Alwayse Engineering gears up with new Lynx CNC lathe

A global specialist in ball transfer unit (BTU) design and manufacture, Alwayse Engineering, has invested in a new DN Solutions Lynx 2100B lathe from Mills CNC. The two-axis, FANUC-controlled 8-inch chuck/65 mm bar diameter Lynx 2100B arrived in March 2025 at Alwayse’s integrated Birmingham manufacturing facility, marking the latest step in the company’s expansion of its machining capabilities. The investment also includes a Hydrafeed MSV65 servo-driven bar feeder to enable continuous, unattended production, and a ROTA-RACK parts accumulator with integrated belt conveyor to improve component handling and protection.

The Lynx 2100B is producing carbon steel bodies for the company’s newly redesigned 805 BTUs, which see common deployment in air cargo applications and feature a low profile with high load capacity.

Machining takes place in a single set-up. Operations include front-end boring to create the internal hemisphere and rear-end parting-off to separate each component from the remaining bar stock. Cycle times are around 80 seconds. The machined parts then transfer to another Lynx lathe, which adds multi-dirt exit holes that help reduce debris build-up and simplify maintenance.

After machining, the components undergo case hardening and zinc plating. Each unit is then assembled with small stainless steel balls and a larger stainless steel or carbon chrome load ball, either 30 or 45 mm in diameter. The assembly is sealed with a stamped retaining ring. As one of Alwayse’s core line products, its 805 series units are kept in stock for rapid dispatch to customers.

Customised solutions for global applications

Alwayse collaborates closely with clients to design modular ball transfer decks using multiple 805 units arranged in a grid and mounted on steel top plates. These plates are affixed to fabricated frames built from strong, stable steel sections. The design of each deck depends on specific requirements such as aircraft cargo bay dimensions, unit load devices (ULDs), warehouse layout, and the type and weight of goods being transported, including cargo, baggage and mail.

In 2023, Alwayse began a full redesign of the 805 series. The project was driven by customer feedback and the company’s commitment to continuous improvement. With prototyping and pre-production testing now complete, Alwayse is ready to begin full-scale production of the new units.

A long-standing relationship with Mills CNC

Alwayse’s relationship with DN Solutions and Mills CNC began in 2006. The new Lynx 2100B joins five existing Lynx lathes already in use at the Birmingham site. These include two Lynx 220LCs, one Lynx 220C, one Lynx 2100LMSB and a Lynx 2100A.

Richard Cutler, Engineering Manager at Alwayse Engineering, says: “DN Solutions and Doosan machines have consistently delivered strong performance. They have enabled us to expand our machining capacity, improve accuracy and repeatability, and boost productivity through faster processing and reduced set-up times. Over the years, we’ve developed a reliable and collaborative relationship with Mills CNC. In addition to supplying high-quality machines, they provide excellent delivery, installation, training and aftersales support.”

When Alwayse began searching for a new machine to manufacture the redesigned 805 units, three suppliers were considered. Mills CNC’s proposal, combined with the company’s prior experience and long-standing relationship, secured the order.

“Given our history with the Lynx range and the service we’ve received from Mills, choosing them again made perfect sense,” says Richard Cutler.

Lynx 2100B: key features

The Lynx 2100B is a popular and compact lathe featuring a 15 kW spindle with a maximum speed of 4500 rpm and a 12-station, servo-driven turret for rapid tool changes. It delivers high-speed movement with 30 m/min in the X axis and 36 m/min in the Z axis, along with a maximum turning diameter of 350 mm and a turning length of 330 mm.

Installing the Lynx 2100B at Alwayse Engineering is a strategic investment that enhances machining capacity and prepares the company to meet growing demand for the updated 805 BTUs. The collaboration between Alwayse and Mills CNC continues to deliver long-term value, combining advanced technology with proven reliability in precision manufacturing.