Case Study: Alliance Tooling Limited achieves 80% faster electrode design and lights-out EDM productivity with Vero Software (VISI Electrode)

Alliance Tooling Limited - Customer Case Study

Alliance Tooling Ltd, a Leicester-based plastic injection mould designer and manufacturer for household, medical, automotive and other sectors, was held back by a bottleneck in creating and sparking copper electrodes for EDM. Complex jobs—such as a mould trigger and a drug dispensing component—required many electrodes and long modelling times (about an hour each), causing production stops and missed throughput opportunities.

By adopting Vero’s VISI Electrode software, a Sodick AG60L 6‑station toolchange spark eroder, a custom four‑chuck jig and improved data export/workholding practices, Alliance transformed the process. Design time fell by 80% (electrodes now take under 10 minutes), electrodes can be batch‑machined and sparking run lights‑out, collision simulation with holder data removes clashes, and coordinated outputs boost accuracy and material reuse—enabling faster delivery and supporting planned growth.

Alliance Tooling Limited

Luke Parsons

Managing Director