A normal mould base at Surface Generation comprises around 200 hours of machining, and among the main challenges is the production of deep pockets in confined spaces.

Here, the through-coolant capability of the VF-4 helps enormously. Another challenge ably accommodated by the Haas machines is shear edge details on compression moulds. The company maintains a gap of between 25 and 50 µm on a compound surface while trying to follow what it describes as "a nasty contour".

Surface Generation selected the Haas VF-3 as it was the smallest model of Haas vertical machining centre available on that particular size of base casting, which Halford felt was a good indicator of rigidity. "We're cutting mostly hard metals," he says. "The VF-3 has proved to be a rock solid performer. The VF-2SS is quick, and the VF-4 has been a great all-round machine, as well.

"Another good thing is that pretty much anyone can use a Haas with a days' training. All the controls are the same, irrespective of machine size. Also, I should mention that availability from Haas UK is brilliant! We bought the VF-4 as we were behind on a big project. I made a phone call to Haas and the machine was installed within seven days - I can't imagine that would be possible anywhere else!"

As well as normal day shift, Surface Generation runs its Haas machines lights out through the night and at the weekends, making parts typically from steel, but also from materials such as Invar and titanium. "Our Haas machines are very reliable. We leave all three running on a Friday night, and they will probably still be running on Sunday. This is how we've geared up our business."

From those difficult days in the aftermath of the global financial crisis, Surface Generation has successfully reinvented itself. The company has recently secured a further £3.1 million of investor funding to help maintain its rapid development - revenue in 2014-15 was £2 million, a staggering 233 percent rise on the previous year!

"Nobody else is really doing what we do," says Halford. "We're attracting the attention of some big name manufacturers, so we're definitely going to need more space and, of course, as our overseas businesses in the US, Taiwan and Japan bring in more orders, we'll also need more Haas CNC machine tools."

Source: Haas Automation

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