DN Solutions measures up at Aberlink

UK metrology equipment manufacturing specialist Aberlink has strengthened its in-house machining capabilities with the installation of two new DN Solutions machine tools supplied by Mills CNC. The investment – the first time Aberlink has purchased DN Solutions machines in its 33-year history – marks a significant step forward for the Gloucestershire-based manufacturer, improving efficiency, productivity and overall manufacturing flexibility within its recently revamped machine shop.

Mills CNC supplied Aberlink with a large-capacity DNM 6700XL three-axis vertical machining centre and a compact Lynx 2100LSYB multi-tasking lathe. Both machines were installed simultaneously at Aberlink’s Stroud facility in March 2025. Since commissioning, the machines have been machining a wide range of high-precision components used across Aberlink’s comprehensive portfolio of manual and CNC-controlled coordinate measuring machines (CMMs).

Precision components, tighter control

Components produced on the new machines include CMM bridge beams and rails of varying lengths and widths, air bearings, racks, plates, pinions and housings. These parts are manufactured in relatively small batches. All are machined to tight tolerances and high surface finish requirements, reflecting the demanding performance standards expected of Aberlink’s measurement systems.

Aberlink’s CMM range spans compact shop-floor models such as Fulcrum and Extol, designed for installation directly alongside machine tools, through to larger bridge-type systems including Axiom, Halo, Horizon and Azimuth, typically housed in dedicated temperature-controlled inspection environments.

Regardless of configuration – manual or CNC-controlled, shop floor or bridge-type – Aberlink says its CMMs are globally recognised for their rigidity, positional accuracy, repeatability, speed, reliability and ease of use. In 2024, the company received a King’s Award for Enterprise in recognition of the design innovation and error-mapping capabilities of its Extol CNC CMM.

Affordability is another defining characteristic. Combined with build quality and Aberlink’s proprietary 3D measurement software, competitive pricing has helped the company grow sales and market share in the UK and overseas. The policy of providing free software upgrades and no annual maintenance fees further reinforces this value-driven approach.

Manufacturing at the core

Aberlink designs and builds CMMs at its Eastcombe manufacturing facility. The majority of components are produced in house, with granite bases and tables, servomotors and selected probing systems sourced from specialist third-party suppliers.

Alongside an expanded assembly area, visitor showroom and dedicated software development and customer support departments, the site houses a well-equipped machine shop split into milling and turning areas. This includes a mix of CNC and manual machine tools, some dating back to the late 1990s.

Since being incorporated in 1993, Aberlink has always maintained in-house machining capability, a strategy that continues to underpin its growth.

“In the early days, when we were developing our first CMM, Aberlink actually started life as a precision subcontract machining specialist,” explains owner and Director Marcus Eales. “As demand for our own products increased, the machine shop grew in parallel. It remains a vital cog in the company’s success.”

With demand rising in both domestic and export markets, Aberlink undertook a detailed audit of its machine shop in 2024 as part of a wider continuous improvement programme.

“Our machine shop produces a high volume of precision components,” says Marcus. “For example, our best-selling Axiom CMM contains up to 150 different parts. To meet tight delivery schedules, the efficiency of our machining processes is critical.”

The audit identified two key issues. First, an ageing large-capacity Cincinnati FTV-640 machining centre, while still accurate, was limiting throughput when machining long aluminium extrusions due to relatively slow processing speeds. Secondly, turning operations were creating a bottleneck. Existing two-axis, single-spindle lathes required multiple set-ups and significant manual intervention to produce complex, high-precision parts, especially where milled features were required.

“Single-spindle lathes are inherently limited,” explains Aberlink Director Ian Rhodes. “Without a sub-spindle, Y-axis or driven tooling, parts often had to be transferred to milling machines, putting additional pressure on that resource.”

The solution was clear: invest in a new high-performance vertical machining centre and introduce a modern multi-tasking lathe.

Partnering with Mills CNC

After researching several machine tool suppliers, Aberlink shortlisted Mills CNC, despite having no previous purchasing history with the company.

“Mills CNC has a strong reputation, including among our own customers,” says Managing Director Rachel Cook. “DN Solutions machines are known for cutting performance, long-term precision and reliability, and Mills’ aftersales support is widely regarded as one of the best in the industry.”

Following discussions with Mills’ technical and sales teams, Aberlink specified a DNM 6700XL machining centre and a Lynx 2100LSYB multi-tasking lathe.

The DNM 6700XL offers generous travels of 2,100 mm (X), 670 mm (Y) and 625 mm (Z), with a 2,200 mm x 670 mm table, 30 m/min rapid traverse rates and an 18.5 kW, 15,000 rpm spindle. A 40-tool automatic toolchanger supports flexible, high-mix production.

Supplied with a FANUC 0i-M control and Renishaw OMP60 and OTS probing systems, the machine has proven ideally suited to Aberlink’s aluminium beam machining requirements.

“Although similar in size to the machine it replaced, the DNM 6700XL is faster, more powerful and far more productive,” says Ian. “It handles heavy roughing of extrusions with ease and gives us much better overall throughput.”

The Lynx 2100LSYB is an 8-inch chuck, 65 mm bar-capacity multi-tasking lathe featuring a sub spindle, Y axis, driven tooling and a 12/24-station turret. With a 6,000 rpm main spindle and driven tools running at up to 6,000 rpm, the machine enables full part completion in a single set up.

Aberlink’s machine was supplied with a FANUC 0i-T control, quick-change collet chucks and a Hydrafeed Multifeed 65 short magazine bar loader.

“Multi-tasking allows us to machine complex, high-precision components in one hit,” says Marcus. “Adding the bar loader means we can now run unattended, boosting productivity while improving consistency and quality.”

A commitment to continuous improvement

Aberlink CMMs are sophisticated measurement systems that demand attention to detail at every stage of production. The investment in advanced DN Solutions machine tools reinforces the company’s commitment to quality, efficiency and long-term competitiveness.

“We’re delighted with both machines,” concludes Rachel. “Mills CNC were proactive, easy to work with and managed the installation process exceptionally well. Downtime was minimal, and the support we received was first class.”