Faulkner Moulds is now celebrating its 25th anniversary. Experienced in high quality toolmaking and product and tool design, we are three times winner of the UK ‘Toolmaker of the Year’ award, in 2019, 2018 and 2016, winning it in 2019 for what our customer called, “exceptional customer service” that is “second to none”. We specialise in creating technically complex tooling solutions, designed for manufacture
GTMA Featured Company
Toolmaker of the Year – 2019, 2018 & 2016
Faulkner Moulds has over 35 years’ experience of high quality toolmaking and product and tool design. Awarded ‘Toolmaker of the Year’ at the 2019, 2018 and 2016 Plastics Industry Awards, we won in 2019 for our what our customer called “exceptional customer service” that was “second to none”, when we created a complex twin-shot medical tool, delivered ahead of deadline, that successfully moulded usable products at the first trial (pictured). We specialise in creating technically complex tooling solutions, designed for manufacture.
“I was very impressed with Faulkner Moulds’ thoroughness in terms of technical detail during the design process for our twin shot medical tool – it really stood out. We are very happy with the product from the T1 trial… We had exceptional customer service throughout the whole project, and the support was second to none – we could not ask for more.”
Glen Wells, General Manager at St Davids Assemblies.
Capacity and Technology
Faulkner Moulds invests in the best machinery and equipment to continually improve the service we provide. Technology is used alongside apprentice-trained, superb manual skills, creating excellence in mould toolmaking.
Our state-of-the-art high-speed vertical 5-axis graphite and hard metal machining centre enables automation of electrode manufacturing and die face finish machining, achieving a repeatable accuracy of 2 micron. Our suite of high specification CNC machinery will machine to a maximum of 1000 x 600 x 500.
Faulkner Moulds’ top range Charmilles CNC spark eroder has a manufacturer’s stated accuracy of half a micron, whilst our latest investment in Autumn 2019 is a top of the range Fanuc wire erosion machine (part funded by the European Regional Development Fund, via the University of York), which allows us to create innovative wire eroded toolmaking solutions, on parts up to 1250 x 975 x 500mm and is able to achieve mirror finishes with maximum accuracy.
As an ISO9001:2015 certified company, we carry out rigorous testing and measurement at every stage and our QCT Quantum 4 coordinate measuring machine measures to an accuracy of 3.5+L/250µm, with an axis resolution of 0.5µm.
Consequently, we have now almost eliminated the fitting time needed at the end of each tooling project and have a strong track record of delivering tooling on time, that moulds right first time. In fact, we won ‘Toolmaker of the Year’ in 2018 for our efforts in delivering a suite of four caravan battery-box and awning light tools early.
“Faulkner Moulds are a rare breed in this field. Excellent quality, on time, every time, no exceptions. I have nothing but praise for this professional toolmaker”.
Wayne Boyd, Director, BCA Group.
Experts in Product Design and Development
Faulkner Moulds have helped to develop many products, including patented ideas, award-winners and world firsts, helping these to achieve their maximum potential and sell successfully. We have our own in-house design team for component and tool design, using current SolidWorks and SolidCAM multiple licenses.
We guarantee complete confidentiality for our customers’ inventions and products. Our design and tool making is all carried out in-house, providing an extra level of security that quality is consistent, whilst ideas remain confidential.
Leaders in Design for Manufacture
Our product and tooling designs are created with both aesthetics and successful manufacturing in mind. We ensure every tool we make provides reliable, smooth-running production, giving a long, profitable life for the customer. Our design for the Flood Company’s world-first and award-winning Universal Water and Rodent Non-Return Valve was a finalist for Industrial Product Design of the Year at the 2017 Plastics Industry Awards.
“Faulkner Moulds designed and made the tooling for our product. It is superb, looking and functioning far better than anything else on the market. A great example of British design and engineering”.
Luke Ruddiman, Managing Director, The Flood Company.
We have served clients from a wide range of industries, on a diverse range of projects, including blue chip customers and ‘household names’. Examples include medical, electronics, automotive, consumer, household, packaging and retail products. For more information, including our gallery and customer testimonials, please visit www.faulknermoulds.net/experience, call 01422 371072 or download our brochure here.