Project Overview
CERN, the European Organisation for Nuclear Research, designed a 10-metre twin-aperture prototype magnet to develop and refine techniques for the future construction of full-scale twin-aperture dipole magnets. H V Wooding Ltd was entrusted with the manufacture of 380 twin-aperture dipole magnet laminations, a project demanding exceptional precision and engineering innovation.
Challenge
The project required 380 lamination components to be produced within tight lead times, while achieving tolerances as fine as 4–8 microns. A fully wire-eroded solution would have been prohibitively expensive, so a more efficient and cost-effective manufacturing approach was essential. The components also needed to meet CERN’s strict dimensional accuracy and surface finish standards to ensure optimal magnetic performance.
Solution
Working closely with CERN physicists, H V Wooding identified the most critical features of the design and developed a bespoke manufacturing route using multiple complementary processes. Precision laser cutting was used for profiling, followed by full deburring, wire erosion for critical features, and final CNC machining for ultimate dimensional accuracy. Dedicated wire-erosion fixtures were designed and manufactured in-house to hold the pre-lasered parts securely and ensure repeatable precision throughout production.
Results
The project was completed on time and within budget, delivering a high-quality, fully conforming product that exceeded CERN’s expectations. The combination of laser, wire erosion, and CNC processes is now regarded as a state-of-the-art manufacturing route for dipole magnet laminations. The accuracy of H V Wooding’s components contributed directly to exceptional magnet performance and test results.
Added Value
This innovative approach established a standard manufacturing procedure for evaluating future dipole magnet designs. It allows CERN to assess new lamination configurations and performance criteria before committing to major tooling investments, significantly reducing both development time and cost. The successful collaboration demonstrated H V Wooding’s capability to deliver world-class precision engineering for advanced research applications.
Trusted by Leading Brands
H V Wooding works with pioneering organisations across science, research, and energy sectors, including CERN, Rolls-Royce, Honeywell, Schneider Electric, and GE Renewables. Our expertise in precision manufacturing, multi-process engineering, and material traceability makes us a trusted partner for projects where absolute accuracy is essential.
Commitment to Quality
Accredited to ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018, H V Wooding maintains rigorous quality control at every stage of manufacture. Our in-house Buffer Management System, advanced metrology capabilities, and commitment to LEAN and FMEA practices ensure repeatable precision, reliability, and continuous improvement across all high-tolerance engineering projects.
