A new spark erosion machine at Ledwell Plastics will enhance its ability to make small and intricate mouldings for agriculture, packaging and electric vehicles.
The new Sodick AD35L spark erosion machine from Sodi-Tech EDM will improve accuracy and reliability in the manufacture of the hardened stainless steel mould tools these parts require.
Ledwell Plastics is an injection moulding and toolmaking specialist that serves many different industries, including agriculture, food packaging and electric vehicles. Founded in 1969 by Paul Simms, father of current Managing Director Benn Simms, Ledwell can mould parts weighing from 1 g up to 1.5 kg, while the largest moulding produced to date measures 900 mm long x 450 mm wide x 90 mm deep. Operating around the clock from two factories in Leicester, negotiations are currently in progress regarding a third premises for this progressive 36-employee business.
“Our toolroom makes moulds from many different materials, everything from aluminium through to hardened stainless steel,” explains Benn Simms. “Recently, however, we were working almost exclusively with the latter material in the production of very small and intricate moulds, a trend that looked set to continue for some time. Our problem was our existing die-sink EDM capability, which was somewhat antiquated, meaning we had issues with accuracy and breakdowns that were impacting project timescales and costing a lot in repairs.”
As a result, Ledwell Plastics sought a new die-sink EDM that could work to tolerances of less than 0.001 inch (0.025 mm). In addition, the highly technical, hardened stainless steel moulds require a large amount of sparking, so fast processing speed was another factor high on the wish list.
“The Sodick AD35L fitted the bill nicely, especially as it was also the perfect size,” states Mr Simms.
Along with the hardened stainless steel moulds, the ISO9001-accredited company uses its new AD35L for jobs involving materials such as aluminium, steel and hardened tool steel. As Ledwell works extensively on the design and development of moulded parts for its customers - often involving patent applications - non-disclosure agreements (NDAs) are in place for almost all projects. Although the company can say little about the moulds it machines, the benefits offered by the Sodick AD35L are clear to see.
“Our new Sodick allows us to run overnight, unlike our previous machine, which we could never trust in that regard, particularly with blind components/features that are difficult to flush,” says Mr Simms. “The high-speed linear technology of the AD35L evacuates the cavities much better with its enhanced flow of dielectric fluid.”
“Our operators love the machine as it’s streets ahead of where we were before,” concludes Mr Simms. “Furthermore, the AD35L will help drive more work through the tool room, upholding our tradition of cost-effective solutions with excellent quality. All of our tooling is guaranteed for a minimum life span cycle, which is bespoke for each individual component.”