The secret behind the success of PtFS is how it uses a custom designed chequer board configuration, where each square on a mould tool is heated and cooled individually, with pressurised air, controlled by a computer.

All types of materials can be processed, up to 850°C, including thermosets, thermoplastics, metals and glass. Surface Generation has quickly built a reputation for engineering solutions when, according to Halford, a customer reaches an impasse because no other processes appear to be working. ‘Torture parts', as he calls challenging projects, are normal, everyday problems. "These are components where the general consensus is that they can't be manufactured.

"For example, last year we were given a part to make, which incorporated a logo that wasn't mouldable using typical processes. But, I'm happy to say we solved the problem with 100 percent yield. In another case, we've taken a cycle time down dramatically from two hours to just 20 minutes. Our process delivers that kind of very significant difference."

Surface Generation's success is also down to solid investment decisions such as, for example, the latest CAE technologies, including SolidWorks and PowerMill. The company has also acquired three US designed and built Haas VF CNC vertical machining centres from UK distributor, Haas Automation UK, Ltd. The VF-3 machining centre, with WIPS (Wireless Intuitive Programming System) arrived first, in 2012, followed by a Haas VF-2SS super speed around 18 months ago and, most recently, a Haas VF-4.

"Previously, we were subcontracting parts to job shops, which just didn't give us the necessary control, quality or flexibility," says Halford. "However, this was addressed immediately with the arrival of the VF-3. We looked carefully at two or three other brands of CNC machine tools, but liked what Haas were doing. Haas UK had an extremely good engineering and support team, which also gave us a great deal of confidence."

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