The TPR interviewed Des Thorpe, Company Director at Hanson Thorpe Precision Toolmakers Ltd. in Middleton, Manchester, U.K.  Hanson Thorpe are Precision Toolmakers specializing in the manufacture of Technical Plastic Injection Moulds, (including twin-shot) and precision medical devices and instruments.  Thorpe is co-founder of the company with Stuart Hanson whose title is also Company Director. 

What is your company niche, and what does your company do that is notable, unique or different?

Hanson Thorpe specialises in complex tooling, working closely with the customer from design stage onwards. The more intricate the component the more likely it’s going to stay in the UK and the better chance we have of securing the work.  Because of tight lead times and our ability to be flexible and react we can, and often do, commence tool manufacture whilst design is still being finalized.  This is something that you would not get from overseas suppliers.  We specialize in the manufacture of twin shot, multi cavity and insert moulds and also the manufacture of high value medical components.  We run a lean company, have a very loyal and hard working workforce and are always honest with the customer.  Delivery on time – short delivery – is a key factor, along with high quality work.

Micro machining of small insert molded dies is something that we have developed in the last year, working to 5 micron tolerances with cutters down to 0.30 mm diameter.

When and how did you get into the industry, what attracted you to it?

Both Stuart and myself served traditional engineering apprenticeships with local toolmaking companies.  We found ourselves working together a couple of times and, recognizing each other’s skills and ambitions, decided to ‘have a go on our own’, setting up Hanson Thorpe in 1991. Our aim was to provide quality tooling on time, utilising the latest technology available through investment in the shop floor.  This is something that we think many of our previous employers had failed to grasp.  The level of our investment in machinery and technology has continued and is now in excess of £1m.  Between us we have over 50 years of experience.

Relate a notable "best time" for your company. 

There have been one or two best times over the years, including our very first anniversary, our tenth anniversary, returning a profit year on year and hitting the £1m turnover mark.  But if we had to pick one then it would probably be winning the Toolmaker of the Year 2006 award at the Plastics Industry Awards in London this month.  We are justifiably proud of this achievement which we feel reflects the endeavour, investment and hard work of everyone involved in the company.  I have spoken to a few customers since and they are equally proud to have an award-winning supplier of tooling that they are working with.

Similarly, relate notable challenges that your company has overcome.

As I have previously mentioned, we work very closely with the customer at the design stage.  One of our key customers was supplying a component which involved assembling two parts of different materials.  He was worried about losing the work abroad as his assembly costs were no longer competitive but he was also under tight budget controls and couldn’t afford the full level of investment for the necessary larger twin shot moulding facility.  With our input on design we were able to supply a custom built twin shot tool which fitted his existing presses and successfully produced the finished product without the need for assembly and kept him the business.  Since then we have produced several tools with similar functions for the same company.

When you are working on projects with your customers, what aspects would you like them to better recognize?

When working on new projects it would definitely help if the component design had been thoroughly investigated and we had been involved at an earlier stage.  I know that this isn’t always possible as more often than not the order is only placed on the same day that the customer wants the design to commence and the delivery clock is ticking.  Most of the problems encountered are at the design and not the manufacturing stage but we would be willing to get involved sooner and let the customer have the benefit of our knowledge.  In the last couple of years we have been doing a lot of prototype tooling before production tooling; pre-production tooling is becoming more and more popular than SLA tooling as well because you come across all the errors at an early stage and get them all out.  We often make a two-impression tool for medical industry products in a pre-production mold that will eventually become a 48-impression mold once all the errors are worked out.

List newly acquired technology, machinery or key personnel (in last year).

Our latest investment has been to add a second Charmilles 350 EDM machine to our spark erosion section.  We have also put in another Coordinate Measurement Machine (CMM), which has 3D facilities and is linked to the recognition of electrodes. On the machining side we have also invested in new, high speed tooling incorporating heat shrink tool holding.  We’re cutting with cutters down to .3 or .4 mm, so we need precise, true cutting capabilities and the heat shrink tool holding helps us with that.  Editor’s note: Hanson Thorpe just placed an order for what is the first HSM 300 Graphite Master' milling machine (a £120,000 machine) purchased in the U.K.

Has your company recently expanded?  Plans to expand or form partnerships/alliances?

We moved into our present 11,500 sq ft factory in April 2003.  This was our third move since the company started and gave us double the space from our previous site.  The move also enabled us to increase our staff from 19 to 23.  We have worked with another tooling company and are open to future alliances, depending on the situation.

Are you involved in any industry organizations or educational programs related to the trade?

We are members of the GTMA (Gauge and Toolmakers Association) and also the local Engineering Centre who train and supply prospective apprentices.  We have what we call an improver (can also be called an apprentice) and we’re currently interviewing another apprentice.

What do you think about changes occurring in the industry due to globalization?  How has it affected the way you do business? 

Globalisation has meant that everyone has to look closely at how we do things, both from a speed of delivery aspect as well as the cost side.  The days of full order books covering 20 weeks are long gone and will never return.  You have to be able to react and be able to offer the ‘value added’ concept to your customer.  Times are hard but through our level of investments and quality of staff we are still here and intend to be around a while longer yet! 

What will the industry look like in 3 to 5 years? 

We believe it’s inevitable that more toolmaking and moulding companies will disappear from the UK.  The industry will be leaner and meaner but the ones who keep investing like we are will have the best chance of survival. 

Additional background information: 

Number of years in business:  Hanson Thorpe was established in 1991. 

Current number of employees:  24   

Current square footage (each location):  11,000 square feet 

Additional locations:  None at this time. 

Website:  www.hansonthorpe.co.uk  

Types of tools built and/or run:  Injection mould tooling, including twin shot, multi cavity and insert moulds 

Industries served:  Medical, automotive and electronic  

Contact Information: 

Hanson Thorpe Precision Toolmakers Ltd.

Joshua Lane

Middleton, Manchester UK

M24 2AZ

Tel: 0161 655 3355

Fax: 0161 655 3322