If you ask toolmakers to name their biggest headaches, many will point to cheap imports and last minute changes in the product designs. In contrast, D & S Moulds, based in Newton Aycliffe in the North of England, has used Delcam’s PowerSHAPE hybrid modelling software and PowerMILL machining system to develop a successful and growing business by taking advantage of both these trends.

“By buying purely on price, many companies receive moulds that need significant rework before they can produce parts successfully,” claimed D&S Moulds Managing Director, Sid Ramshaw. “Even when the tool is perfect, there will often have been some alteration to the component design while it is being made. There isn’t enough time to ship the tool back to the original manufacturer so we will do the corresponding modification to the tool.”

Of course, taking work on at such a late stage in any project puts considerable pressure on D & S Moulds to deliver in the shortest time possible, which is why the company puts such high value on its Delcam software. “With PowerSHAPE, we can define even the most complex split line imaginable in less than an hour,” claimed Mr. Ramshaw. “Electrode manufacture is ten times faster than it used to be.”

The impact of the PowerMILL machining software has been even more dramatic. “Within a week of completing the training, we were looking at a completely new way of working,” said Mr. Ramshaw. “We now have the confidence to machine to the finished size. Previously, we used to leave “metal-on” conditions and then use a secondary operation to achieve the final shut-offs. The results are now so precise that the time we spend on the final shut-off and other surface finishes is dramatically reduced.”

Mr. Ramshaw also praised Delcam’s excellent support. “Even when they can’t provide an immediate answer, they will call back within half an hour,” he reported.

The success of its repair and modification business prompted many customers to ask D & S Moulds to quote for new tooling. At the same time, demand for tooling modifications keeps growing. For example, the company is currently busy on a series of projects converting tools for handles on electrical appliances to new soft-touch designs.

“Before we had our Delcam software, we used to sub-contract work. Now, we do everything in-house,” said Mr. Ramshaw. “This gives us better control of both quality and delivery times. Customers are amazed at how fast we can turn a tool around, whether it is a modification or a complete new tool.”