United Machining UK Ltd

New laser machine tool investment opens up new business opportunities for creative engineering specialist.

United Machining UK Ltd — 05/10/2026

Luzzo Bespoke, a creative engineering specialist supplying highly-bespoke products to a range of customers in the automotive, marine, life-style and consumer luxury markets, acquires a new Charmilles LASER P 1000U 5-axis digital laser texturing and engraving machine from GF Machining Solutions, now United Machining.

The new machine, installed in early 2025, is proving to be transformative; a real technology differentiator that has a) increased and strengthened Luzzo Bespoke’s in-house design and manufacturing capabilities, and b) helped the company expand the range of unique and innovative 2D and 3D surface textures it can apply to machined products.

The LASER P 1000U machine’s arrival has not only provided Luzzo Bespoke with a distinct competitive advantage in the markets it serves but, it is anticipated, will also help generate new business opportunities (i.e., applying high-accuracy decorative and functional textures to mould tools and mould inserts etc.), in the future.

GF Machining Solutions, now United Machining, the EDM, milling, laser and Additive Manufacturing (AM) machine tool manufacturer, and advanced tooling and automation systems’ supplier, has recently supplied Luzzo Bespoke, a market-leading creative engineering design and manufacturing specialist, with a new Charmilles LASER P 1000U (laser texturing) 5-axis machine.

The machine, installed at the company’s 1000m² manufacturing facility in Brackley, Northants in January 2025, is the first laser machine Luzzo Bespoke has acquired from GF Machining Solutions in its 28-year history, although the company is no stranger to GF Machining Solutions’ machine tool technologies, having invested in a number of Mikron 5-axis machining centres with integrated work-piece pallet changers in the past.

Says Brian Challenger, Luzzo Bespoke’s managing director:

“We have developed good relationships with GF Machining Solutions over the years, and the 5-axis machines we have acquired from them previously, starting back in 2001, have helped us increase our productivity and improve our process efficiencies.

“As a consequence, when we decided to invest in the new laser machine, it was only natural that GF Machining Solutions would be one of the companies we would approach to discuss our requirements.”

The laser investment - rationale

Luzzo Bespoke is committed to continuous improvement and regularly invests in its people, in its plant and equipment, and in its systems and processes as a route to improving quality, reducing lead times and controlling costs.

Being strategically proactive, the company is always looking to keep ahead – searching out, and ultimately investing in, new and emerging technologies that can help it secure meaningful competitive advantage in and across the markets it serves.

A recent discussion with a customer helped reinforce the validity of Luzzo Bespoke’s business ethos and approach, and was instrumental in the company accelerating its laser machine tool investment.

Explains Brian Challenger:

“Not that long ago we were asked to add the finish machining touches to a (one-off) high-end steering wheel that had been machined in China for a luxury car manufacturer in the UK.

“The steering wheel was, in truth, machined to high accuracy and certainly looked the part and I estimated that if we were asked to machine the whole job from scratch to the same quality standards the cost, including the purchase of the raw billet and all associated machining and programming operations, would be in the region of £7k.

“When I found out that the cost from the Chinese manufacturer was just $950, it reinforced my conviction that competing toe-to-toe on cost with Far East and other low-cost manufacturers was a ‘fool’s errand’, and that, instead, we needed to be offering something new, different and unique to the market, that was valued by customers, and that could not be easily replicated or achieved by our competitors.”

It was decided that the technology that would help Luzzo Bespoke ‘stand out from the crowd’ would be an advanced 5-axis laser texturing machine to meet the company’s immediate and future laser texturing, engraving and ablation requirements.

Luzzo Bespoke’s products and solutions

Luzzo Bespoke designs, manufactures and assembles a range of bespoke, high-quality products for a number of customers.

The company’s portfolio of previously completed projects is impressive and diverse, and comprises everything from customised interiors and instruments for concept and one-off cars through to luxury furniture and luggage, and from trophies and awards through to highly sought after backgammon sets.

These products, often described as special and deluxe editions and, limited run, collectors’ items, can be made from a range and/or combination of materials (i.e., metals, plastics, wood, glass, leather etc.), and are manufactured and supplied in low volumes.

Luzzo Bespoke works closely, in collaboration, with designers, engineers, artists and its customers’ marketing teams, taking and interpreting their initial product concepts and designs and making them a reality.

Design for Manufacturing (DfM) technical consultancy and problem solving skills, combined with Luzzo Bespoke’s knowledge of different materials (i.e., properties, machinability etc.), and the company’s rapid prototyping capabilities, in-house advanced manufacturing technologies and integrated finishing and assembly operations, ensure high product quality and fast turnarounds.

Luzzo Bespoke – laser history

Luzzo Bespoke is no novice when it comes to laser technology and in 2000 invested in a CO₂ laser machine to etch soft materials (i.e., leather, acrylic, wood veneers etc.).

However, this machine with its small working envelope and inability to texture and engrave harder materials (i.e., metals), had its limitations and did not eliminate the use of third party suppliers.

Says Brian Challenger:

“Sub-contracting work out is expensive and can have a negative impact on quality and lead time fulfilment.

“To address the situation and enable us to handle the engraving of metal parts, in-house, we made the decision, back in 2016, to invest in our first fibre laser machine.”

The investment in this compact, bench-top laser machine was ideal for engraving (deep etching) small metal badges and similar sized parts, but could not (easily) handle laser engraving on larger work-pieces.”

The machine’s limitations were brought into sharp relief when engraving fine details on a large metal plate.

The part, which was larger than the machine’s working window, involved a number of clamping and re-clamping operations but, despite the company’s best efforts, and the use of an expensive fixture, the engraved detail could not be replicated successfully or to the standard required.

The end result was that this part had to be subcontracted out to a third party.

Since 2022, Luzzo Bespoke has been approached and asked to produce laser textured patterns and details on complex 3D-shaped metal parts with concave and convex surfaces.

To achieve the desired effects on such parts it was clear that a 5-axis fibre laser (as opposed to a 3-axis model) was the way forward.

This ‘need’ was the catalyst behind Luzzo Bespoke’s LASER P 1000U investment.

The Laser P 1000U investment

The company, back in early 2024, approached a number of laser texturing machine tool manufacturers with its requirements.

One of the companies contacted was GF Machining Solutions.

Initially, Luzzo Bespoke was looking at investing in a smaller Charmilles LASER P 600U machine but, through discussions, it was ultimately decided that the larger LASER P 1000U had more potential.

Says Brian Challenger:

“Visits to GF Machining Solution’s facility in Geneva where we could see the laser machines in action and talk directly with the company’s laser product and applications experts were invaluable.

“GF Machining Solutions were extremely supportive, they liked what we were doing and could see that we would be an ideal, UK-based, de-facto reference site for their laser technology.

“As a result, they offered us a great deal on a new LASER P 1000U and we decided, from a cost, machine specification and availability perspective, to place the order with GF.”

Since being installed, and with training completed, the LASER P 1000U has been put through its paces and has been used in a number of projects. One of these has involved the engraving of titanium legs on luxury, folding director’s chairs.

Because not all of Luzzo Bespoke’s projects have/require a laser texturing or etching requirement, the company has had time to experiment and test the machine “to see exactly what it can do.”

The company is currently producing samples and a best-practice product and applications’ portfolio to show new and existing customers the capabilities, possibilities and potential of laser texturing on a range of metals that include titanium, brass, copper, stainless steel, aluminium etc.

The investment in the LASER P 1000U has not just opened up a whole new world of possible laser textured surfaces for existing customers, it will also be used to help Luzzo Bespoke diversify into new markets i.e., the creation of surface textures on mould tools and inserts, the application of functional hydrophobic or hydrophilic surfaces on specific products etc.

The Laser P 1000U – a closer look

The Laser P 1000U is a flexible, large-capacity nano flexi-pulse (50/100 Watt) laser machine equipped with a B-axis table (380mm diameter) that can handle workpieces up to 510mm x 480mm in size and 150kg in weight.

The machine features an A-axis tilting laser head (-50/+135 degrees) that guarantees high positional accuracies, and is supplied with three lenses that enables the focal length (100mm/160mm/254mm) to be adjusted and fine-tuned to suit the application and optimise quality vs speed requirements.

Laser P 1000U machines are supplied with GF Machining Solutions’ powerful and user-friendly software and a sophisticated iHMI that enables customers to quickly master all aspects of the laser machining process:

job set up (including selection of the desired CAD generated pattern or texture required), material selection and work-piece positioning.
laser parameter selection (i.e., power, pulse duration and frequency, beam size and shape.
laser scanning
post-processing (i.e., cleaning, inspection etc.

To improve productivity the machines are also supplied with high-quality reference systems (tooling), that ensure the delivery of high-accuracies and repeatability’s, and allow jobs to be set up away from the machine.

Like all GF Machining Solutions’ EDM, milling and laser machines, the Laser P 1000U is equipped with the My rConnect remote machine tool monitoring, diagnostics and assistance system that provides customers with direct and seamless access to a range of GF Machining Solutions’ support services to help improve productivity and ensure machine uptime.

Summary

Luzzo Bespoke’s investment in a LASER P 1000U is paying dividends.

In addition to completing a number of fee-paying jobs, the machine is also being tested to enable Luzzo Bespoke to show actual and potential customers its potential for producing unique and highly innovative decorative and functional textured surfaces as a route to opening up new business opportunities.

Redefining precision at the micro level.

United Machining UK Ltd — 05/10/2026

With the LASER X 500 U, CHARMILLES has introduced an innovative 5-axis laser machine that delivers uncompromising accuracy for the most demanding micro-cutting, micro-drilling and micro-machining parts.

From intricate watch components through small, delicate and feature-rich parts for the electronics industry, the LASER X 500 U sets new standards in precision for micro-manufacturing.

The innovative 5-axis laser system integrates an ultra-short femtosecond pulsed laser (1 femtosecond = 10-15 seconds) ensuring clean material ablation that eliminates timely and costly post-processing operations.

In line with CHARMILLES’ high-precision solutions, the machine is fully thermo-stabilised and its unique kinematics are designed to ensure extreme accuracy. With a spot size (i.e., the diameter or width of the focused laser beam where it hits the target material's surface) of just a few microns, the LASER X 500 U enables high quality machining of fine details.

Ideal for high-precision components, the LASER X 500 U can process any metal – including silicon carbide, ceramics, sapphire or glass, which are challenging to process with conventional machine tools. The dynamic optics, combined with high-speed linear motors, boosts productivity and customers also benefit from precise, consistent and predictable results.

Powered by the advanced CAD/CAM LaserSUITE360 software, the system allows intuitive programming even during complex operations and streamlines tool path generation, enhanced parameter management and anti-collision simulation.

High-quality and sustainability

With travel ranges of 550mm x 400mm x 500mm, a B-axis swivel range of -/-110° and C-axis rotation up to 720° the LASER X 500U delivers high accuracy, processing speeds and flexibility.

“The LASER X 500 U’s capabilities redefine excellence in electronics, medical applications, watchmaking, and micro tools machining,” says Adrien Rodrigues, Product Expert at CHARMILLES.

Another key advantage of the LASER X 500 U is its sustainability: without no tool wear, electrode use or cutting forces to factor into the equation, the machine combines high manufacturing quality with economic and ecological benefits, thanks to low energy consumption and minimised operating costs.

A new Transformer hits the streets.

United Machining UK Ltd — 05/10/2026

SYSTEM 3R’s new TRANSFORMER 3-axis 600 (T3- 600) is an innovative and flexible automation solution designed for a wide range of machine tools and applications.

Despite its compact size the solution’s robust three-axis design is able to handle transfer weights up to 600kg and, with an extended 2000mm X-axis that allows easy to large machine tables and a slim telescopic arm that can reach into tight workspaces, the Transformer T-3 600 is incredibly versatile and will have universal appeal.

Comparable industrial robots on the market often have payload limitations and use six axes which increases their size footprint and makes their installation and maintenance more demanding.

By enabling stationary or rail-mounted installation, the T3-600 operation and use can be scaled up effortlessly: from operating individual machines to linking over 20 machines in an automated cell.

The T3-600 handles SYSTEM 3R tooling systems, ranging from the small Macro 54mm x 54mm to Delphin 800mm x 800mm pallets for larger workpieces, and is compatible with a number of milling, grinding, EDM and laser machine tools.

Specific pneumatic grippers enable the quick and safe transport of lightweight components, like EDM electrodes or milling tools, between magazines and machines, enhancing machine autonomy and overall cell efficiency. Workflows are orchestrated via the Work ShopManager software, which coordinates even complex processes in automated cells.

The solution also supports industry-standard communication protocols, offering a unique blend of power, flexibility, and user-friendliness.

As a pallet-based automation solution, the T3-600 suits all manufacturing sectors requiring pallet transport to and from machines. Its high payload capacity and compact design make it ideal for mould making and toolmaking and for component manufacturing in the automotive, aerospace, energy and medical sectors.

A site for sore eyes.

United Machining UK Ltd — 05/10/2026

United Machining has launched a new website designed to provide improved access to its precision machining technologies, products, and services.

The updated digital platform, with improved navigation, page layouts and graphics supports United Machining Solutions’ brand strategy by giving each technology area its own dedicated online presence.

The redesigned website provides a streamlined user experience, allowing visitors to quickly access information on United Machining’s market-leading specialisms and solutions - EDM, milling, laser texturing, laser micro-machining, spindle technology, automation and tooling.

The company brings together six Swiss and Swedish-engineering brands, that include: AgieCharmilles (EDM), Charmilles (laser texturing and laser micro-machining), Mikron Mill (3- and 5-axis milling), Liechti (aerofoil machining), StepTec (motor spindles), and System 3R (workholding and automation).

The new website provides manufacturers across aerospace, medical, automotive, electronics, tooling, and precision manufacturing sectors industries with easier access to brand information, global locations, sales contacts, service resources, and upcoming events.

Partnership means going the extra mile.

United Machining UK Ltd — 05/10/2026

The outbreak of a devastating fire in April 2025 could have spelt curtains for Western Pegasus, a precision engineering company based in Birmingham.

But, through the leadership, resilience and doggedness of President Andy Wincel, the dedication of the company’s 40-strong workforce, a sympathetic bank that provided immediate funding assistance to help the company get back on its feet, and strong business partnerships, most notably with United Machining, Western Pegasus was able to get back on its feet and be up and running within three months.

United Machining, the EDM, milling, additive manufacturing (AM) and laser texturing machine tool manufacturer, and supplier of advanced automation, software and tooling systems, has recently supplied Western Pegasus, a market-leading precision engineering company specialising in the design, manufacture and supply of high-accuracy and customised spline gauges, master gears and spline related inspection gauging, with three new advanced AgieCharmilles wire EDM machines.

The machines, a CUT 2000 and two CUT 1000 models, were installed at Western Pegasus’ Kitts Green facility in Birmingham – premises that the company had only recently (and hastily) relocated to following a major fire that destroyed its original Tyseley-based operation that had been the company’s home for 40-years.

The three new machines, secured in part by an overdraft facility of £850,000 followed by a funding package of £1.2 million from HSBC UK, have replaced a number of previously acquired AgieCharmilles EDM machines that had been effectively ‘put out of action’ by the Easter Sunday fire.

Steve Eames, Relationship Manager at HSBC UK added: “Supporting Western Pegasus through such challenging times been a highly rewarding experience. We acted quickly to support its recovery, and the resilience shown by the team was remarkable. It’s fantastic to see the business thriving.”

Says Andy Wincel, Western Pegasus’ president:

“We have developed strong relationships with United Machining (previously GF Machining Solutions) over many years and, to increase our capacity and improve our capabilities, have regularly invested in the company’s high-end wire EDM machines.

“These machines, renowned for their ability to deliver consistent and repeatable high accuracies and superior surface finishes, are our ‘technology of choice’ for machining Western Pegasus’ custom master gears, spline gauges and spline related inspection gauging etc.”

Western Pegasus’ gauge and gear inspection equipment used and specified globally by the automotive, aerospace, marine and agricultural industries, measure the precise dimensional accuracy and geometric tolerances of gear teeth including – tooth profiles, pitch deviations, thickness and size, lead and helix angles, runout etc.

Accuracy in the manufacture of gear and spline inspection equipment is critical and is non-negotiable (i.e., better than +/- 2 microns on gear teeth flanges and profiles), and is why Western Pegasus has invested, and has continued to invest in AgieCharmilles advanced wire EDM machine tool technology.

Equipped with a range of innovative technologies and features (i.e., Intelligent Spark Protection (ISPS), iWire Technology, the Uniqua iHMI interface and Automatic Wire Change (AWC) capabilities), AgieCharmilles wire EDM machines deliver high precision, fast processing speeds and unrivalled machining flexibility and reliability.

The fire

Armed with an array of advanced machine tool technologies, robust and proven manufacturing processes and a highly-experienced workforce, Western Pegasus was literally ‘geared up’ for further growth.

Then the fire started in an adjacent factory, and one of the “most advanced wire EDM facilities in the UK”, according to Andy Wincel, “was destroyed.”

Any manufacturing company that has experienced a major fire understands the myriad of different, and often competing, demands that need to be addressed and resolved.

To make things worse, if at all possible, for Western Pegasus was that the fire broke out on Easter Sunday which affected company communications and that Andy Wincel was thousands of miles away – at home in Australia.

Continues Andy Wincel:

“You wouldn’t wish this on your worst enemy.

“Dealing with loss adjusters, assessors and insurance claims is one thing, but when you add in to the mix a workforce that, quite understandably, is on tenterhooks wondering whether they still have jobs to go to, as well as a number of customers wondering about the ‘status’ of their respective jobs, the situation was fraught…to put it mildly.

“We lost a lot. Our servers and IT equipment went ‘up in smoke’. Our advanced machine tools and ancillary technologies were severely compromised, at best. And all records, documentation and work in progress were gone too.”

It’s all about the customer

With an unswerving focus on customer care, Andy Wincel made the decision ‘not to call it quits’, and set about planning, almost phoenix-like, the rebirth of Western Pegasus.

He decided that a warehouse facility he had acquired previously in Kitts Green, some 16 miles away from the damaged and, as it transpired, soon to be condemned Tyseley factory, would become Western Pegasus’ new home.

From this initial decision others, often made concurrently, followed in quick succession.

“We wanted to become operational as soon as possible,” remembers Andy Wincel. “But it was important that we did things methodically and clinically.”

As well as removing plant and equipment from the old site, checking on its viability and usefulness, and storing it for future use or disposal, a complete modernisation and revamp of the Kitts Green facility had to be planned and implemented.

This was a big task as it involved not only clearing out and cleaning the whole premises but, also included sorting out the electrics and plumbing, laying new floors and erecting a new roof, building office spaces and toilets, designing and configuring a temperature-controlled machine shop, and constructing an accredited inspection laboratory etc.

It was a monumental undertaking made more difficult by the tight timescales involved.

Says Andy Wincel:

“In addition to the building works, I also contacted United Machining UK, specifically managing director, Martin Spencer, to see if he could assist us in acquiring a number of advanced wire EDM machines in double-quick time.”

As mentioned previously, Western Pegasus has developed strong relationships with United Machining and over the years has acquired ten advanced AgieCharmilles wire EDM machines and two System 3R automation systems from the company.

These machines comprising 4 x CUT 1000, 2 x CUT 2000, a CUT P 350, a CUT 300mS/Sp, a Progress V2 and an older Agie Vertex 3 (forerunner to the CUT 1000 machine), had been severely compromised by the fire and, from Western Pegasus’ perspective, were no longer fit for purpose.

Remembers Andy Wincel:

“United Machining was our first port of call and fortunately the company mobilised its resources to help us out.”

United Machining’s response

“First and foremost we wanted to help,” says Martin Spencer, United Machining UK’s managing director:

“Western Pegasus is a good and loyal customer, and we believed that Andy and his team, with the right support, could turn it around and make a success of things.

“Having spoken to Andy about his immediate requirements, we identified the type and number of new AgieCharmilles wire EDM machines he needed to re-start machining operations; these comprised a CUT 2000 and two CUT 1000 models.”

However, because of the urgency of Western Pegasus’ situation and that advanced and highly sophisticated EDM machines, like the CUT 1000 and CUT 2000, are not stock machines but are built to order, the assistance provided to Western Pegasus took on an international dimension, with the AgieCharmilles’ manufacturing factory in Zandone, Switzerland marshalling its capabilities to build three replacement machines at breakneck speed.

Says Martin Spencer:

“It was a real collaborative effort, and one that demonstrated how United Machining is able, and always willing, to pull out all the stops for its customers.”

This lateral bit of thinking was inspired, and it worked.

Starting in June and over a period of six weeks, three wire EDM machines were delivered and installed separately, one at a time, at Western Pegasus’ facility enabling production to occur and high quality parts to be made.

Summary

“When you are up against it, you really find out who your partners are,” says Andy Wincel.

“United Machining pulled out all the stops for us. They not only helped us clear the old site and arrange safe storage of the equipment that was in there, but also identified where and how we could acquire three new machines, as well as organising their delivery and installation to fit in with our building schedules.

“They also provided us with expert applications and logistics advice and support to help us ‘hit the ground running’.

“The fire completely took out our manufacturing operation but in just two and a half months we were back in business. We simply could not have achieved this without United Machining and its suppliers – and that’s what a real partnership is all about.”

Getting a foot in the door!

United Machining UK Ltd — 05/10/2026

United Machining’s advanced laser technology revolutionises the design and manufacture of high-quality textured shoe moulds. The laser process delivers high accuracies and repeatability’s combined with unrivalled design and manufacturing flexibility, predictability and reliability.

To meet the growing and evolving demands from designers of footwear brands for increasingly fine and complex surface structures, United Machining’s laser texturing technology offers a new and cost competitive way forward that can be relied upon to deliver perfect geometric and natural textures.

The process, based on United Machining’s extensive knowledge of high-quality surface finishes, allows manufacturers to achieve perfectly-structured and fine textures in competitive lead times when compared to conventional design and manufacturing processes.

United Machining’s laser texturing technology is a completely digital and repeatable process that reduces manual operations, allows unlimited design flexibility and allows manufacturers to significantly reduce time to market; it is these commercial advantages that have alerted the footwear sector to the potential of 3- and 5-axis laser technology.

Fine and complex surface structures

With United Machining’s laser technology, manufacturers can improve texture quality thanks to the laser sources (i.e., femtosecond and nanosecond) used.

The dimension of the laser spot is 0.05mm that allows fine, intricate and complex surface structures to be created that are beyond the scope of conventional technologies.

A digital and repeatable process

This digital approach, using United Machining’s proprietary software, helps manufacturers reduce manual operations and a reliance on specialised, manual expertise.

Freedom of design thanks to the characteristics of this laser solution and the digital processes involved, enable manufacturers to design and apply any and all kind of textures on parts and mould inserts – a huge source of differentiation in the market.

Reduce time to market

In the past, when manufacturers wanted to develop their own bespoke textures, the traditional route forward was to subcontract the work out to specialists which often impacted lead times and, on occasion, could affect quality too.

By bringing this element of design in-house, via investing in a laser machine tool, manufacturers can retain their independence, and better control operational efficiencies and costs.

No cutting tools needed

The use of laser technology means an end to tool breakage issues (i.e., downtime, part quality, scrap etc.). and the delivery of a safe, flexible and reliable texturing process.

Positioning of EDM generators: The closer to the spark - the better the surface finish achieved.

United Machining UK Ltd — 05/10/2026

Modern micro-electronics are redefining the capabilities and performance of modern die-sink EDM machines. Equipped with advanced, thermally-efficient generators that are able to dynamically control spark energy and intensity, these machines deliver faster processing speeds and unrivalled accuracies and surface finishes.

Since the dawn of the semiconductor age in the 1970s, electronics have transformed nearly every facet of our lives. Fifty years ago, one computer filled a room and its processing power was a fraction of what now fits in the palm of a hand. Today’s smartphones pack millions of times more transistors than the computers that guided last century’s space missions or powered early machine controls. The same accelerated semiconductor capability that puts a talking atlas in our hands is driving a transformation inside EDM.

With faster switching speeds, tighter integration and cooler-running, more compact generator designs that control spark energy in real-time, the new generation of microelectronics has reshaped the capabilities of die sinker EDMs, particularly for mould and die shops.

From transistors to sparks

Early EDM generators used analog systems that occasionally produced inconsistent sparks and required skilled operators to be on hand to ensure precision. As semiconductors advanced, EDM control systems evolved from simple spark timers into intelligent, feedback-driven pulse management systems. Each improvement meant more refined control over the spark, which is at the heart of EDM.

While much attention has focused on the sophistication of spark control, an advancement that is perhaps less talked about and understood is the physical location of the generator itself.

Says Martin Spencer, United Machining UK’s managing director:

“By keeping generator modules cool and close, today’s die-sinking machines achieve a higher level of thermal and electrical stability.”

Location, location, location

Traditional EDM machines often house their generators in separate cabinets or compartments, connected to the spark gap via several meters of heavy cable. This layout was logical when power supplies were large, heat-intensive and less susceptible to signal degradation. However, as generator components became smaller, more thermally stable and increasingly efficient, EDM machine builders began to ask, “Can we improve the process if we move the generator closer to the spark?”

The answer has is a resounding “Yes”, and is one that has proven transformative.

When a generator is located physically closer to the spark, the electrical path between the power source and the gap shortens. In electrical terms, shorter cables mean lower inductance and capacitance, both of which are critical for EDM. Reduced capacitance enables faster and more precise control of voltage changes, and also enables the generator to produce high-frequency bursts of energy that deliver controlled discharges with no overshoot or delay. The needle-like pulses are ultra-fast and deliver faster erosion rates, less heat transference into the workpiece and smoother surface finishes.

When we say ‘ultra-fast,’ we are talking about tens to hundreds of nanoseconds. Shorter pulses allow higher frequencies, as they reduce the risk of wire breakage in wire EDM and electrode damage in die-sinking machines. Additionally, this pulse type minimises contamination of the workpiece by the wire or electrode material - especially critical in industries like aerospace and medical device component manufacture.

The answer to the question about location is therefore clear clear. The closer the generator is to the spark, the more immediate and accurate each spark becomes. The payoff for mould and die shops is higher throughput, improved accuracy and surface quality, less rework and polishing, reduced heat-affected zones (HAZs), more compact machine footprints and easier thermal management

Put into practice

For example, a manufacturer producing precision turbine blade moulds for the aerospace industry must meet extreme dimensional tolerances while maintaining material integrity. Even microscopic cracks caused by thermal stress can lead to defects in final components, and ultimately, in their rejection.

Using a patented die-sinking EDM platform featuring a compact, high-speed generator mounted directly on the Z-axis or behind the back wall of the work pan and only inches from the electrode, the mould manufacturer can experience up to 20% reduction in cycle times.

Most important to the end-user, a close quality-assurance inspection shows a reduced HAZ on the workpiece. With less HAZ, the risk of micro-fractures is reduced, and the workpiece is more stable for finishing applications. In high-performance mould and die work, these kinds of improvements translate into significant productivity gains.

Modern Generators

Additional and related advancements have made it possible for a generator to be in close proximity to the spark.

Where older EDM generators required bulky transformers and large heat sinks, today’s systems rely on high-efficiency semiconductor switches [Metal-Oxide-Semiconductor Field-Effect Transistors (MOSFETs) and Insulated-Gate Bipolar Transistors (IGBTs)] and liquid-cooled modules that can operate in compact enclosures.

Modern generators are highly energy-efficient, converting over 80% of electricity directly into material erosion. In contrast, older models operated at significantly lower efficiencies, typically ranging from 30% to 50%.

The temperature-stable designs not only allow closer physical placement to the spark but also improve reliability too. Heat management is critical in EDM because thermal drift can alter pulse performance. By keeping generator modules cool and close, today’s die-sinking machines achieve a higher level of thermal and electrical stability.

Broader trends

The move toward placing generators near the spark reflects a broader manufacturing trend that blends mechanical engineering with advanced electronics. For example, with the advent of high-bandwidth memory (HBM) microchips that embed artificial intelligence (AI), EDM systems will be able to process and interpret far more operational data than a human operator ever could.

There are multiple parameters to control, and even the best operator cannot adjust them all manually. AI can act on multiple parameters simultaneously and apply solutions automatically. What’s more, AI can explore unconventional parameter combinations that humans might overlook or avoid, sometimes leading to surprisingly better outcomes.

At the same time, electronic sensor technology has advanced and become more affordable, enabling sensors to be placed throughout an EDM to automatically compensate for thermal deformation. This intelligent integration of sensors ensures consistent accuracy even as machining temperatures fluctuate.

Continues Martin Spencer:

“The payoff for component manufacturers and mould and die shops is higher throughput, improved accuracy and surface quality, less rework and polishing, reduced heat-affected zones (HAZs), more compact machine footprints and improved thermal management.”

Looking Ahead

The line between hardware and control software will continue to blur, with AI, digital twins, predictive algorithms and adaptive spark control pushing EDM into new realms of precision and productivity. One core principle does remain timeless, though. In EDM, everything starts with the spark. And the technology has shown that the closer we can get to the spark physically and electronically to the action, the better the results.

United Machining’s dedicated EDM service package helps customers achieve NADCAP certification.

United Machining UK Ltd — 05/10/2026

NADCAP (National Aerospace and Defence Contractors Association) accreditation for EDM (Electrical Discharge Machining) is a critical, rigorous certification standard required for suppliers in the aerospace, defence and space industries, focusing on non-conventional machining processes.

To help its EDM customers achieve and maintain NADCAP certification, United Machining has developed a dedicated service package for its AgieCharmilles EDM machines that optimises their high performance, repeatability and traceability.

NADCAP certification ensures that wire and spark erosion technologies and processes used by component manufacturers in the global aerospace, defence and space sectors meet a range of standardised, high-quality controls for critical components and the processes employed to manufacture them.

United Machining, previously GF Machining Solutions, has developed a dedicated service package to help its AgieCharmilles EDM (wire, sink and fast hole drilling) customers achieve and maintain this global mark of excellence.

The core element of this package focuses on planned preventive maintenance conducted by highly-experienced United Machining engineers, in accordance with NADCAP AC7116 specifications, to guarantee the repeatability and traceability of their EDM processes and ensure that their EDM machines are operating at peak performance.

According to NADCAP AC7116 specifications, repeatable EDM machining results require perfect mastery of the EDM spark. Using highly calibrated oscilloscope technology, United Machining engineers, during their customer visits, measure and, where and when appropriate, adjust the shape of the spark to guarantee repeatability, ensure tight tolerances and consistent surface finishes, and reduce the heat affected layer.

NADCAP compliance also requires customers to have in place procedures that record, validate and document EDM parameters used; these can include dielectric fluid condition, generator settings and machine maintenance etc., and that all processes and procedures, including machine operator skills, qualifications and training match NADCAP checklist requirements.

Says Martin Spencer, Managing Director of United Machining (UK):

“NADCAP certification is tough and intensive. Our dedicated and proven service and support package can help customers prepare for, and pass, their scheduled NADCAP audits by ensuring that their EDM documentation is up to scratch and that strict and robust EDM process controls are in place.”

A guaranteed high precision performer!

United Machining UK Ltd — 07/10/2026

The new MIKRON MILL P 500 VHP delivers exceptional surface quality and reliable accuracies even over extended machining runs and long periods of operation.

The 3-axis high-precision MIKRON MILL P 500 VHP machining centre is specifically designed and suited for demanding mould tool manufacturing. Thanks to its special linear direct-drive design, the machine achieves accuracies critical for producing high-precision micro-components typically used and found in the information and communications technology sector (ICT).

Competing machines traditionally use ball screw technology, which can negatively impact surface quality/surface finish due to backlash issues. The VHP’s polymer concrete machine bed, with its excellent damping properties, reduces vibrations and, as a consequence also ensures high precision.

Optimal force distribution and long-term thermal stability is ensured by the machine’s symmetric portal design. This is complemented by innovative and smart technologies such as Intelligent Thermal Control (ITC), the Operator Support System (OSS), and Step-Tec Opticool/CoolCore spindles, which can operate up to 42,000 rpm.

Together, these features guarantee high process reliability - essential for when the machine is operating continuously and subject to prolonged machining runs.

IDEAL FOR ICT AND PRODUCTIVE PRECISION APPLICATIONS

The P 500 VHP’s precision and performance makes its ideally suited to the machining of high-quality mould inserts for lenses or connectors used in the ICT sector.

However, its applications extend to other industries: from reflector moulds for automotive or household appliances to fuel cell tools and medical device moulds: in fact anywhere where extreme accuracies and superior surface finishes are required.

“The intelligent automation concept with rear-loading enables significant productivity gains, and its compact footprint allows space-efficient integration into a range of different environments,” says Juan Martin, Head of Customer Development at UNITED MACHINING.

The MIKRON MILL P 500 VHP offers exactly what modern manufacturers need to remain competitive: reliable precision combined with high productivity.

A driving force for impeller manufacture.

United Machining UK Ltd — 05/10/2026

United Machining’s MIKRON MILL P U series is the ideal simultaneous 5-axis machining centre range for complex open, semi-open and closed impeller manufacturing.

With their rigid design and construction, the incorporation of high torque motors, direct-drive STEP TEC spindles, advanced thermal compensation, integrated spindle protection, and advanced calibration systems MIKRON MILL P U series help manufacturers machine complex impellers quicker, faster and more efficiently.

Impeller machining is a precision process typically involving simultaneous 5-axis machining to create complex blade geometries and specialised CAM software and cutting tool technologies, in both roughing and finishing operations, to achieve the hub, fillet and blade profiles required.

The machining of an impeller involves a complex, multi-stage process that demands precision, strategy, and specialized tooling.

The machining process is typically divided into three primary stages: roughing, semi-finishing, and finishing, with each performing a crucial role in processing, sequentially, the workpiece into a high-precision component capable of performing, predictably and reliably, under extreme conditions.

Roughing operations focus on the rapid removal of bulk material and shaping the basic geometry of the impeller.

Semi-finishing refines this shape and prepares the all-important surfaces ensuring their high performance.

Finishing delivers the required surface finish quality and dimensional accuracies, especially important with the thin-walled, complex geometries of impeller blades.

Together, these stages form a structured workflow that ensures both efficiency and high-quality outcomes in impeller production.

Roughing

Roughing is the initial stage of impeller machining process, primarily focused on the rapid and efficient removal of material to establish the basic geometry of the part.

Several strategies can be applied during roughing, including:

• Z-level roughing (multi-pass surface cuts)

• Axial roughing (cuts aligned with the part’s axis)

• 5-axis plunge or “dive” roughing

• Adaptive roughing with toolpath strategies that optimise engagement and reduce tool wear

For impellers, specific roughing techniques often include cavity roughing (i.e., clearing internal spaces such as the hub and channels) and multi-blade roughing, where several blades are machined in a single operation for better tool engagement and time efficiencies.

While surface quality is not the primary goal at this stage, tool orientation in 5-axis machining must still be carefully managed to avoid collisions and ensure consistent material removal. (Inaccurate tool positioning can negatively affect tool life and roughing performance).

Semi-finishing

Semi-finishing is the intermediate step between roughing and finishing.

Its main objective is to leave a uniform and controlled amount of stock material across all surfaces, which is critical to achieving optimal results in the finishing pass(es).

Toolpaths used in semi-finishing often mirror those used in finishing, but with greater step-over and step-down values, as well as increased stock allowance.

This prepares the surface by eliminating large roughing marks while maintaining enough material to avoid air cuts and ensure stable cutter engagement during finishing operations.

In impeller machining, especially on thin and complex blades, tapered ball-nose cutters and end mills are widely used. Their geometry provides increased rigidity, minimising deflection and vibration.

The finishing stage achieves the final dimensional accuracy and surface finish requirements and necessitates precise control over toolpaths, tool orientation and cutting parameters. Z-level finishing, or constant-stepdown contouring, is a commonly used strategy to ensure even surface quality and optimal tool contact.

Finishing impeller blades is particularly challenging due to their complex geometry. Blades are often:

• Thin and flexible

• Tapered or twisted

• Uneven in height from hub to shroud

• Closely spaced

To avoid surface defects and tool marks, the entire blade should be machined using a single uninterrupted toolpath, ideally with the tool vector remaining normal or tangential to the central surface of the blade.

This method reduces abrupt changes in tool movement and helps maintain a consistent surface finish.

Additional considerations

Maximising the efficiency of impeller machining depends heavily on optimising the roughing stage, as this phase consumes the most machining time and removes the largest volume of material.

Advanced five axis roughing strategies help ensure consistent material removal, minimising sudden tool engagement and producing smoother tool paths.

Effective use of machine kinematics and toolpath planning, such as continuous five axis motion, also reduces the need for part repositioning and improving cycle times as a result.

Overcoming machining challenges with 5-axis MIKRON MILL technology

MIKRON MILL P U (5-axis) machining centres address common machining challenges in impeller production such as complex material cutting, tool wear and high precision.

Machine tool features include torque motors, direct drive spindles up to 120Nm and symmetrical machine designs for unrivalled stability and accuracy.

Other highlights include a range of automation systems that can increase productivity, even with high-mix, low-volume batch manufacturing, and integrated turning capabilities on the MIKRON MILL P 800U for one-hit machining achieved in a single set up.

Ergonomics, compact design and minimal footprint

The machines’ ergonomic design (i.e., layout, configurations. Etc.), enables easy access to undertake maintenance and set-up purposes. Furthermore, their compact and small footprints maximise productivity per square meter of floor space available.

Torque motors add additional benefits

MIKRON MILL vertical 5-axis machines are equipped with torque motors asa standard feature enabling them to undertake the simultaneous 5-axis machining of blade edges.

Torque motors deliver increase rigidity resulting in improved stability and vibration damping. Additionally, torque motors operate without friction, thereby eliminating any possibility of wear and reducing the chances of pitch error or reverse error. This translates into superior accuracy and precision throughout the machining process, whilst also contributing to the longevity of the machine.

Automated Machine Calibration

With Automated Machine Calibration (AMC), the complex and challenging process of calibration becomes effortless. Even operators without specific milling knowledge can successfully calibrate the machine.

The system streamlines the calibration process, reducing the potential for human errors and ensuring consistent and accurate results.

Incorporating advanced algorithms and technology to optimize the calibration process, AMC automatically adjusts key machine components to restore the desired precision and accuracy.

Thanks to its user-friendly interface and automated cycle, operators can efficiently manage data, reducing the time and effort required for calibration.

Machine Spindle Protection (MSP)

Milling crashes between the spindle and the part are a common occurrence, often resulting in spindle breakage, machine downtime, broken tools and scrapped parts and costly repairs.

Fortunately, the Machine Spindle Protection (MSP) system on MIKRON MILL machines helps avoid all these problems.

Strategically located sensors instantly detect a collision and promptly halt the machining operation. In the event of a crash, the machine remains unharmed, preserving its geometry, and preventing spindle damage.

With a brief intervention from a human operator, the machining process can swiftly resume by simply relaunching the job through the CNC interface.

High quality STEP TEC Spindles

MIKRON MILL machines are equipped with high-performance, Swiss-quality spindles renowned for their speed, precision, and reliability.

These spindles deliver exceptional stability at high RPMs, ensuring consistent performance from roughing to finishing, regardless of the material being machined. Whether working with titanium or aluminium, STEP TEC Spindles provide the highest level of performance and efficiency for every machining process.

Summary

The manufacturing of impellers demands a seamless integration of advanced machine tool technology, precise multi-stage machining workflows, and intelligent process optimisation.

The 5-axis MIKRON MILL machines deliver all this and more, providing exceptional stability, rigidity, precision, fast processing speeds and excellent cutting performance.