SGS Carbide Tool invests in UK manufacturing

Representing an investment of over £6 million in facilities and new CNC tool and cutter grinding machines, the 25,000 ft2 manufacturing and logistics supply centre will form the hub of the company’s European operations. This will provide a springboard for further growth with customers in the aerospace, defence, motorsport, medical, power generation, oil & gas, as well as precision general engineering sectors.

These are, of course, the most technically demanding industry sectors and customers often require bespoke solutions for their machining tasks. As one of the most advanced high performance cutting tooling manufacturers, SGS is well aware that it has to provide specific solutions to address the machining challenges faced by industry. New ferrous and non-ferrous alloys and advanced composite materials are creating many opportunities, and the investment in the new facility will allow customers to directly access the cutting tool technology available from SGS.

After a warm welcome, Company president and CEO, Tom Haag, presented the company’s ‘Past, Present and Future’. “The company was established in Akron, Ohio in 1951, by Seybold, Graves and Stahl – that’s the SGS,” he explained. “Originally, we reconditioned cutting tools for the local mould and die market that had set up to support the tyre manufacturers in the area.”

Today, SGS has evolved primarily into a major manufacturer of high performance solid carbide rotary cutting tools for the machining and metalworking industry. Significant business growth began in 2000, when the company acquired the patent for a new variable helix end mill. Called Z-Carb this milling cutter designed with unequal helix geometry offered significant machining performance benefits, and the much extended range is still very popular. The company also produces solid carbide drills and milling tools under the brands S-Carb, V-Carb, HiPer-Carb and Multi-Carb brands for customers across the globe.

Employing 210 people in North America, last year the company produced over 7 million cutting tools. Growth and investment has allowed the company to support complementary technologies, including Action Super Abrasives, producing vitrified and diamond grinding wheels, Hardcoating Technologies providing advanced multi-layer cutting tool coating services and Oakview Tooling producing solid carbide tools for orthopaedic manufacturing and stainless steel tools for medical operations.

SGS opened its first UK office in 1986 and began manufacturing tools here in 2005. Today the UK operation employs over 40 staff supporting and supplying customers in the automotive, aerospace, medical and high precision engineering sectors. Demand for its range across Europe has risen to the point where it had to increase production and stock levels as well as enhance its focus on Research & Development.

This new facility provides SGS staff with the opportunity to bring more technology to its customers under one roof. Currently equipped with eight 5-axis Walter CNC tool and cutter grinding machines with automated robotic loading producing tools, plans exist for additional machines to match growth from the market. Three state-of-the-art non-contact CNC Walter Helicheck inspection machines ensure product quality.

A separate section has also been set up where advanced hard coatings, including Super Nitride, can be applied. In-house design capabilities allow new tool geometries to be developed for specials ordered by customers. As the European headquarters the new site also holds more than 150,000 tools, valued at £3 million, ready for next day delivery to customers across Europe.

With the unveiling of a ceremonial plaque the new building was officially opened by company President, Tom Haag and Richard Noble, former land speed record holder and Project Director of the Bloodhound SSC project that aims to build the first car to achieve 1,000mph in South Africa next year.

As a product sponsor of Bloodhound SSC project, SGS is providing the cutting tools required to produce many of the components for the car. Richard Noble took the opportunity to inform guests of the latest project developments, including the success of the firing of the rocket engine, and the inspirational work he and his team is promoting in schools to stimulate the next generation of engineers.

After a series of conferences led by SGS partners such as DMG and Delcam, visitors were invited on the ‘Build a Tool’ tour which guided them, step-by-step, through the comprehensive process adopted by SGS to produce its high performance cutting tools. From initial enquiry to design, manufacturing and inspection, and on to product testing, the tour provided everyone with an insight into the commitment to quality and customer satisfaction adhered to by the staff at the company.

At the end of the tour, visitors were able to discover the new Technical Centre, designed to offer tool demonstrations and machining solutions for customers. Equipped with a DMG/Mori Seiki DMU 50 full 5-axis machining centre linked to the latest Delcam software, which will also provide a centre for staff training, the Technical Centre supports the company ethos that is solutions based. Discussions with customers will provide clear objectives regarding what they want to achieve. They may wish to reduce cycle times or lower their tooling costs. Whatever their needs the team at SGS aims to deliver a solution that best suits the goals.

One of the greatest strengths will be the ability to test tools and machining strategies for customers. The Technical Centre has the right machine tool with state-of-the-art tool holding and work holding, as well as advanced coolants, to provide customers with an overview of what can be achieved on their shop floor. The customer can come and see how they can address their challenges.

The total investment demonstrates SGS’s commitment to providing bespoke tooling for customers tackling the latest materials, increased competition and demanding contracts. The new factory will also export tools back to America.