Our First Project....

has been completed on our new CMS Poseidon 5 axis CNC machining centre.

We finished our training yesterday and couldn't wait to utilise the machine for real!  The machine will place P&M at the forefront of CNC technology within the UK, giving us an unrilvaled position within the composites industry.

We will be releasing a video soon of the installation, which we have documented to demonstrate the sheer size & scale of the new machine! 


It's in and switched on!

Our new CMS Poseidon 5 axis CNC machining centre is in and it's on!

Despite a few 'hairy' moments with the crane, the installation has proceed accordingly to plan and we are looking forward to commencing our training next week. 

Once installation is completed and the machine is fully commissioned, it will allow us to machine parts up to 13mtrs x 5mtrs x 2.5mtrs.

Here's some images of our progress so far:



A trip to Italy.....

So we spent a few days last week in Italy having a look at our new machine - a CMS Poseidon 5 axis machining centre.

Whilst we knew the size of the machine, it is always eye opening to see it in the flesh!  There's still some work to be done, but all being well, it will be dismantled in Italy and onto a truck to start installation with us over the next couple of weeks!

We are very excited to start the installation proper on site and will keep you updated with images.


Work has started

Work has started preparing 11,500sq ft of manufacturing space alongside our existing factory to house our new CNC machine - a CMS Poseidon 5 axis machining centre.

The new machine, which will be commissioned by the end of July, will allow us to machine parts up to 13mtrs x 5mtrs x 2.5mtrs.

The CMS Poseidon will be capable of producing patterns, direct tooling & styling mock ups, scaled or full size, across a variety of industries & markets.

Check out our progress below:




New CNC Machine

Patterns & Moulds are pleased to announce we are expanding our CNC capabilities with the installation of a CMS Poseidon 5 axis machining centre.

The new machine, which will be commissioned by the end of July, will allow us to machine parts up to 13mtrs x 5mtrs x 2.5mtrs.

The machine will be within a new production facility giving a further 11500sq ft of manufacturing space alongside our existing factory units.

The installation of the CMS Poseidon adds to our existing 5 axis machines increasing our capacity for CNC machining within the UK

Our other cnc machining capacity comprising of:

Morbidelli Universal 3615 machine offering 3600 x 1500 3 axis machining & sheet processing

Multiax Type L, 5 axis machine offering 7500 x 3500 x 1600mm capacity

Multiax Type T, 5 axis machine offering 3600 x 2600 x 1200mm capacity.


Contact Gary Lucas, Managing Director, for more information on 01509 881 581



P&M Exhibit at The UK Concrete Show

We are justing putting together the finishing touches to our exhibition stand for the UK Concrete Show, later this week at the NEC - We'll be on Stand E70 ON Thursday 27th & Friday 28th February - come and say Hi if you're passing!

P&M Invest in new CNC to boost capacity

Patterns and Moulds have boosted their capacity with the purchase of an additional CNC machine.

The high speed and very accurate sheet processing CNC router machine has been commissioned complete with additional 10 tool auto tool changer and 8 head drilling attachment, ideal for the production of formers and jigs.


The machine is also suitable for less contoured patterns in MDF and model boards along with plastic sheets.
Commenting on the installation of the new machine, P&M Managing Director Gary Lucas:
'The new machine compliments our existing two 5 axis machines, giving us increased capacity and we will now be able to manage our workload much more efficiently.'


P&M Accepted into the British Precast Concrete Association

Patterns and Moulds are delighted to be announce we have been accepted into the British Precast Concrete Association.

Ahead of exhibiting at the Concrete Show in February, this accreditation allows P&M to link with other associated companies.  We are looking forward to showcasing the exciting projects we have been working on with other members and hope this will be the start of a mutually beneficial relationship.




Staircase at Tate Britain

Patterns and Moulds recently completed the master patterns for the new staircase at the revamped Tate Britain in London.  The spiral staircase beneath the rotunda leads up to the circular balcony of the domed atrium, which has been closed to visitors since the 1920's.

The reopening featured in various press this week, making the front page of The Independent on Tuesday.


Composites Exhibition 2014

Last week we returned to the NEC for the 3rd year to the Composites Exhibition which is now part of he Advanced Engineering Group of Events.

The stand was bigger and better than we'd had previously and we were delighted with the number of visitors to the stand.

We will be following up with all the visitors over the next few weeks and are looking forward to next year already!!

Chester Racecourse - Entrance

The images below show the 'gull wing' style mould we produced for the new entrance at Chester Racecourse.  The mould was cast as 3 separate units, 2 flat and 1 as the central curved 'wing' element.

The 2 flat areas were cast from an existing mould we'd previously manufactured for our client. The curved central park was cast from a bepoke CNC machined mould, made from MDF and refaced in a layer of GRP to give it a seamless & smooth surface.

The units were cast in a product called 'Ductal' which is an incredibly high strength concrete material, that can be cast in very thin sections & able to span large distances unsupported.





Coop's New Headquarters - Manchester

The images below show the timber moulds created for Thorp Precast for the Coop's new headquarters.  We cast 3 concrete tubes called Earth Tubes, that pass ventilation in & out of the building, enhancing the environmental credentials of the building.

The bottom images show the finished construction on site.

Euroresin's Masterclass

We recently hosted 50 delegates at our Site in Leicestershire, for a masterclass hosted by Euroresin's. The day included machine demonstrations, presentations and factory tours.  We felt the day was incredibly successful and it's always great to show off our facilities and allow delegates to see the sheer size of scale of P&M.

We're building a Train!!

Work has started on a full size styling mock up for the new HS1 trains, we are producing all the master tooling on our 5 axis CNC machine align the the GRP cladding panels for the train cab exterior and internal carriage panels - images to follow!

Alder Hey Children's Hospital

We have been working on a project based at Alder Hey Children's Hospital in Liverpool

This is the first of 16 large GRP mould bases that will be used for casting around 1,000 concrete cladding panels for the new Hospital.


Retail Moulding

We recently completed a project for a retail outlet, to provide moulds for their point of sale displays in store.  This is a new sector for us.  The tables were CNC machined, then clad and wrapped.


Merry Christmas from us all!

P&M at the Composites Engineering Show 2012

For the 2nd year running, we exhibited at the Composites Engineering Show at the NEC last week.  Hoping to build on the success of last year, our stand had evolved to give us some height in the hall and we were really looking forward to meeting existing and potential new clients.

Last year, 7,000 visitors arrived over the 2 days, This year 5,000 had arrived by lunchtime on day 1! Day 2 continuted to be incredibly busy and we are incredibly excited about the opportunities that were being presented!  Here's some images of the stand.  The table & stools & display cabinet were all manufactured in house by our team!


Olympic Fever Hits P&M

We are very excited about the Olympics at P&M and so inspired by Team GB who have made a cracking start to the games.  To date we've had success in the pool, on the road, and I don't think anyone could not be impressed by the performance on our men's gymnasts!

We've decided to 'tweak' our logo to show our support for the Olympics & Paralympics - Go Team GB


Sir Bobby Robson

Working on behalf of the Sculptor Tom Maley, Patterns & Moulds recently CNC machined the master patterns for his latest project, a 9’6’’ high statue of Sir Bobby Robson.  The statue has now been completed and unveiled outside Newcastle FC’s ground.

The actual statue is cast in bronze.  Our parts were the actual master pattern that formed the sand mould which the bronze casting was produced in.

Tom Maley is pictured besides the 'legs' of the statue.

Proud to be part of the Olympic Torch Relay

P&M were fortunate enough to be involved in part of the Samsung vehicle leading the Olympic Torch relay throughout the UK.

The Samsung mould was epoxy seamless modelling paste on a polystyrene and timber substructure, approx. 2.5 x 2.5 x 2.5 mtrs with a machined surface area of around 10sq mtrs. In total we made 5 separate moulds for 5 different grp mouldings on the Samsung vehicle from the main wind deflector on the cab roof to the large rear section with the 3 openings within it.

They asked for a cake stand.....

So we gave them one, P&M style!

A local primary school asked P&M to help with their Diamond Jubilee Celebrations by designing & manufacturing a cake stand large enough to hold 400 cupcakes.

Designed on our CAD system, manufactured from MDF, cut on our CNC then painted, the finished result stood over 1.5 metres tall and there was plenty of space for the cakes!


Composites Engineering Show 2011 - A fantastic success

Last week we exhibited at the Composites Engineering Show at the NEC.  We were somewhat nervous about what the show would bring, it's a new arena for us to promote our business and we were hopeful for the returns it would bring.

The show was a fantastic success.  Our stand attracted lots of attention and by the end of the first day we were really pleased with the contacts we had made.  Day Two proved just as busy and the contacts visiting our stand came not only for the P&M M&M's, but also to learn about our capabilities and how we can help within the industry.

The mix of the 4 shows, which also included Aero Engineering and Energy Engineering, brought us into contact with other market places.  

We've booked for next year, but the focus now needs to be on following up those contacts made and building of the success of the exhibition.

Thanks to all the team involved in making the exhibition such a success.

Composites Engineering Show 2011

Just a reminder that Patterns & Moulds will be exhibiting at the Composites Engineering Show at the NEC in November this year.  We are on stand 841.  We are putting together what we hope will be a really impressive stand, truly showing off our capabilities in the composites industry.  We'll keep you posted with developments and hope to see you on the stand at the exhibition.


New Offices

New offices have been completed at our factory, giving us much more space.  We now have 3 additional offices, a reception area and have converted the original offices to a meeting room, with new toilets & kitchen area.  This is allowing our new look to be carried through to the factory, if you're passing, feel free to pop in to see the new layout for yourself!

Posted by G Lucas - Sept 2011


Fully Utilised

Another major Building Schools for the Future project has been completed, Barnsley Holy Trinity School,with the manufacture of 8 large fully GRP lined timber moulds at 8.5 x 4 metres.  Producing the external cladding around this unusually shaped new school.  Each mould took around 3 - 4 weeks to manufacture, we completed the project on time, overall taking 10 weeks and fully utilising the factory.

Posted by G Lucas - Sept 2011


Town Centre Redevelopment

We have recently completed a 12 week project, manufacturing 16 moulds varying from 10m x 4m to 3m x 2m, for the external cladding panels around the outside elevations of the Leeds Trinity Shopping Centre.  Some of the moulds had the slabs of natural stone placed into the moulds prior to casting, other moulds were for high quality finished precast elements.  An interesting scheme with some challenging geometry, which utilised our 3D CAD modelling and CNC machining to ensure accuracy and consistency.

Posted by G Lucas - Sept 2011

Busy Summer

After a bumper start to the year, it looks to continue throughout the summer.  Our CNC machines are running consistently with work for 3 of the main UK based luxury motor boat manufacturers, producing master patterns.

We are soon to complete a major tooling and production GRP panel project with EDM ltd, for a training simulator contract.

We are also researching the production of full Finite Element analysis of our moulds to ensure and prove through 3D design their strength & integrity.

Posted by G Lucas - June 2011


Composites Engineering Show 2011

Patterns & Moulds will be exhibiting at the Composites Engineering Show at the NEC in November this year.  This is the first time we have exhibited at such an event and are keen to build our database of contacts and showcase the work we have produced.  We will let you have more details of the show and how to attend nearer the time.

Posted by G Lucas - June 2011


Gatwick Airport

During late 2010, we manufactured a series of timber and GRP moulds for the production of vertical columns, cross beams, external straight & curved parapet walls for the winding ramps at Gatwick Airport. Our client believes that these are the first 'D' shaped ramps to be totally constructed using precast components.  This proves a very efficient method of construction and provides an innovative looking solution.

Posted by G Lucas - May 2011

P&M Refreshed!

Over the past 12 months Patterns & Moulds have been through a refresh of our brand identity, the culmination of this is our new website.

We recognised that we needed to refresh our corporate image and have included new stationery, case studies, clothing for our staff & external signage.

We are really pleased with the results and hope the new look & feel to the business will allow us continued success in 2011.

Posted by G Lucas - May 2011