Complete confidence in complex machining

For precision subcontract manufacturer WES Engineering Solutions, confidence is fundamental to every machining operation. Producing complex components for demanding industries that include aerospace, defence, nuclear and oil & gas demands absolute faith in every CNC program before the first chip is cut. By integrating Vericut simulation, verification and analysis software into its programming workflow, the Redruth-based company is verifying four- and five-axis CNC programs before they reach the machine. WES Engineering is therefore leveraging the benefits of this advanced software to safeguard expensive equipment while enabling productive unattended machining.

WES employs around 40 people across three specialist divisions. Alongside its subcontract machining business, the company operates a hard metal engineering division specialising in grinding and EDM, together with British Classic Car Performance Braking, which manufactures high-performance brake calipers for vintage vehicles.

Cross-division precision

Since 2022, WES has boosted its machining capability by installing a trio of palletised Matsuura CNC machining centres. An H.Plus-300 four-axis horizontal model with 15 pallets was the first to arrive, followed by two five-axis vertical machining centre, namely an MX-520 with four pallets in 2024 and an MX-330 with 10 pallets in 2026.

“The first Matsuura machine held tolerances exceptionally well, so when we needed additional five-axis capacity it made sense to invest in Matsuura again,” comments James Humphrey, Production Engineer at WES Engineering Solutions. “The latest MX-330 further increases our unattended machining capability, which is becoming increasingly important as customer demand continues to grow.”

Licence to mill

Alongside the new machine tools came investment in a licence of Vericut simulation, verification and analysis software. Using Autodesk Fusion 360 CAM software, WES programmers generate the machining strategy before transferring the job directly into Vericut via its integrated Fusion interface.

With Vericut’s Verification, Multi-Axis and Machine Simulation modules, WES simulates every machining process against digital models of its Matsuura machining centres, checking for collisions, over-travel and other potential issues before releasing programs to production. Vericut’s Auto-Diff module provides an additional layer of confidence by comparing the machined component with the original CAD model, highlighting any remaining stock or potential gouges.

“Vericut gives us complete confidence that the machine isn’t going to do something different to what we’ve programmed,” states James.

Trust, then cut

For WES Engineering Solutions, independent verification is invaluable. The company regularly manufactures high-value components using equally expensive cutters and machines. Even a minor programming error can result in broken tooling, scrapped workpieces or machine damage.

“We’ve all heard the stories of programming mistakes causing expensive collisions,” he notes. “Repairing or replacing a spindle on a five-axis machining centre wouldn’t be cheap. Every programmer, however experienced, worries about making that one tiny mistake. Vericut goes a long way towards mitigating this concern.”

The software also transforms and expedites the proving-out process on the shop floor. Rather than operators cautiously monitoring every new program with a finger poised over the feed-hold button, they can approach such jobs with considerably more confidence.

Stand-out performer

Before selecting Vericut, WES evaluated several alternatives. However, alongside Vericut’s proven capabilities, access to UK-based technical support proved an important consideration. Following a trial period that included deliberately introducing programming errors, the purchase decision quickly became clear.

“We wanted reassurance that Vericut would correctly identify problems before they reach the machine,” remarks James. “During the trial, the software detected everything we expected it to. Since then, the ongoing support has been very responsive whenever we’ve needed assistance.”

Value-added investment

Although the financial return is difficult to quantify precisely, James believes the investment continues to deliver daily value by preventing problems before they occur: “Complete peace of mind allows us to concentrate on producing high-quality parts and meeting the delivery expectations of customers.”

Quality is everything at WES, which carries accreditation to ISO 9001 and AS9100 (aerospace) quality management system standards. In addition, the company is certified to Fit For Nuclear (F4N) and JOSCAR. The latter is a collaborative accreditation system used by major aerospace, defence and security organisations.

Confidence in tomorrow

As WES Engineering Solutions continues expanding into increasingly complex, higher-value manufacturing sectors, Vericut provides the assurance that every program has been thoroughly simulated and verified before manufacturing begins. The result? Safe, efficient and reliable machining.