With 35 years’ experience of plastic injection mould toolmaking and product and tool design for manufacture, Faulkner Moulds combines state-of-the-art technology with superb manual skills. We specialise in bespoke, complex tooling solutions
GTMA Featured Company
Toolmaker of the Year – 2018 & 2016
Faulkner Moulds has 35 years’ experience of high quality toolmaking and product design. Awarded ‘Toolmaker of the Year’ in 2016 and 2018, customer comments about our work have included, “Genius” and “Exemplary”. We specialise in creating technically complex tooling solutions, designed for manufacture.
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. 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.
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 SolidWorks and SolidCAM 2018.
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.
“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
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 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
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 automotive, electrical, consumer, household, packaging, retail and medical products. For more information, including case studies, our gallery and customer testimonials, please visit http://www.faulknermoulds.net/experience, call 01422 371072 or download our brochure here.