Sheffield Forgemasters Reaches Key Milestone with First Bespoke Vertical Turning Lathe

Sheffield Forgemasters has successfully passed a significant milestone in the development of its new state-of-the-art machining facility, with the completion of Factory Acceptance Testing (FAT) for the first of 11 large, bespoke Vertical Turning Lathes (VTLs). Built by German machine specialist WaldrichSiegen, the ProfiTurn 6500/120Y VTL will be shipped to the UK as part of the company’s recapitalisation programme.

The first machine, a full five-axis system with a 5m faceplate and a maximum turning height of 4.7m, is designed to handle workpieces up to 120 tonnes. It features five new interchangeable machining heads, offering significant advancements in efficiency and machining precision.

John Cocker, Sheffield Forgemasters’ Recapitalisation Machine Tool Lead, commented: “The completion of FAT for our first new VTL is a critical milestone for Sheffield Forgemasters and solidifies our confidence in WaldrichSiegen to deliver the remaining machines for our programme. Despite the size of these machines, they offer precision at the finest tolerances, improving machining and inspection accuracy for large forgings and castings, particularly for the defence sector.”

The VTL incorporates advanced probing technology, ensuring high operational accuracy before shipment. Fully configured for Industry 4.0, it provides digital connectivity, automation, and real-time analytics, enabling seamless integration into the company’s network. This will allow Sheffield Forgemasters to optimise machine capacity, speed, and status, enhancing operational efficiency across its new facility.

Set to be the most advanced of its kind in Europe, the new Sheffield Forgemasters machine shop will occupy 35,000m² in the Meadowhall district of Sheffield. The facility will house 21 heavy-duty machine tools from WaldrichSiegen and 9 large cranes to support the UK’s defence programme, including components for the SSN-AUKUS submarine programme.

In addition, the company is installing a 13,000-tonne forging press and other equipment for civil nuclear and defence nuclear contracts. This ambitious expansion will create highly skilled jobs for the future and strengthen Sheffield Forgemasters’ position as a leader in UK manufacturing.

Sheffield Forgemasters is also proud of its award-winning apprenticeship scheme, which comprises 10% of its workforce, with an impressive 81% apprentice retention rate, significantly above the industry average of 65%.