Bespoke luxury product design and manufacturing specialist strengthens its 5-axis machining capabilities with its latest Mikron machining centre investment.
GF Machining Solutions, the 3- and 5-axis milling, EDM, laser texturing and additive manufacturing (AM) machine tool specialist and automation systems’ solutions provider, has recently supplied Luzzo Bespoke Ltd., a well-known and highly regarded design and manufacturing specialist of innovative bespoke products, with a new Mikron MILL E 700U 5-axis machining centre.
The rigidly built and ergonomically designed machine, which features an integrated 7-station Automatic pallet Changer (APC), was installed at the company’s 10,000+ sq. ft. facility in Brackley in April 2021 and is being used to machine, in low volumes, a range of high-precision (and often complex-shaped) components that go into the bespoke products manufactured by Luzzo Bespoke for its growing number of high-end automotive, motorsport, and lifestyle customers.
These components, made from a diverse range of materials i.e., aluminium, brass, Stainless Steel, Carbon Fibre, wood, plastics etc., are machined to high accuracy (typically +/- 0.1mm) and to exacting surface finishes.
The MILL E 700U is also being used to machine special and innovative work-holding and fixtures, as well as numerous prototypes and pre-production parts – integral to the company’s Design for Manufacturing (DfM) services.
The machine joins, and has been installed adjacent to, another Mikron 5-axis machining centre, a HEM 500U, acquired by the company in 2016. Together, these two high-performance 5-axis machining centres provide Luzzo Bespoke with fast, efficient and reliable milling capabilities, and proven machine tool technology designed to improve part accuracies and repeatability’s and increase productivity.
Investment rationale
Like many other manufacturers, Luzzo Bespoke felt the impact and effects of the pandemic. Staff were furloughed and several orders and contracts were postponed…some were cancelled altogether.
However, during the Summer of 2020, business began to pick-up and has been on an upward trajectory ever since.
Says Brian Challenger, Luzzo Bespoke’s Managing Director:
“Since the beginning of 2021 things have improved considerably – so much so in fact that we could see that if we didn’t strengthen our existing milling capacity and capabilities, sooner rather than later, production ‘pinch points’ would occur that would detrimentally affect our operational efficiencies and productivity.
“As a result of these deliberations we decided to invest in a new machining centre”
To address its potential milling capacity shortcomings the company spent time identifying the ‘need to have’ specifications and capabilities of the new machine.
Got to be 5-axis
Luzzo Bespoke is a keen advocate of 5-axis machining…and of automation.
Explains Brian Challenger:
“Over the past 12 years our machine shop has changed and improved dramatically from having no CNC machine tools to one that boasts high-performance CNC multi-tasking lathes and 3- and 5-axis machining centres.
“We believe that 5-axis machining is the way to go. The technology makes us more flexible and enables us to machine parts in fewer set ups – often in one hit. This makes us more efficient and productive.”
The same is true of automation.
Continues Brain Challenger:
“Machines with integrated automation have the ability to run ‘lights out’ overnight and over the weekends. A machine with integrated pallet change capabilities can give us up to 14 hours additional machining time per day: a massive boost to our productivity.”
In addition to the machine having to be a 5-axis machining centre equipped with integrated automation other machine requirements included:
- A high-speed, high-torque spindle
- Full simultaneous 5-axis machining capability
- Good sized working envelope with easy part loading/unloading
- Generous sized ATC (Automatic Tools Changer)
- Efficient and effective swarf management
- The latest Heidenhain control
Got to be Mikron
The decision to invest in a Mikron 5-axis machine from GF Machining Solutions was not a foregone conclusion, however, explains Brian Challenger, “our existing (good) relationships with GF Machining Solutions did put them in the box seat…so to speak.”
Luzzo Bespoke has invested in a number of Mikron 3- and 5-axis machining centres over the years and, prior to the arrival of the new MILL E 500U, had two 3-axis machining centres (VCE 800 Pro and one 5-axis machine (HEM 500U) at its disposal.
“We approached GF Machining Solutions and other companies with our requirements”, remembers Brian Challenger. “Taking the machine cost, its availability and its technical specifications into account, as well as the applications and service back up of GF Machining Solutions, we invested in the Mikron MILL E 700U.”
Mikron MILL E 700U
The MILL E 700U is a high-efficiency 5-axis machining centre that has a rigid C-frame construction, large-sized guideways, a double-supported (trunnion-type) direct-drive rotary tilting table and an integrated 7-station Automatic Pallet Changer.
Equipped with the Heidenain tnc 640 control and featuring a powerful, high-speed 36kW/20,000rpm (OptiCool) spindle with oil-air lubrication, the MILL E 700U delivers excellent cutting performance, unrivalled machining flexibility and best-in-class process reliability.
Says Brian Challenger:
“The machine’s advanced spindle technology with oil-air lubrication enables us to maintain part accuracies and keep within tolerances during long machining runs, and its direct-drove rotary table technology, in combination with the StepTec spindle, means we can achieve super-fine surface finishes on machined parts.
“All in all, the MILL E 700U is a versatile, high-productivity machine – and is a real asset to the company.”
About Luzzo Bespoke
Luzzo Bespoke designs and manufactures a range of high-quality bespoke products for a diverse range of markets and industries.
One of the most important of these is the luxury car market where the company designs and manufacturers high-end products that include drinks cabinets, picnic hampers, under seat fridges, humidors, customized and bespoke clocks, dials and instrumentation panels etc., for the world’s most prestigious car makers i.e., Rolls-Royce, Bentley, McLaren, Bugatti and Jaguar Land Rover etc.
The company also manufactures a range of motorsport and classic car parts and, to lessen a potential over-reliance on the automotive sector, has diversified its operations designing and manufacturing products for the marine and furniture markets.
Many products manufactured by Luzzo Bespoke, especially for its luxury car maker customers, are supplied as ‘finished’ products – with all manufacturing and assembly etc., occurring at its Brackley facility.
Explains Brian Challenger:
“We are a ‘one-stop shop’ design and manufacturing solutions provider.
“In addition to our comprehensive machining capabilities, we provide a range of ‘other’ manufacturing and finishing services and specialisms in-house; these include wood veneering, laser engraving/marking, spray painting, polishing etc.”
Bringing all these services and specialisms under one roof helps the company maintain its high-quality standards, and keep control of its operational costs and customer delivery schedules etc.
“We made a conscious decision some years ago,” says Brian Challenger “to avoid subcontracting work out. This move has helped make us more competitive and has differentiated us positively in our markets, and with our customers.”
Case in point: Champagne chest
A good example that helps illuminate the range of Luzzo Bespoke’s in-house capabilities is the Rolls-Royce Champagne Chest.
Part of Rolls-Royce’s accessories portfolio the chest, made from machined aluminium and carbon fibre, comes wrapped in Natural Grain black leather and Tudor Oak wood.
The chest opens at the touch of a button, with the illuminated central bay exhibiting four hand-blown crystal champagne flutes, which Rolls-Royce says are “arranged to evoke memories of a V12 engine”, and the owner’s choice of Champagne – kept at the ideal temperature thanks to black anodized aluminium and carbon fibre coolers.
Rolls-Royce Champagne chests are innovative, luxurious and expensive. They are all manufactured and assembled in-house by Luzzo Bespoke using many of the company’s in-house services and are indicative of the type of product designed and manufactured by the company.
Summary
The new Mikron MILL E 700U machining centre is helping Luzzo Bespoke improve its productivity and performance.
Since being installed the MILL E 700U’s full simultaneous 5-axis machining capabilities have been put to full use machining complex features and details that could only be achieved previously by using a multitude of special fixtures or multiple set-ups.
The machine’s integrated automation is also proving its worth with multiple parts being set-up during the day on its 7 pallets and machined to completion overnight.
Concludes Brain Challenger:
“The future is 5-axis machining and over the next few months, we intend to make further investments in this technology.”
