Broadwater Mouldings Ltd

Quality Assurance and Certifications

Throughout our organisation we are committed to Quality Assurance, we are fully compliant with ISO 9000: 2008.

About Broadwater

Broadwater Mouldings Ltd, was established in 1973 and is a subsidiary of the Betts Group of companies which employs a total of 136 people.

We operate from a recently completed, purpose built manufacturing facility with works extending to 6, 500m² (70, 000ft²) on a site of 17, 500m² (4. 3ac) near Beccles in Suffolk. The size of the workforce may vary slightly, depending on workload, but at present 82 people are employed.

Defining Our Capabilities

We are an experienced and highly skilled team, offering engineering solutions in the manufacture and supply of Glass Reinforced Plastic (GRP) mouldings and assemblies. Broadwater Mouldings has a diverse and considerable experience accumulated over more than 35 years, providing a service spanning many industries worldwide.

We employ a number of moulding techniques including: Hand Layup, Spray Layup, LPPM (Low Pressure Press Moulding), RTM (Resin Transfer Moulding), RTML (Resin Transfer Moulding-Light) and Vacuum Assisted Resin Infusion. By offering such a wide range of moulding techniques, we are able to provide the most appropriate solution, at a competitive price, in volumes ranging from one to several thousand per year.
Moulding Processes

The four main moulding processes are similar in that they all produce a composite moulding incorporating a resin matrix and glass fibres. Our most commonly used resin type is Polyester, and it may be modified in its liquid state to give various specific properties, such as reduced shrinkage or flame retardancy. Phenolic or epoxy resins may also be used to achieve specific properties, such as low smoke emission or high strength composites.

During the moulding process, the resin is converted from a liquid into a solid polymer, encapsulating the glass fibres to form a composite structure. Most mouldings produced have a polyester gel coat surface, which may be high gloss, mat, or sand-able for paint preparation. Depending on geometry, gel coats can be textured to enhance the aesthetics of the moulding. Post moulding operations would include, trimming, drilling, assembly, and in some cases painting. Trimming and drilling may be either manual or robotic.

Assembly

Many of our customers are now looking for complete finished assemblies, which are in a condition ready to fit on line, or on site. Broadwater is able to supply such "black box" assemblies, and has created the appropriate environment for carrying out this type of work. The complexity of supplied assemblies may range from trimmed, finished mouldings with a few bonded location brackets, to ones with calibrated lasers, electronic components, wiring harnesses, and sealing systems.

Robotic Machining

Where accuracy and consistency are priorities, robotic trimming offers the best economic solution. Broadwater employs two multi-station robotic trimming centres providing repeatable accuracy, and high throughput.

Project Engineering /Management

Producing complete assemblies inevitably means that procuring components and sub assemblies becomes part of our remit. In some cases this may simply mean sourcing and fitting customer specified "off the shelf" components. In other cases, it may require managing the development of components, including sourcing and purchasing of tooling and equipment. This is accepted as an essential part of the service we provide.

Design

During the design and development phase of a project, our engineering staff will endeavour to guide and advise customers. We aim to arrive at a solution which will satisfy the technical and cosmetic requirements, as well as offering the best value for money.

Whilst a face to face meeting, or a design review would be the preferred option, timescales and location may dictate that other methods are employed. By using CAD and CAD reading software, many iterations of a design may be evaluated, modified and then re-evaluated in a very short space of time. Thus enabling simultaneous engineering, so that components, tools, and assembly fixtures can all be designed and manufactured at the same time, reducing the time to manufacture, and of course, to market.

Broadwater has recognised the importance of operating a CAD system compatible with that used by it's customers. To this end, Broadwater have invested in two PTC (Parametric Technology Corporation) Pro /Engineer Wildfire seats. We believe that design and development does not finish when production begins. We have a strong focus on continuous improvement, and believe Value Engineering is a key tool which will help us to stay competitive in the future, along with our customers.