“This means they would require a considerable number of set-ups using traditional 3-axis machining, so we went for a 5-axis centre to overcome that issue. “We were waiting too long for essential components that we needed to test and develop our products, so decided to bring that machining operation in house.” The components are quite small, mostly within a 500mm manufacturing area, and are extremely detailed and complex.
Before purchasing its simultaneous 5-axis Mazak Variaxis i-500 it also subcontracted the prototype machining work out to a number of other companies, but found the slow turnaround frustrating and uneconomical. “Our closed loop gas cooled system uses the density of the combustion gas to absorb heat from the rotor and circulate it through a heat exchanger, prolonging the engine's life.” Once Bailey and his team of 15 employees complete the development and prototyping of each component and product at their 6,500ft 2 premises, the bulk manufacture is carried out by The Proving Factory in Rotherham, in conjunction with Tata Steel. AIE's patented technology addresses the historic Achilles heel of rotary engines – keeping the rotor bearing cool. Its core market is aerospace, especially for unmanned aerial vehicles – or drones. AIE has a worldwide customer base for its unique engines, particularly amongst defence companies and military research organisations. And it has considerably enhanced our in-house capabilities.” The Staffordshire company develop Wankel rotary engines with a number of its patented technologies built into the cooling and exhaust systems and its exhaust expander technology improves efficiency.
Managing director Nathan Bailey says: “We had no 5-axis machining experience, but felt the rewards would outweigh the risks. Edgecam made it much easier than it imagined to produce complex, high precision components on a top end machine, just weeks after installing the technology for the first time.
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