ENSURING YOUR DESIGN IS

VIABLE, VALIDATED & VERIFIED

/ ADVANCED ENGINEERING SERVICE

A FULLY INTEGRATED

DESIGN FOR MANUFACTURE SERVICE

/ ADVANCED ENGINEERING SERVICE

COMPREHENSIVE SERVICE OF 

CONCEPT, DETAILING, VALIDATION & PROTOTYPING

/ ADVANCED ENGINEERING SERVICE

ENGINEERING CHANGE MANAGEMENT

AVOIDING OBSOLESCENCE

/ ADVANCED ENGINEERING SERVICE

MONITORING EACH PROJECT

VIA A SERIES OF KEY MILESTONES

/ ADVANCED ENGINEERING SERVICE

UNPARALLELED EXPERIENCE

FROM AEROSPACE, RAIL, DEFENCE, AUTOMOTIVE

/ ADVANCED ENGINEERING SERVICE

Our 5 step process

Advanced engineering service

01|Concept

Is your concept feasible and viable for development. Our structured approach ensures the development of each concept is validated, timely and cost efficient.

02|Detailing

Precise, meticulous detailing is paramount with a ‘right first time’ methodology for optimal manufacturing and product quality.

03|Validation

Via simulation, we identify the correct materials and how parts will look before the tool is made. In-house engineering reviews follow before a design is agreed for the process of manufacture.

04|Prototyping

Prototyping is crucial to evaluate the development of a product before manufacture, and allows us to explore design alternatives and confirm performance.

05|Re-Validation

Projects often change direction and ‘goalposts’ move. Our engineering change management experience allows for the re-validation of a product.

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Review

An initial overview of the brief, deciding upon the required project team. A first sight feasibility review, where the viability of a given schedule is discussed with the customer. A detailed proposal of cost then follows.

Analyse

Simulation identifies the correct materials and how parts will look before the tool is made. Following a customer review and further in-house engineering reviews a design is agreed for the process of manufacture.

Launch

The appropriate level of detail is decided upon, including timescales, tools to manufacture, required outcomes & resources, recommended methods. A further project overview and review is carried to 'clarify and confirm'.

Change management

Projects often change direction, briefs revised, ‘goalposts’ move. We manage & action these modifications to ensure a project stays on track. To avoid obsolescence we fast track engineering changes where appropriate.

Explore our other divisions

Manufacturing Sheet Metal Niche Vehicle Production

/Premier Projects

#01 / Exhaust Nacelles - A Prototype Aircraft

We were commissioned by a leading aircraft manufacturer to reduce manufacturing times and costs in the manufacture of skin panels for exhaust nacelles of a prototype aircraft. Historically hand formed and trimmed by sheet metal workers, panels were labour intensive and consequently expensive.

Following analysis we used a press process for the forming of the skin panels. Using Autoform press simulation we were able to present Catia designed press tools detailing the parts required being formed in the press. Employing this press simulation, average time per part was reduced from 24 hours to minutes. All the panels became a welded assembly and were hand trimmed using masks and hand shears, with 3D laser cutting.

We are currently working on reducing the part count per assembly, which will reduce weld requirements and manufacturing costs.

 

/Premier Projects

#02 / Manufactured Rail Rolling Stock

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.

Commissioned to manufacture large formed under-body skins and structural supports in heavy gauge formed steel sections, our aim was to reduce lead time, utilising a ‘rapid react’ system, ensuring rail stock is back in service as soon as possible.

Many disciplines are employed 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.

Train carriage downtimes have been reduced considerable.

/Premier Projects

#03 / The Manufacturing of the Olympic Torch

We were tested to the full following our appointment as the official manufacturer of the London 2012 Olympic and Paralympic torch.

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

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.

 

 

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FAQS

How does Premier Group ensure that your concept is feasible?

Using state of the art predictive tools such as Autoform for sheet metal press feasibility we can redesign or advise any component geometry changes required to ensure the part is feasible.

We can evaluate multiple parts in an assembly to ensure that the assy as designed is feasible, and appropriate processes are available to produce the assy delivering the quality / tolerancing required.

What are the cost implications?

Advanced engineering feasibility is mainly cost avoidance and saves you money in the long run.

The cost of using technology is much lower than the cost of moving into the manufacturing phase without any assurance that the design is feasible.

How do Premier Group validate the concept prior to development?

In any design and manufacturing process, there are tolerances, the key to achieving a successful outcome is validating the design principles applied to the component are achievable. All too often designs and budgets do not align with the required engineering released. We ensure the design and processes are aligned with the budget!

We use a digital mock up and 3D visualisation to review the designs as though they are physical objects allowing engineers to see the products designed in a magnified virtual world allowing detailed review exposing potential areas of concern.

What industry sectors do Premier Group specialise in?

Premier specialise in the field of forming and joining metal and mixed material assemblies.

Joining technology. TIG, MIG, Gas, spot and laser welding, Self-piercing rivets, and adhesive applications (hot and cold) and in-press nutting.

We specialise in Automotive, Niche vehicle, Rail, Aerospace, Off Road, Agricultural, industrial and architectural sectors.

Where will the prototype and production take place?

The production will take place in our bespoke facilities that have been designed to meet all the needs of the markets we serve.

What quality controls do Premier Group have in place?

ISO14001, ISO9001, TS16949, Member of The Guild of Craftsmen.

What support will Premier Group offer throughout the process?

We will dedicate a project team with the profile that’s supports your needs and deliver the controls and reporting structure to ensure the project is delivered and any issues that arise are managed and resolved in a timely manner.