Our multi-axis mill-turn machines combine milling and turning operations in a single setup, allowing us to machine complex components more efficiently while maintaining exceptional accuracy.
Our capability includes:
- 3 × 5-axis mill-turn centres
- Milling capacity up to 3000 mm × 1250 mm
- Turning capacity up to Ø1600 mm
- Simultaneous multi-axis machining for complex geometries
These machines enable the production of intricate mould tooling, large-format components and multi-feature parts while reducing handling, setup time and potential sources of error.
We also operate:
- 1 × 5-axis turning centre with robotic loading
- Capacity up to Ø300 mm
This automated cell is ideally suited to medium- and high-volume production, delivering consistent quality, reduced cycle times, and improved manufacturing efficiency through unmanned operation.
Our CNC milling department is equipped with ten machining centres from leading manufacturers including OKK and Mazak. These machines support the manufacture of mould tools, large plates, fixtures, assemblies and complex precision-engineered components for demanding industrial applications.
Key capabilities include:
- 10 × CNC milling centres
- Maximum machining envelope of 3000 mm × 1250 mm
- Large-format machining up to 2500 mm × 1500 mm
- 3-axis and multi-axis machining capability
Our turning department provides the flexibility to machine everything from precision mould inserts and O-ring tooling to large structural and industrial components.
Our equipment includes:
- 10 × CNC lathe centres
- Machines from Mori Seiki, Mazak, Hardinge, Akebono and Puma
- Turning capacity up to Ø1600 mm
- Capability for sub-2 mm internal diameters
Some features can’t be produced using conventional machining methods. Our EDM (electrical discharge machining) capability allows us to create highly accurate cavities, sharp internal corners, and intricate geometries. These processes are particularly valuable in mould tool manufacture, where precision cavity detail and complex internal features are critical to tool performance.
Our EDM equipment includes:
- Sodick EDM Spark Erosion – 850 mm × 520 mm
- Mitsubishi EDM Wire Erosion – 700 mm × 500 mm
Grinding plays a vital role in achieving the extremely tight tolerances, flatness and surface finishes demanded by modern tooling and precision engineering. It ensures accurate split lines, mating faces and sealing surfaces across mould tools and engineered assemblies for precise fits and controlled tolerances.
Our surface grinding equipment includes:
- 3 × surface grinders
- Two large Okamoto machines with capacities up to 2000 mm × 1000 mm
- Jones & Shipman grinder for smaller precision work
Our cylindrical grinding equipment includes:
- 5 × universal grinders
- Capacity up to Ø300 mm
While advanced CNC technology forms the backbone of our manufacturing capability, the skill of experienced toolmakers remains central to producing high-quality tooling. We carefully assemble complex mould tools and engineered systems, before adjusting and testing them to ensure correct shut-offs, alignment and operational performance before delivery.
Our toolroom includes:
- Manual lathes
- Manual milling machines
- Cylindrical grinders
- Dedicated fitting and assembly benches
Quality and repeatability depend on accurate measurement. Our metrology and inspection department verifies every stage of manufacture to ensure that your components meet specification before they reach you. This allows us to maintain tight dimensional control and provide confidence in the quality of every component we manufacture.
Our inspection equipment includes:
- 3 × Mitutoyo CMM inspection centres
- Precision gauges and micrometers
- Shadowgraph inspection systems
- Cold-moulding verification techniques
We offer in-house laser engraving for component identification, branding and pattern marking. This provides a durable and accurate method of marking components without compromising dimensional accuracy.
Capabilities include:
- Engraving area up to 150 mm × 150 mm
- Part identification marking
- Tooling and component traceability
- Precision pattern engraving
Every successful manufacturing project begins with accurate design and efficient programming. Our in-house CAD/CAM team provides complete support from concept through to production, using the latest systems to allow seamless integration between design, programming and manufacture. As well as ensuring accuracy, repeatability and manufacturability from the outset, this approach also helps to reduce lead times throughout the production process.
Our software platforms include:
- Autodesk PowerMill
- Autodesk PowerShape
- Autodesk Inventor (4 workstations)
- Autodesk AutoCAD (4 workstations)
- ECS Concerto (4 workstations)
- AlphaCAM for shop-floor programming
Technology alone doesn’t create exceptional tooling. It’s the combination of advanced equipment and experienced people that sets Burnsall Engineering apart.
Our team consists of highly skilled, time-served engineers with an average tenure of over 20 years. Their expertise spans mould tool manufacture, precision machining, assembly and problem-solving across a wide range of industries and applications.
Alongside our experienced workforce, we remain committed to developing the next generation of engineers by investing in apprentices from the local area. By combining decades of practical knowledge with emerging talent, we ensure that the skills, craftsmanship and engineering standards that Burnsall is known for continue well into the future.
Why choose Burnsall?
- 70 years of toolmaking experience
- Fully insured and BS EN ISO 9001 accredited
- In-house team of expert designers and engineers
- State-of-the art modelling and programming applications
- Established relationships with approved contractors
- High quality and competitive lead times
- Awarded the only preferred supply status to a facility in Europe by DuPont Performance Elastomers
