The turbine seal strip is a vital component of a jet engine.
Turbine Seal in context
The turbine seal strip is a vital component of a jet engine.

A laminated press-brake tool, used to bend the sealing strips in precisely the desired angles.
Laminate press-brake tool
A laminated press-brake tool, used to bend the sealing strips in precisely the desired angles.

A laminated press-brake tool, used to bend the sealing strips in precisely the desired angles.
Laminate press-brake tool
A laminated press-brake tool, used to bend the sealing strips in precisely the desired angles.

Tooling for the turbine sealing strips, and some of the product
Tools and parts
Tooling for the turbine sealing strips, and some of the product

A complete set of turbine sealing strips, ready to go.
Turbine sealing strips
A complete set of turbine sealing strips, ready to go.

Part of the turbine component with our sealing-strips in place (uppermost).
Turbine component with sealing strips
Part of the turbine component with our sealing-strips in place (uppermost).

The context for the CMM (co-ordinate measuring machine) application to fan blades.
A jet engine’s fan blades
The context for the CMM (co-ordinate measuring machine) application to fan blades.

CMM Leading Edge Inspection Fixture (fan blade uppermost).
CMM Leading Edge Fixture
CMM Leading Edge Inspection Fixture (fan blade uppermost).

The fan blade is mounted in the CMM fixture, and its profile is precisely scanned in the Metrology Lab.
CMM fixture in metrology lab
The fan blade is mounted in the CMM fixture, and its profile is precisely scanned in the Metrology Lab.

Our titanium spring technology holds the blade firmly, yet without distorting its profile.
Leading edge of blade, clamped
Our titanium spring technology holds the blade firmly, yet without distorting its profile.

Co-ordinate measuring machine, showing the laser-sensor at work, scanning the blade profile.
CMM with laser
Co-ordinate measuring machine, showing the laser-sensor at work, scanning the blade profile.

The vanes in a jet engine: welded using MetLase oxygen-free gas-shield technology.
Vanes in a jet engine
The vanes in a jet engine: welded using MetLase oxygen-free gas-shield technology.

The CAD design for this welding gas shield.
Gas shield CAD design
The CAD design for this welding gas shield.

The CAD design for this welding gas shield.
Gas shield CAD design
The CAD design for this welding gas shield.

The welding gas-shield is assembled permanently and with minimal leakage, using slot-rivets.
Gas shield structure
The welding gas-shield is assembled permanently and with minimal leakage, using slot-rivets.

The gas shield, shown clamped onto the vane, before welding
Gas shield clamped onto part
The gas shield, shown clamped onto the vane, before welding

The gas shield, shown clamped onto the vane, before welding.
Gas shield clamped onto part
The gas shield, shown clamped onto the vane, before welding.

The Argon is flowing, and the weld is performed in an oxygen-free environment.
Welding with a gas shield
The Argon is flowing, and the weld is performed in an oxygen-free environment.

View from further back, showing the vane, the welding operator, and the MetLase gas shield.
Gas shield in context
View from further back, showing the vane, the welding operator, and the MetLase gas shield.

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The CAD model of the MetLase fixture which allows assembly and robotic welding access.
PROVE: CAD model of the exhaust and mounting fixture
The CAD model of the MetLase fixture which allows assembly and robotic welding access.

A CAD model of the MetLase fixture, into which the exhaust assembly would be placed.
CAD model of the MetLase fixture
A CAD model of the MetLase fixture, into which the exhaust assembly would be placed.

A CAD model of the exhaust system which needed to be clamped, aligned and welded.
CAD model of exhaust system
A CAD model of the exhaust system which needed to be clamped, aligned and welded.

The MetLase fixture, loaded up with the exhaust-pipe parts, prior to welding
The fixture, loaded with parts for assembly
The MetLase fixture, loaded up with the exhaust-pipe parts, prior to welding

A second fixture for a different part of the pipework, mounted on the welding robot.
A second fixture, in the welding robot
A second fixture for a different part of the pipework, mounted on the welding robot.

The Aston Martin test vehicle: sucessfully completed 5000 miles with our exhaust system.
Aston Martin Car
The Aston Martin test vehicle: sucessfully completed 5000 miles with our exhaust system.

The engine mounting vanes, which need to be maintained.
Engine mounting vane, in situ.
The engine mounting vanes, which need to be maintained.

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Left: jet engine from behind, showing the support vanes. Right: Rolls-Royce engineers testing an early version of the MetLase tool on the same part, when not in the engine.
Testing one version of the tool, before the final iteration.
Left: jet engine from behind, showing the support vanes. Right: Rolls-Royce engineers testing an early version of the MetLase tool on the same part, when not in the engine.

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The reprofiling tool, aligned, clamped, and ready to use. MetLase ingenuity makes this operation reliable, repeatable, and straightforward.
Pantograph cutter, in place
The reprofiling tool, aligned, clamped, and ready to use. MetLase ingenuity makes this operation reliable, repeatable, and straightforward.

The MetLase fixture, in a flight-case, ready to be deployed into service.
MetLase fixture, in box
The MetLase fixture, in a flight-case, ready to be deployed into service.

An engine repair technician uses the MetLase fixture to re-machine the profile of the mounting vane.
Guided maching tool, in operation
An engine repair technician uses the MetLase fixture to re-machine the profile of the mounting vane.

A costly and precise assembly, made by crogenic insertion of struts into the strut-ring.
The completed strut ring in-situ.
A costly and precise assembly, made by crogenic insertion of struts into the strut-ring.

The strut, located in its carrier, within the guide-rails.
The MetLase Insertion Alignment tool
The strut, located in its carrier, within the guide-rails.

A strut, within its holder, during development trials, being cryogenically frozen and shrunk in liquid nitrogen (-196°C).
Liquid nitrogen bath.
A strut, within its holder, during development trials, being cryogenically frozen and shrunk in liquid nitrogen (-196°C).

Multiple strut holders, being loaded and prepared. (Even the workbench uses MetLase twist-dowels).
Workbench, for strut insertion
Multiple strut holders, being loaded and prepared. (Even the workbench uses MetLase twist-dowels).

After insertion. This must be completed within seconds, since water vapour in the air freezes quickly into layer of ice.
The finished strut, correctly inserted, and now covered in ice.
After insertion. This must be completed within seconds, since water vapour in the air freezes quickly into layer of ice.

The finished product: 11 struts successfully inserted into the strut ring, without errors.
Finished product
The finished product: 11 struts successfully inserted into the strut ring, without errors.

This workbench integrates a liquid nitrogen bath, to prepare 6 holders at a time. The flexure bearing is visible within the slide unit.
A second iteration of the workbench
This workbench integrates a liquid nitrogen bath, to prepare 6 holders at a time. The flexure bearing is visible within the slide unit.

The fan-track liner minimises the leakage of air, while not interfering with the spinning compressor blades.
Fan Track liner, location in Jet Engine
The fan-track liner minimises the leakage of air, while not interfering with the spinning compressor blades.

The cutting head, shown profiling the surface of the composite liner material.
MetLase Profiling Fixture, close-up
The cutting head, shown profiling the surface of the composite liner material.

The cutting head, shown profiling the surface of the composite liner material.
MetLase Profiling Fixture, close-up
The cutting head, shown profiling the surface of the composite liner material.

Prototype, most of this design is in place, but iteration is needed to perfect the design.
MetLase Profiling Fixture v1
Prototype, most of this design is in place, but iteration is needed to perfect the design.

The cutting head (central) is guided around an arc. The liner (black) is supported in place, and cut precisely.
MetLase Profiling Fixture, face on
The cutting head (central) is guided around an arc. The liner (black) is supported in place, and cut precisely.

The cutting head is guided around a circular track. The liner (grey) is supported in an arc, and cut precisely.
MetLase Profiling Fixture
The cutting head is guided around a circular track. The liner (grey) is supported in an arc, and cut precisely.

The ergonomic tool, in use to correct the fan blade profile. This is "simplicity on the other-side of complexity".
Fan Blade Edge-Repair tool, in situ
The ergonomic tool, in use to correct the fan blade profile. This is "simplicity on the other-side of complexity".

If a tool can slide along the edge, while being correctly self-aligning and re-adjusting, it can precisely repair the blade-profile.
Edge-repair tool: the concept
If a tool can slide along the edge, while being correctly self-aligning and re-adjusting, it can precisely repair the blade-profile.

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The tool is supplied in a protective case, with additional blades.
Finished product, in flight-case
The tool is supplied in a protective case, with additional blades.

The internals: contains cutting edge, casters, and calibrated titanium springs.
The cutting head
The internals: contains cutting edge, casters, and calibrated titanium springs.

This shows 3 steel test pieces, assembled with the twist-dowel fastener. Rapid assembly, precise, and strong.
Twist Dowel Demonstration
This shows 3 steel test pieces, assembled with the twist-dowel fastener. Rapid assembly, precise, and strong.

This shows the Mazak Laser cutter in action.
The Laser Cutter
This shows the Mazak Laser cutter in action.

Inside the Mazak Laser-cutter, in action.
The Laser Cutter
Inside the Mazak Laser-cutter, in action.

MetLase press-brake tools can be made quickly to any desired form-factor.
Laminated Press-Brake tool
MetLase press-brake tools can be made quickly to any desired form-factor.

Parts are laid out optimally to fit them onto a sheet of steel before they are laser-cut. This is the nesting process.
Nested Parts
Parts are laid out optimally to fit them onto a sheet of steel before they are laser-cut. This is the nesting process.

The software used for nesting the parts of a project.
Nesting, in software
The software used for nesting the parts of a project.

Parts are laid out optimally to fit them onto a sheet of steel, and then laser-cut.
Nested Parts after cutting
Parts are laid out optimally to fit them onto a sheet of steel, and then laser-cut.

Mild Steel, Titanium and Nickel alloys, all 2-3mm thick.
Different Metals
Mild Steel, Titanium and Nickel alloys, all 2-3mm thick.

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This shows the component parts of a twist-dowel
Twist Dowel - annotated (1)
This shows the component parts of a twist-dowel

This shows the component parts of a twist-dowel
Twist Dowel - annotated (1)
This shows the component parts of a twist-dowel

This shows the twist dowel parts before assembly
Twist Dowel - disassembled
This shows the twist dowel parts before assembly

*This shows a slot-rivet assembly, before the rivet is hammered.
Slot Rivet (before-hammering)
*This shows a slot-rivet assembly, before the rivet is hammered.

*Slot-rivet assembly, after the rivet is hammered almost flush. Unlike twist-dowels, the slot-rivet is permanent.
Slot Rivet (after-hammering)
*Slot-rivet assembly, after the rivet is hammered almost flush. Unlike twist-dowels, the slot-rivet is permanent.

*A titanium spring: part of a mechanism for an over-centre clamp.
Titanium Spring)
*A titanium spring: part of a mechanism for an over-centre clamp.

Made with an internal titanium spring, and assembled with slot-rivets. (This is a detail from the profiling fixture)
Over-centre clamping mechanism
Made with an internal titanium spring, and assembled with slot-rivets. (This is a detail from the profiling fixture)

Caption 51
Title 51
Caption 51

Here are the parts. Can you put them together?
Disassembled parts
Here are the parts. Can you put them together?

The finished result: a mobile phone holder.
Assembled version
The finished result: a mobile phone holder.

The Unipart Way Award for Innovation: Best in Group, awarded to MetLase, AME, UMG and UPA.
MetLase joint winner of the Unipart Way Award for Innovation
The Unipart Way Award for Innovation: Best in Group, awarded to MetLase, AME, UMG and UPA.

At the official opening of the new MetLase building, in the Rotherham AMP, the Business Secretary is given a demonstration of the MetLase fixture used in PROVE.
Business Secretary Sajid Javid visits MetLase
At the official opening of the new MetLase building, in the Rotherham AMP, the Business Secretary is given a demonstration of the MetLase fixture used in PROVE.

MetLase is now officially one year old: the Joint Venture was incorporated on September 1st 2015.
MetLase’s first birthday!
MetLase is now officially one year old: the Joint Venture was incorporated on September 1st 2015.

Steve Dunn, Managing Director of MetLase at AMRC Factory 2050 with IMG Theme Lead in Automated Assembly, James Illingworth.
MetLase joins the AMRC to develop the fixtures of the future
Steve Dunn, Managing Director of MetLase at AMRC Factory 2050 with IMG Theme Lead in Automated Assembly, James Illingworth.

The MetLase Team in summer 2016.
The MetLase Team
The MetLase Team in summer 2016.

A pigtail fuel-rail support bracket: must be bent in a very precise way.
Bracket (desired product)
A pigtail fuel-rail support bracket: must be bent in a very precise way.

Loading a bracket onto the centralising jig, before bending
Centralising Jig, in use.
Loading a bracket onto the centralising jig, before bending

The entire mechanism which contains the centralising jig
Centralising Jig, full mechanism.
The entire mechanism which contains the centralising jig

Original concept for the centralising jig.
Centralising Jig, v1
Original concept for the centralising jig.

Centralising jig, 2nd iteration reduces play.
Centralising Jig, v2
Centralising jig, 2nd iteration reduces play.

Centralising jig, 3rd iteration eliminates binding.
Centralising Jig, v3
Centralising jig, 3rd iteration eliminates binding.

Centralising jig, 4th iteration enforces lockstep.
Centralising Jig, v4
Centralising jig, 4th iteration enforces lockstep.

Centralising jig, 5th and final ’perfect’ version.
Centralising Jig, v5
Centralising jig, 5th and final ’perfect’ version.

Alignment and clamping of pipes, ready to weld. This photo is from the PROVE projct.
Pipe and assembly
Alignment and clamping of pipes, ready to weld. This photo is from the PROVE projct.