Since its inception in 1994, Carlow Toolmaking Services Ltd has specialised in manufacturing components, jigs and fixtures for the medical, pharmaceutical and automotive industries. To support its growth, the Carlow based company has continually invested in Mitsubishi EDM technology from the Engineering Technology Group (ETG).
John Whelan, Design Engineer at Carlow Toolmaking Services says: “22 years ago we bought a Mitsubishi FX10 wire EDM machine – and it is still running every day.”
With the company enjoying continued growth, it added a second Mitsubishi EDM machine, an MV1200S five years ago. This has since been followed by a Mitsubishi MV2400R that was installed before the pandemic. However, the global hiatus on much of the manufacturing industry hasn’t halted progress and at the start of 2021, it added a second Mitsubishi MV1200S.
Pat Amond, Director at Carlow Toolmaking Services adds: “What it has helped us change is the efficiency on the machines. With an awful lot of the higher quantity parts we are making at the moment, we are using the Mitsubishi wire eroder rather than our milling machines. Over the years, we discovered that we can stack parts and prepare them on the EDM and it is more efficient. Additionally, the machines can run overnight unmanned and this has given us an edge; and our customers have benefited from that.”
The two MV1200S wire EDM machines and the MV2400R incorporate Mitsubishi’s Tubular Shaft Motor technology that delivers extra-smooth axis movements with drives positioned right in the centre of the moving weight. Highlighting this smooth axis movement and precision, the machines have glass linear scales right next to the workspace to assure users of maximum precision. In fact, Mitsubishi provides a 12-year positional warranty on all drives.
When asked if the Irish company is running the machines at their limits, John says: “We run overnight when we have the right type of work to go on the machines. We can cut anything from graphite right through to PCD. At the moment, we are cutting a bronze component that conventionally may have been milled, but it is much better to do this job on the wire EDM. We tend to do jobs slightly differently. We think around wire eroding rather than milling. As we design many jobs in-house, we design to suit our abilities. So, we often design around wire erosion, as it is more efficient.”
Adding to this, Pat comments: “Over the years, John and Conor in our design department have the Mitsubishi wire eroder in mind from the very beginning when they are doing the initial design of components. This allows us the benefit of working overnight and our customers get the benefit because, from the very outset, there are no modifications.”
Commenting upon this method, ETG’s resident EDM expert, Mr Scott Elsmere says: “Carlow Toolmaking has intelligently adapted its strategy whereby the profiling of multiple components can be undertaken on an EDM machine as opposed to a machining centre. By using EDM to profile parts rather than rough milling, Carlow Toolmaking can reduce labour and costs by profiling parts overnight unmanned. This adds capacity to milling departments whilst reducing cutting tool costs, power consumption and even eradicating excessive swarf from the process.”
Pat concludes: “What has changed for us is the way that we do our work. We now do a lot more medical device and oral care work, which now accounts for around 70% of business. Over the last 6 to 7 years, we have changed our processes to be more efficient, and both Carlow toolmaking and our customers have both benefitted. The service and support that we have received from ETG on the Mitsubishi machines has been second to none.”
