Model railway manufacturer Dapol has installed a new CNC tool station to increase its UK production capability.

The new machine is a Hurco VM10HSi three-axis machining centre, which will significantly increase the capability of the company’s tool room.

Up to 20 tools can be fitted to the machine, which can change all of them automatically. Machining is accurate to one micron. Software to drive the process is through a program called Win Max, which allows precise instructions for the machine to execute to be input manually or through output from CAD. An integrated monitor provides the operator with a simulated preview of the upcoming process.

Installing the new machine in the tool shop was a challenge and required the cooperation of Dapol’s neighbours for access through their storage yard.

The initial stage in using the machine in practice was to install a cavity plate on the machining table. This was accurately measured by a taster probe fitted to the machine, which was necessary because multiple plates will be required, which need to align perfectly and maintain tonnes of force on the moulding machine.

Cuts are then made in the cavity plate to receive the various inserts required for a particular project. A water-based milling fluid keeps both the tool head and the metal plate being cut cool during the cutting process.

Once the recess has been cut in the cavity plate, four “pillars” will remain to help guide all the various plates together safely and ensure they all align. Three of the pillars are 32 mm across, and the fourth is 30 mm across, the different sizes ensuring that the mould can never be assembled the wrong way round. Insert plates engraved with the model details will later be placed in the recesses.

The announcement of the new CNC capability comes soon after the arrival of Dapol Class 59s, and O and OO gauge wagons with a Christmas livery.