, Chris has 30 years’ experience in the industry as a time-served toolmaker and business manager. Beginning with just one vertical machining centre, and working at nights and weekends, 2G Tooling soon evolved into a full-time concern. With more machine-tool capability soon arriving, the recent requirement to invest in the latest wire EDM technology seemed a natural progression.

“We were receiving more and more enquiries for the cutting elements of press tools, such as punches and dies, especially ones capable of the high volumes required in the automotive industry,” explains Chris Peters. “Manufacturing punches and dies benefits from the capabilities of EDM, but we were subcontracting this requirement. However, with the ongoing success of the business, we had reached the stage in our development where we could afford to bring wire EDM in-house.”

Mr Peters scrutinised three major vendors of wire-erosion technology, opting for Sodi-Tech EDM as a result of “the whole package” solution available.

“Beyond the price and performance, it was important that we found an EDM partner able to provide exemplary service and support,” says Mr Peters. “We are a small business with only one EDM machine, so response times are key. Since the machine was installed in April 2017 we have only had one issue – a timing problem with an interlocking guard – but Sodi-Tech sent out two engineers who sorted it immediately. Having that peace of mind is invaluable.”

Another factor that heavily influenced the purchase decision was the build quality of the Sodick VL400Q.

“We had a series of trials on the machine and could see immediately the quality of the machine’s construction,” says Mr Peters. “As a small business I am still relatively hands-on, so I notice these things. I could also see that attention had been given to ease-of-maintenance. Overall, the machine was miles ahead of lower-priced machines on the market, and significantly better than many higher-priced ones too!”

The learning curve for the new Sodick machine proved extremely short, with just half a day training for Mr Peters and three days for one of the company’s apprentices; both programmes were delivered by Sodi-Tech EDM. The apprentice now runs the machine.

Press tool punches and dies manufactured on the Sodick VL400Q are used to produce automotive body-in-white (BIW) panels for “all the major OEMs”. Made from hardened tool steel, accuracy between the top and bottom (clearance) is normally in the region of 0.05mm, which Mr Peters says is “achieved without problem” using the Sodick machine.

“Furthermore, the surface finish capability is second to none, while the really tight corners produced by the machine are perfect for complex punch and die manufacture,” he states. “Using less capable or older technology would require hand-fitting or diamond filing to achieve the required corner profile, but not with the Sodick VL400Q.”

Despite being a secondary process machine for 2G Tooling, the Sodick VL400Q has been working almost constantly since its installation. This medium-sized model features Sodick’s Linear Motor Technology and is ideal for a wide range of machining applications.

“It’s not so much about what the new machine has saved, but what it brings,” concludes Mr Peters. “We design in-house, so we design all of our tools, jigs and fixtures around what we have. Now that we have the Sodick VL400Q, we can offer a lot more design capability. There are a lot of machine shops in the Midlands, but a diminishing number of toolmakers, largely due to the high level of skill involved. Knowledge is our USP, and this is increasingly supported by a growing number of machining processes at 2G Tooling, including milling, turning, grinding, and now, wire EDM. Quality, on-time tooling is always at the forefront of what we strive to achieve.”