Case Study: Horstman Defence Systems Limited achieves up to 70% reduced machining time and increased 5-axis capacity with Vero Software (Edgecam)

Cell Partnership Increases Horstman Capacity Mazak, Edgecam & Iscar

Horstman Defence Systems, a UK specialist in high‑performance suspension systems for military vehicles, needed additional capacity and repeatable high‑precision machining to fulfil a contract for NATO Infantry Fighting Vehicle components (4,200 suspension assemblies over seven years, nine parts per assembly). The challenge was to ramp up complex multi‑axis production quickly while meeting tight tolerances and reducing cycle times compared with conventional shopfloor programming and machines.

A £1.25m manufacturing cell—built through a partnership between Mazak, Edgecam and Iscar—combined two Mazak Integrex i‑400s and an i‑200s programmed with Edgecam, 111 Iscar tools with tool management, SPC and in‑machine Renishaw inspection. The cell cut machining time by up to 70% (average 40%), has delivered zero scrap since full‑rate production began, is producing 360 parts/month with capacity to increase to 60–90 units at maximum run rate, and achieves 10–15 µm accuracy with excellent surface finishes, while freeing other machines for sub‑contract work.

Horstman Defence Systems Limited

Nigel Hammett

Manufacturing Engineer for Process Development