BDL Tool & Die - MTD take a trip around the factory checking all their HAAS machines

MTDCNC.com recently visited BDL Tool & Die's facility in Daventry.

Daventry based BDL Tool and Die Engineering have spent 25 years as die makers and a Haas customer for over 11. Now run by Managing Director, Phil Morris, the company first started out as a heading die specialist, but has diversified into other industries, including hydraulics, pneumatics, automotive, motorsport, oil and gas, with a broad range of high-end customers. The die business, however, still makes up around 25% of their trade.

BDL have experienced a rapid growth in the past few years, purchasing 12 machines from Haas in the last 18 months and now employ a workforce of over 60 fully skilled personnel . In April 2017 the company invested in a VF-2SS Super Speed vertical machining centre with a 5-axis trunnion and a UMC-750 5-axis machining centre, both with through spindle coolant. May 2017 saw the installation of an ST-15 lathe with tailstock, further increasing capacity and flexibility.

The 5-axis UMC, originally bought for Mercedes F1 work, has produced some small batch work for Haas F1 Team and also provides extra capacity for hydraulics contracts.

The hydraulic components are first turned on the Haas lathe, before being face drilled in the Haas VF cell to fit on to the fixture. The UMC-750; their first true simultaneous 5 axis machine, is used for the remaining 5 axis/face-datum work.

MD Phil Morris' father was one of the founders of BDL and the company has always prided themselves on taking their knowledge of cutting difficult materials like tungsten carbide and applying it to other tough materials. Hydraulic tensioners, for example, have become a simple job for BDL by streamlining their production techniques. The high demand for this kind of product has led to further investment in new, shop floor based, programming offices to assist with production planning. This approach allows a fluid segway into the variety of Haas mills and lathes at their disposal, most of which have Super Speed specifications and are equipped with additional options such as Wireless Intuitive Probing.

"We settled on Haas predominantly because of the service and support,” explains Phil Morris. “Both those on the factory floor and the company directors have formed a good working relationship with Haas. We prefer being transferred to an engineer over the phone to diagnose any issues. The engineer then arrives with his van stocked with the necessary parts, ready to fix the machine."

He added, "We felt it was crucial to standardise, where technically and commercially viable, on one brand of machine tool and control system. In the end it was easy to settle on Haas; their controls are the same across the range of machines, allowing our operators to easily swap between lathes and mills. The build quality is high and the service and back-up is exactly what we need. The UMC-750 has made the transition into 5-axis machining a very smooth process. The operators love it."

BDL are certainly a company looking to the future and with further expansion in mind have recently invested in process control. The new programming office, with a bank of computers, supports the shop floor helping to minimalise cycle and setup times and improve production capabilities.

“Our aim has always been to offer a reliable tooling solution based on quality, service and delivery,” concludes Phil Morris. “Investing and engaging with Haas has enabled us to break into wider markets both in and outside the UK.”


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