Case Studies

/ The 2012 Olympic Torch
12,100 Aluminium Alloy Torches
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Manufacturing of the Olympic Torch

The Challenge
Our advanced engineering and manufacturing skills were tested to the full following our appointment as the official manufacturer of the London 2012 Olympic and Paralympic torch.

The Process
The complex design presented numerous technical challenges, all of which were overcome by our unique blend of innovation and experience. A world-class skill set and technological capabilities allowed us to develop a process to manufacture the unique design of the Olympic Torch to the exacting standards required, and all within a challenging time frame. 

The Technology
We invested in an innovative five-axis laser cutting machine to create the double skinned aluminium alloy triangular torches, as well as laser butt welding along the entire length of the torch. We were one of the first companies to use this technology in production.

The five-axis laser, a state-of-the-art 2D Prima Syncrono is the worlds fastest 2D laser, with off-line programming and nesting.

The Outcome
12,100 torches were cut and produced in just 6 months, requiring 100 million holes in total! The apparently seamless torches were finished in a glistening gold colour, with a burner enclosed and fuelled by a gas canister.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ MORGAN 3 WHEELER
Re-engineering Of The Car Bodyshell
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Morgan 3 Wheeler

The Challenge
Producing the bodyshell for the Morgan Motor Car Company’s legendary Morgan 3 Wheeler requires precision and vision! The iconic design of the Morgan 3 Wheeler has been updated with 21st Century technology, and we have been instrumental assisting the re-engineering and design of the car bodyshell, and the subsequent niche vehicle production processes.

The Process
Taking inspiration from the original car but with modern technological influences, the initial plan was to build 400 Morgan 3 Wheelers, but due to its incredible global success, we have now produced over 1,000. This particular contract has seen PGM work with Morgan throughout the initial design stage of the 3 Wheeler to ensure all body panels could be manufactured to the highest standards expected by Morgan’s loyal customer-base.

 The Technology
The latest cutting-edge computer-aided technology has been paramount to the 3 Wheeler project. The firm’s automotive prototype production is underpinned using the very latest CAD design, CAE virtual development, and CAM manufacturing techniques, generating significantly reduced lead-times when it comes to end-production.

All Morgan cars are coach built. One of the brands strongest selling points is the care taken in the manufacture of each car; leading design capability, an extensive array of luxurious materials and the latest drive-train technologies combine to create an unparalleled driving experience.

The Outcome
The relationship not only continues with Morgan but has flourished. We now also manufacture the bespoke coach built bonnets and boots for Morgans other iconic production vehicles.

Graham Chapman, Technical Director at Morgan, said, ‘One of our key suppliers in the development of the Morgan 3 Wheeler has been PGM. We’re delighted with the strategic counsel, design and manufacturing expertise they provide. They’re a substantial Midlands sheet-metal manufacturing operator and a significant link in our supply chain.’

Call us on +44 (0)2476 362886 if you have a project in mind.

 

/ Jaguar Land Rover
A special relationship with JLR
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Jaguar Land Rover

An Established Partnership
It has been a privilege to work with Jaguar Land Rover (JLR) for more than half our company life! We have an established partnership with JLR for prototyping and fast response problem resolution. More recently, the relationship has evolved to add strength and depth to the partnership through:

  • Low volume production proven in automotive and aerospace
  • Enhanced facilities and streamlined systems
  • Relocation and strategic development

The new XJ is a recent testament to the strength of our ‘special’ relationship with JLR. Manufacturing every single panel, including the closures, closure assemblies, superstructure and underbody, it demonstrates our expertise in aluminium and validates our low volume production capabilities.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ The Bentley Arnage
Fully Stretched and Ready to Paint
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The Challenge
PGM is proud of its long-standing relationship with Bentley, commissioned for many years to supply them with Body in White vehicles – fully stretched and ready for paint.

The Process
It was recognised from the beginning of the programme that our full vehicle bespoke service would need to cater for many variances during the manufacturing lifetime of the Arnage. All tooling was manufactured on-site in steel or cast iron. Variant vehicle lengths required all doors to be remanufactured, stretching both the front and rear doors enabling a style line between them that could encompass all lengths. Where possible, all manufactured parts were to be shared across the variance of vehicles to keep tooling costs to a minimum.

The Technology
All tools were designed and manufactured using Autoform simulation, ensuring the feasibility of all new part and tool designs. The build fixture was designed and manufactured to be flexible. This gave the option to set differing vehicle build lengths throughout the programme utilising one main build station.

The Outcome
PGM has currently supplied over 700 bespoke Arnage BIWs straight into the paint at Bentley. The variance completed was 240mm, 450mm and 728mm stretched vehicles. We also completed high roof variances, deep D Posts, opera light windows, sunroofs and on the 728mm central infill panels between the doors. Major parts were tooled and manufactured, including doors, roofs, floors and internal structural panels and assemblies.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ JCB Mesh Grilles
A One Piece Unique Grill
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JCB Compact Tractors

The Challenge
The Advanced Engineering division of PGM has designed, engineered and developed a one-piece mesh grill for JCB Compact Tractors, with the objective of reducing production costs, improving its strength and improving the cosmetic design.

The Process
With our fully integrated ‘design for manufacture’ service, JCB received a comprehensive package of Detailing, Validation (via simulation), Part Feasibility and Prototype Testing.

The Technology
Prototype Hand worked parts were developed together with soft tooling to ensure a cosmetically approved quality standard was achieved, considering the formability constraints of the material used “perforated mesh.” Part of the scope of work was to develop prototype tooling and a manufacturing process that replicated ‘production intent’ parts to facilitate durability testing.

The Outcome
The efficient and structured approach of our Advanced Engineering division, incorporating comprehensive project management, played a vital role in the success of this project for JCB. The result was not only an improved one-piece design with new styling features adding strength and stability but a reduced unit cost and a reduction in unit weight.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ Stretched Range Rover
Custom Vehicle Bespoke Stretch
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Range Rover Vogue

The Challenge
Commissioned by one of London’s most prestigious vehicle suppliers, PGM was commissioned to design, and manufacture of a fully bespoke 300mm stretched Range Rover Vogue.

The Process
To adhere to the vehicle’s ergonomics and style, the stretch was engineered into the rear quarters of the vehicle from the rear doors back. This reduced body changes and maintained body dynamic performance. As a ‘one off,’ all Body in White Parts were to be hand manufactured. The modified vehicle was scanned, and all modifications were digitised. The design of parts and tooling were CATIA-based.

The Technology
The BIW parts were manufactured by hand, utilising, in some cases, rubber-pressed tooling and parts. Working from one of our dedicated build studios, the project team stretched, fully assembled and trimmed the Vogue, covering all aspects of the manufacture, including glazing, electronics, mechanical, paint and trim. Static and portable measuring systems were utilised to ensure product integrity.

The Outcome
Premier delivered a fully packaged, ‘turnkey’ stretched Range Rover to the customer.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ London Underground
Improving the Efficiency of Ventilation
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London Underground

The Challenge
London Underground receive numerous complaints about the lack of ventilation within London’s tube system. Hot, stuffy days on the London underground are unpleasant at best, and when the ventilation system is not performing then it compounds the unpleasant experience!

Our challenge was to improve the efficiency of the installed ventilation system by re-engineering and replacing the current steel air exit vent structure, with a lightweight aluminum system that whilst reducing the overall weight, dramatically increased the air circulation inside the passenger carriage.

The Process
There were two elements to our recommended solution. Initially, we reviewed, analysed and re-engineered a new aluminium extruded fin. Secondly, we utilised aluminium lasered vent assemblies to replace the steel welded structures, which were heavier, susceptible to clogging and subsequently far less efficient.

The Technology
Utilising extruded product and a combination of lasered tight tolerance parts we engineered a product that allowed airflow in much greater volumes. Our state-of-the-art fin design also eliminated clogging and reduced the need for regular removal and servicing, and Train service down time.

The Outcome
The increased circulation gave a ventilation improvement of 90% and resulted in a huge increase in passenger comfort. The system is fully installed on the first underground line, and it has been met with overwhelmingly positive feedback from regular travellers. The system has also been rolled out to cover further lines with potential for a network-wide implementation

Call us on +44 (0)2476 362886 if you have a project in mind.

/ Rail Rolling Stock
Manufactured Rail Rolling Stock
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Manufactured Rail Rolling Stock

The Challenge
Corrosion impact and fatigue on the rail rolling stock of national train operators remains an important topic and the subsequent reinvestment in operating rolling stock. 8mm thick under-body skins are now replaced at 3 to 4mm in many cases, as opposed to 2mm in years gone by. The consequence of this is a shortening of the operating life of a carriage.

The Manufacturing Division of PGM has been commissioned to manufacture large formed under-body skins and structural supports in heavy gauge formed steel sections.

The key challenge is to reduce lead time, utilising a ‘rapid react’ system to ensure rail stock is back in service as soon as possible.

The Technology
Many disciplines are employed by the Sheet Metal Division during the manufacture of the under-body skins, including our state-of-the-art quality and inspection equipment to analyse and review the state of the corrosion, and our flexible hydraulic and mechanical press shops – all supported by project management expertise.

The Outcome
Operating a bespoke inventory system, the national rail service centres can now ‘call off’ dedicated stock as and when required. Premier can supply parts to service site from stock, with 24hours…

Train carriage downtimes have been reduced considerable.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ Polestar P14
Build Management
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Polestar P14 Build Management

The Challenge
To manage the interface of the Build Programme and to manage the Engineering Changes identified within the  build with all associated parties

The Process
Strong Project Management Control and daily review meetings identifying build issues/corrective actions on the “Build Issue Log”

The Outcome
Successful completion of the build of 7 Prototype Vehicles over a 6 month period

Call us on +44 (0)2476 362886 if you have a project in mind.

/ SVO Project 8 Show Car
SVO Project 8 Show Car
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Jaguar XE Show Car

The Challenge
To modify 3 off standard Jaguar XE vehicles into Project 8 show cars for the Goodwood Festival of Speed and Pebble Beach.

The Process
Part Feasibility, Formability and Manufacturing Feasibility studies.

The Technology
Manufacture of New Rear Doors & Rear Quarters and fitment to BIW, using traditional sheet metal craftsmanship.

The Outcome
High Quality Product supplied on Time and to specification.

Call us on +44 (0)2476 362886 if you have a project in mind.

/ Samsung
Battery Tray Assembly
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Samsung SDI Battery Tray Assembly

The Challenge
Support product development, offer feasible design solutions, manufacture press tooling & produce parts, and assemble with the first off tool parts available in 14 weeks

The Process
To work from Concept CAD data, undertake part feasibility/formability analysis to identify design changes to give full stamping feasibility and tolerance confirmation

The Technology
Intensive use of Forming Simulation to develop the product and tool design. Fast track methods developed during the tool and fixture design stages to reduce timing

The Outcome
PGM delivered the first unit to plan, 14 weeks from receipt of PO. Battery Tray Assembly fitted to vehicle without out any issues and a further 6 prototypes where built for development and crash testing

Call us on +44 (0)2476 362886 if you have a project in mind.

/ SVO F-Type SVR (X152)
Front Fender
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SVO F-Type SVR (X152) Front Fender

The Challenge
To design and manufacture Production Tooling and develop a process to support total life time volume of 3500 units

The Process
Part Feasibility, Formability and Manufacturing Feasibility studies

The Technology
Manufacture of cast iron draw tools, supported by 5 Axis Laser Trimming

The Outcome
Quality standards achieved using manufacturing techniques and tooling, to achieve low to medium volume cost and lead time targets

Call us on +44 (0)2476 362886 if you have a project in mind.

/ Airbus A400M
Upper & Lower Engine Intake Ducts
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Airbus-A400M

Airbus A400M Upper & Lower Engine Intake Ducts

PGM Manufacturing were commissioned to review the manufacture of the engine intake ducting to reduce production time and costs through the application of automotive manufacture processes.

To provide a high-quality manufacture process, PGM Manufacturing undertook a formability analysis on the existing engine induction ducting.

An automotive process including laser trimming was developed for the manufacture of the assemblies, although the customer had a strict ‘no laser’ policy for the manufacture of their parts.

PGM Manufacturing demonstrated how automotive processes and technology could be developed and was approved by the aerospace industry after detailed analysis.

Sheet metal pressing and laser trimming was developed by PGM Manufacturing to manufacture these parts, reducing weld assembly time and lead to considerable cost savings for the customer.

PGM Manufacturing became the first supplier to be authorised for laser trimming of Aerospace parts.

/ Siemens Mobility Ltd
South West Rail Upgrade
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Siemens Mobility Ltd

Siemens Mobility Ltd – South West Rail Upgrade

PGM Manufacturing were commissioned to provide aluminium single and double 3-pin socket box housings to replace the existing composite units for the SW Rail upgrade contract.

PGM Manufacturing designed and manufactured 25,000 assorted Socket Boxes for the project from lluminium Al 5754 sheet material being 2D Laser cut and pierced, folded and TIG welded to completion with the addition of internal Earth Stud and threaded inserts. The finished assemblies were powder coated to the customer’s RAL standards and supplied with felt mounting Gaskets to the customer’s fire standards.

/ McLAREN AUTOMOTIVE LTD
Rear Lower Panel Manufacture
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McLaren-Automotive

McLaren Automotive Ltd – Rear Lower Panel Manufacture

PGM Manufacturing were commissioned to provide low volume production of aluminium pressed and Laser trimmed & pierced Rear Panels for their vehicle manufacture programme. The finished parts were e-coated to the customer’s standards and CMM dimensionally inspected to achieve the required quality standards of manufacture.

In addition to the successful manufacture and supply of the rear lower panel, PGM Manufacturing were engaged to supply various other pressed mesh panels and parts for McLaren Automotive Ltd extending over several models.