Strategic investment underpins expansion at ComplexaHPE

Precision injection moulding, machining and tooling specialist ComplexaHPE is reporting a record order book following more than £2 million of investment in advanced manufacturing technology and a strategic focus on building strong supplier partnerships, including with Erodex UK.

ComplexaHPE was formed in January 2021 through the amalgamation of Glossop-based ComplexaTools and High Precision Engineering (HPE). The company now offers a comprehensive manufacturing capability spanning toolmaking, precision machining and injection moulding, and has recently secured new contracts with high-end medical companies in the UK, Ireland and overseas.

Group Managing Director Paul McHugh says the company’s growth is the result of sustained investment, technical expertise and close collaboration with key suppliers.

“Our objective has always been to provide a full turnkey solution,” he explains. “Rather than supplying only a tool or a mould, we support customers from design for manufacture through to final sign-off, including end-of-arm tooling and inspection fixtures. Increasingly, customers are asking for this complete service because of time pressures and the need for consistent quality.”

To meet these demands, ComplexaHPE has prioritised improvements in machining accuracy and production efficiency. Investment has focused on high-performance equipment and automation technologies, including robotics and palletisation, to support lights-out manufacturing.

Since 2021, the company has invested more than £2 million in new machinery, including HSM 400 high-speed milling machines, multiple five-axis Hurco machining centres, Agie Charmilles spark erosion and wire erosion machines, and a second Mazak Millturn.

“Investing in advanced machinery is essential, but it is equally important to optimise how that technology is used,” says Paul. “That’s where the support of Erodex has played a significant role, particularly in maximising EDM performance.”

Following a detailed review of ComplexaHPE’s EDM processes, Erodex recommended the use of POCO EDM 200 and EDM1 graphite grades, with EDM3 and EDMC3 used where required. The range of POCO materials enables the company to select the most appropriate grade for each application while maintaining the precision demanded in mouldmaking.

Andrew McFarlane, Area Manager at Erodex, highlights the importance of material consistency in automated production environments: “Because ComplexaHPE operates lights-out machining with robotics, consistency is critical. When electrodes are programmed to run unattended, the material must perform reliably. POCO graphite delivers that consistency and supports predictable machining outcomes.”

He adds that ComplexaHPE has achieved improved machinability, longer electrode life, reduced cycle times and enhanced surface finishes since adopting POCO materials.

Paul notes that the quality of POCO graphite has been central to the company’s ability to serve high-value sectors such as medical manufacturing: “The level of definition and detail we can achieve is crucial for high-end moulds. We’ve also worked with Erodex on consignment stock, which allows us to respond quickly to customer requirements while supporting our investment in automation and lights-out machining.”

Reflecting on the company’s current position, he adds that ComplexaHPE is experiencing unprecedented demand.

“In nearly 29 years in toolmaking, I’ve never seen an order book approaching 24 months of work,” he says. “That reflects the trust our customers place in our quality and reliability. It also demonstrates the value of strong partnerships with suppliers such as Erodex.”

Senior Tool Room CNC Miller and CAM Technician Dave Hill also highlights the practical benefits of POCO graphite in daily operations: “From a machinability perspective, POCO graphite is highly reliable. Its consistency allows us to machine complex electrodes with confidence in a 24/7 lights-out environment. Tool life is improved and wear during the EDM process is very low, which reduces the number of electrodes required and improves overall cost efficiency.”

Paul concludes by stating that the company’s success is built on a combination of technical capability, skilled personnel and supplier support: “Our performance is driven by the quality of our products, the expertise of our team and the strength of our supplier relationships. With the support of Erodex and the performance of POCO graphite, we have raised standards in precision manufacturing and strengthened our competitive position.”