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Inplas Plastic Fabrications Ltd is a blockbusting manufacturer and fabricator for the television and film industries!! The company’s success has recently seen it work on high profile films such as Harry Potter, Charlie & the Chocolate Factory, ThunderBirds and Die Another Day.
Inplas also works with industrial designers, graphic designers, exhibition companies as well as the blue-chip and retail industries. Formed in 1995 by co-directors Ashley Wright and Trevor Smith, the company continually grows by 25-30% year on year.
Trevor Smith comments: “The growth is down to our investment in technology and machine tools and the support from our suppliers - and ITC Tooling has been a major contributor to our success.”
Inplas has recently invested in new 3D CAD/CAM software, diamond polishing equipment and a machine tool with an 11 tool carousel awaiting delivery. The new machine will enable Inplas to work at 24,000rpm with a feed rate of 423mm/sec; its current machine runs at 24,000rpm with feeds of 254mm/sec. Operating at 254mm/sec, cutting tools at Inplas were cutting at a maximum depth of 1.8mm per pass. The introduction of ITC cutters immediately enabled the company to increase the depth of cut to 5mm per pass, increasing productivity by up to 30% on a number of jobs.
The exceptional capability of the ITC cutters will comfortably enable Inplas to maintain 5mm depths of cut on the forthcoming machine that will run at 423mm/sec. Smith continues: “ITC cutters have enabled us to double the depth of cut on current machines and they will maintain this at higher feeds on a new machine. The machine has the capability to increase our productivity by 40%, so it is vital it is tooled correctly.”
The ITC cutters are used to produce film set props, signs, retail displays, industrial models and conduct engraving operations on a multitude of materials. The company manufactures anything from prototypes to batches of 10,000 and each component must be of the highest quality.
Product quality is yet another reason Inplas uses ITC cutters. “Working on high profile projects means aesthetics are of vital importance. Machining marks on parts often proved problematic and second operations were often required. Since the introduction of ITC, the surface finish has been impeccable and it has eradicated second operations in many instances. This can also be said of the excellent edge finish we now achieve. Previously we had rough edges and this also caused re-working. The cutters have improved our product quality and as a by product saved us time.”
One recent project that required quality of the highest order was the production of the famous glass elevator for ‘Charlie & the Chocolate Factory’. Inplas used a single flute long series ITC cutter to produce the Perspex elevator.
Since Inplas started using ITC Tooling four years ago, the partnership has progressed and Inplas now uses specialised engraving tools, autocarving tools, single and triple flute and long series and ball nosed cutters among others. A number of these were used for ‘Charlie & the Chocolate Factory’ to produce the elevator, the Perspex tubing that sucks up the gluttonous Augustus Gloop and additional elevator parts.
The company also used a full compliment of ITC tools when producing props for the ThunderBirds film. Inplas was heavily involved in the manufacture of the perspex roof, cockpit components and additional parts for the pink FAB1 car for the popular children’s film. The full scale vehicle was delivered to Inplas for the company to undertake intricate, high quality work that was required to complete the vehicle prior to filming.
With films that have been and will be seen by millions, aesthetics are of vital importance – and ITC contribute considerably toward this.
“Prior to the introduction of ITC Tooling we suffered considerable downtime from poor tool life. Our previous cutters would break frequently; this would have a detrimental effect on productivity, product quality and it also became a financial burden. The improved tool life has been a revelation; the tools last an eternity and breakages are very rare. This has reduced our tooling costs by at least 30%. Add productivity gains and improved product quality to this equation and I have to confess that ITC tools have performed brilliantly for us,” concludes Smith.
