The range of projects that the Weir Minerals iron foundry at Todmorden is engaged with, aimed at increasing sustainability and competitiveness, was the topic that ICME Members and guests of the branch were treated to by Lee Jenkins FICME Director of Operations for Weir Minerals, in an evening that was, perhaps, one of the technical highlights of this year’s branch programme.

The first project was around 3D printing of large-scale patterns which is being carried out in conjunction with the Manufacturing Technology Centre, MTC, at Ansty, near Coventry.  The MTC focuses on providing solutions to UK manufacturing companies as a technology playground supported by technical experts in industrial manufacturing solutions.

Lee explained that the aim of this project is to enable a 70% reduction in energy consumption associated with pattern manufacturing, with a 50% reduction in lead time, and employing robotic printing that will be easy to use by an CNC operator.  The company needs to be able to produce a huge range of casting designs often in small numbers, so the range and number of patterns required is also huge, but with tooling used perhaps only once in three years.

By printing the patterns, using a fully recyclable printing media, this would mean that the patterns can be produced on demand with a reduced need for pattern storage.  Trials are underway, using a metrology grade scanning, to develop a self-correcting robotic cell capable of printing patterns up to 3m in diameter as well as to test the recyclability of the printing medium and the facility is intended to be a demonstrator facility that companies will be able to visit.

At the same time, the company is working with technology partners including Omega Sinto Foundry Machinery Ltd and Clansman Dynamics Ltd to develop handling systems for prototyping and single-piece items including robotic sand milling, as well as voxeljet UK Ltd to increase the use of complex printed cores.

A further project has the aim of linking the tooling printing with a fully integrated casting upgrade facility that can digitally scan, check and then grind or weld castings, removing the need for hand grinding, with the aim of zero waste, using automated (robotic) wire arc deposition for casting repair The aim is also to be able to correct any pattern/tooling design as an interactive and fully automated process.

Lee explained how, by working with organisations like the MTC, CMF, and the University of Sheffield, as well as City and Guilds, ICME and the Net Gen Makers Apprentice Best Practice Programme, the company is working to build a Digital Academy to train the workforce of tomorrow – smart, agile and technically adept, providing solutions to customers and removing all non-value-added elements from the process.

The attendees were impressed by the vision and ambition of the company, recognising how, with Lee leading a team of highly qualified technicians and engineers, his team are able to draw on a range to technical resources to enable a forward-looking, future-proofed and world-leading casting facility in the UK for a challenging and highly competitive sector.

Following Lee’s presentation there was a short Q&A session, facilitated by Branch President Trevor Ayre FICME, then further conversation over a buffet supper sponsored by Weir Minerals.

The presentation can be seen here: https://www.youtube.com/watch?v=vxs1fOfSK7c