As a specialist in fast-turnaround metal and plastic additive manufacturing, CA Models is using its new investment in two wire-erosion machines from Sodi-Tech to optimise the process of removing 3D-printed parts from their build platforms. With the Formula One industry currently developing cars for the 2023 season, the new Sodick machines are making a real difference to operational efficiency at CA Models.
CA Models has excelled in rapid prototyping since its inception in 1983. Providing a streamlined service to meet the challenges and demands of a growing market, Stirling-based CA Models has five different additive manufacturing departments, including metal laser sintering. This process allows components to be 3D printed from powdered metals such as aluminium, titanium and steel.
“We had two Sodick wire EDM machines that were getting on in years but still running well. It was the right time to bring in some new technology. At CA Models, we are in the ‘quick’ business, where just about every client wants their parts yesterday. That’s why we need an in-house resource when it comes to wire erosion. Every time we have a really complex, accurate part to produce, the clock is ticking,” explains Founder and Managing Director Clark Campbell.
With two Sodick machines already in-situ and proving their worth over many years, the 35-employee company had no hesitation in returning to Sodi-Tech EDM for its new investment. “I think Sodick technology is brilliant and the reliability of the machines warrants some loyalty. I went to an open day at Sodi-Tech EDM’s Warwick facility and was really impressed with the latest machines, which will play their part in a big way over the coming years,” adds Mr Campbell.
Installed in September, the new Sodick ALC600G and ALC800G wire EDM machines are very busy. “For example, take a titanium build platform with 14 motorsport parts on the base,” says Mr Campbell. “When the printing process is complete, the entire platform goes into our furnace for heat treatment for 24 hours, after which, we wire-off all the components from base plate using our Sodick technology. As the wire cuts so finely, we do not lose any dimensional accuracy in the parts. Furthermore, the machine cuts so quickly that we get a head start in finishing the components. Although this process is the underlying reason behind our investment, we also get many subcontract CNC machining projects, some of which lend themselves to wire EDM. It’s great to have that flexibility, particularly for complex, intricate parts.”
The ALC600G is a rigid linear motor driven wire EDM machine with Sodick’s next-generation SPW control with Smart Pulse Generator. While offering axis travels of 600 by 400 by 350mm, CA Models thought it prudent to also invest in the larger Sodick ALC800G wire EDM, which provides 800 by 600 by 500mm.
Mr Campbell continues: “As far as wire EDM is concerned, it’s always nice to have a big machine because we sometimes get large or unusual requests. I think we’re the only company in the UK to have the ALC800G model.”
Without the Sodick wire EDMs, CA Models would have to remove additively manufactured parts from base plates using its large bandsaw, which is far from ideal. “It’s something we’ve done before, but it always feels a little unsafe and not exactly best-practice. Wire EDM is far more practical, efficient and effective. Furthermore, once finished, the support plate looks brand new and ready to use again, which is really helpful,” states Mr Campbell.
“I think we will be particularly busy, as Formula One currently has one dominant team, so the others are very keen to make up ground. We received a nice order recently from a team towards the back of the grid, who should really be towards the front. These are aerodynamic body parts made from aluminium and we will additively manufacture and finish the parts in-house. Undoubtedly, the parts will end up on the Sodick machines for base plate removal. It’s something we’ve come to rely on,” concludes Mr Campbell.