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ComplexaHPE gain leading edge with over £2 million investment and Erodex support
Precision injection molding, machining and tooling firm ComplexaHPE are celebrating a record order book thanks to investment of over £2m in new technology in recent years and a focus on developing strong partnerships with key suppliers including Erodex UK. The company, ComplexaHPE, an amalgamation of Glossop based ComplexaTools and High Precision Engineering (HPE) Ltd, counts new contract wins with high end medical companies among a very healthy order book. According to Group Managing Director Paul McHugh, this is a direct result of significant investment in new machinery, the dedication of an expert team and the support of key suppliers in order to ensure the firm is positioned to provide best-in-class levels of accuracy and efficiency. “ComplexaHPE was formed in January 2021 as a result of the amalgamation of High Precision Engineering (HPE) - specialists in lay up tools, press tools, high precision parts as well as special machining - and ComplexaTools, a small tool room in Glossop with an excellent reputation. “Our aim is to offer the full turnkey solution, taking the headaches away from the customer. This means offering more than just a tool or a mold; providing design for manufacture upfront, all the way to sign off, with end of arm tooling and inspection fixtures. Some customers may just want to give us different elements of this, but increasingly due to time pressures we are seeing more of our customers demanding the full package”. This was particularly the case with new business acquired overseas and in Ireland within the high-end medical industry, where premium quality is also a prerequisite. To deliver on this, Paul and his team had to ensure that they maximized cutting accuracies whilst at the same time investing in technology to optimize efficiency, such as robotics and palletisation. McHugh continues: “We have invested £2 million since 2021 in HSM 400 high speed milling machines, numerous 5 axis Hurco milling machines, Agie Charmilles spark erosion and wire erosion machines as well as our second Mazak Millturn. “But having the latest technology is not enough, we focused on utilising it in the best way possible including maximizing EDM performance, which is where the support of our supplier partner Erodex UK was invaluable”. Erodex conducted a full review of what ComplexaHPE were using and recommeded POCO EDM 200 and EDM1, with occasional use of EDM3 and EDMC3. Having a broad range of graphites catering for every specific application of mold making was important, but ensuring precision was paramount from every single grade used. Erodex Area Manager Andrew McFarlane emphasises: “Because ComplexaHPE are lights out machining with robotics, they need to know that the quality of the material will cut consistently. You don’t want to program a suite of electrodes on the weekend and come in on Monday morning to find that half of them are chipped and you need to cut them again - emphasising the importance of the consistency in the POCO material. “Over the course of our relationship, talking to their EDM engineers, they find that it does everything that they need it to do, has better machineability than the previous material in use and they get a better all round EDM performance whether that be from longer electrode life, reduced cycle time or better surface finish. Everything ComplexaHPE require from a graphite, is covered by Erodex” McHugh adds: “What has always been evident is the quality that Erodex are offering across all of the different grades, from EDM 200 right the way through to EDMC3, the copper impregnated graphite. “We have raised the bar with the support of Erodex, because of the definition and crispness that we can get on the detail with the Poco product. This is crucial when targeting high end molds for the medical industry. To increase efficiencies, we’ve also worked on consignments, where we have Erodex products on site and can therefore offer quick turnaround for a customer. We’ve heavily invested in robotics, palletisation and lights out machining and without Erodex supporting us with putting thousands of pounds worth of consignment stock on site, I would not have been able to do that. “I have been in tool making for 29 years and I have never seen the almost 24 months worth of work in the order book that we have now. That is the trust and level of commitment that our customers have in us because of our quality. “The quality that we are able to achieve is testament to the skill and dedication of our people. We have hit an all-time high, which is down to the ongoing efforts and of our highly skilled, motivated team, supported by strong partnerships with key suppliers such as Erodex and their experts such as Andrew. I have developed a great relationship with Andrew over the years and I trust that I or anyone in my team can contact him with a requirement and we don’t have to worry about it. It just gets done, to the usual consistent high standards that Erodex offer”. Senior tool room CNC Miller/ CAM Technician Dave Hill echoes the thoughts of Managing Director Paul: “From a machinability perspective, POCO graphite is totally reliable, and its consistency means I can confidently rely on it when machining the complex and intricate electrodes we require, running lights out 24/7. “From super fine blades to high-definition detail, POCO has never let me down. It is cost efficient too, as cutting tool life is vastly improved and its extremely low wear during the EDM process means fewer electrodes need to be manufactured”. In summing up, Paul concludes “The success of our business is down to the quality of our product, the skill and dedication of our staff and, the support of key suppliers such as Erodex. In a nutshell, we receive expert advice, a consistently high-quality product and service. I would have no hesitation in recommending Erodex and POCO graphite anyone”.
Read Time: 4 minutes
February 19, 2026
Erodex Brass Electrodes Deliver Exceptional Performance for Fast-Hole EDM Applications in US Market
Halesowen, England, Wednesday 22nd October 2025 Erodex continues to set the global industry standard for high-performance brass electrode applications in the aerospace and power generation sectors. Josh Bye - Head of Development for Europe and North America at Erodex – recently explained what sets Erodex tubing apart, “Erodex brass tubes deliver exceptional performance, combining substantial cycle time reductions with superior concentricity and dimensional consistency. These qualities ensure predictable and stable wear rates and cycle times from one cooling hole to the next. This is a critical advantage as our customers move towards an increasingly automated EDM process. Our unique manufacturing capabilities enable our customers to push the boundaries of what’s possible, achieving ever-greater lengths across smaller diameters with precision and reliability.” “The continuously increasing production demands across the aerospace and power generation industries means that speed and reliability in the fast hole EDM process is paramount,” Mr Bye continues. “As the recommended brass tube supplier to many of the leading engine manufactures in Europe and the USA, and with over 50 years of experience in the industry, we have a comprehensive understanding of our customers EDM requirements.” During a recent evaluation with a leading engine OEM, Erodex brass tubes reduced cycle times by over 25%. This outstanding result has since led to Erodex being endorsed as the recommended supplier for other fast-hole drilling facilities within the group. Erodex remains committed to supporting its customers with high-quality brass and copper tubing, engineered for demanding Fast-Hole Drill EDM applications. Their global supply capability – with distribution facilities in North America and the United Kingdom - coupled with deep technical expertise and longstanding OEM partnerships, positions Erodex as a trusted partner for precision tubing solutions.
Read Time: 4 minutes
October 27, 2025
Erodex Goes From Strength to Strength
With another fantastic month of sales, Erodex UK Limited marks a strong continuation of its growth trajectory in 2025. The company, a leading supplier of graphite and EDM consumables, continues to see rising demand across its core markets. Group Operations Director James Kirk commented, “Our continued success in 2025 is testament to the hard work of the whole team at Erodex – whom we’d like to take this opportunity to thank - and the excellence of our products, from design-led graphite and tooling solutions to our comprehensive range of EDM consumables. We are excited by the opportunities being presented to us by our customer base and look forward to a continued upward trajectory over the coming 12 to 18 months.” The record performance reflects Erodex’s focus on innovation, quality, and customer partnerships, positioning the company for sustained growth and new opportunities in both domestic and international markets. Midlands Machining Facility - Erodex (UK) Ltd
Read Time: 4 minutes
October 22, 2025
Erodex announces best ever sales quarter
Recently, Scott Horton - Head of UK Sales at Erodex - caught up with Dave Tudor from Production Engineering Solutions Magazine to discuss how the team have achieved their best ever quarter during times of economic turbulence. Here's an excerpt of what Scott had to say: “It would be true to say that EDM underpins everything we do,” Mr Horton explains, “and our product and service offering is extensive. “For example with wire EDM, we’re the official UK distributor for Bedra wire from Berkenhoff GmbH and we offer consumable sales on machine and wear parts. Then there’s die-sink EDM consumables and products, as well as a range of filters, carbon vanes, flow tested single and multi-channel brass and copper tube (for EDM drill applications), and products for the heat treatment industry and vacuum furnace applications. We’re also the exclusive UK distributor for Poco graphite products." Erodex Graphite “The Darlaston site predominantly serves the aerospace and IGT industries with the machining of graphite electrodes for blade and vane products,” he adds. “While this is mainly for the UK market, we also supply customers in America. In fact, we’ve recently set up a graphite electrode manufacturing facility in the US because it’s such a growing market for us. It’s going extremely well.” For the full article, click here: https://www.pesmedia.com/erodex-announces-best-ever-sales-quarter
Read Time: 4 minutes
June 25, 2025
World Engineering Day
Join us in the collective recognition of our engineers worldwide this March. World Engineering Day was first launched by DiscoverE in 2016, as an opportunity to highlight the achievements of engineers around the world, and improve the public understanding of the importance of engineering and technology. Today, World Engineering Day is a reflection of the profession’s impact on modern life and sustainable development. As market leaders, Erodex takes this opportunity to share the initiative of World Engineering Day and how we can show our gratitude for our team this March. Changing the World for the Better In 2020, the global celebration became a joint venture between The United Nations Educational, Scientific and Cultural Organisation (UNESCO) and The World Federation of Engineering Organisation (WFEO). A time to promote engineering as a career and highlight how the profession can change the world for the better. Engaging with government officials and industry to address the need for engineering capacity and the quality of engineers around the world. In order to develop strategic frameworks and best practices to introduce solutions for sustainable development. How to get Involved At Erodex, we take pride in being the UK’s leading supplier of EDM materials. It is our duty to be aware of our environmental responsibilities and to act accordingly. This March there are a number of ways to get involved, run and supported by the founders of the day. Enabling all businesses, engineers and supporters to celebrate and share their encouragement for the cause. Get Involved World Engineering Day Hackathon Interested in utilising your theoretical knowledge? The World Engineering Day Hackathon, is a fast-paced simulation of a real-world project, perfect for those seeking a challenge. Engineers work collaboratively on a problem of their choosing, providing a set of deliverables within a short timeframe.This year the theme is green, striving for sustainability: Engineering Solutions for a Sustainable world. 24hr Global Stream If you’d prefer to watch the events unfold, The 24hr Global Stream will follow the events of the day, showcasing how engineers celebrate across the globe. This will include high-profile local events, interviews with ambassadors and discussions on key engineering topics. Global Events And if you’re planning to host your own event, register it with WED and make it official! Promote your celebrations and allow people from all over the world to see and take part.
Read Time: 5 minutes
February 20, 2024
Erodex Welcomes Two New Apprentices
In an exciting development, Erodex Group, the United Kingdom's foremost experts in designing and manufacturing graphite electrodes, tooling, and fixtures, has recently onboarded two promising apprentices. These young talents are set to join Erodex's cutting-edge graphite machining facility, based in Wednesbury, West Midlands. Erodex's state-of-the-art machining facility boasts over 35 years of expertise, making it well-equipped to transform various graphite grades into intricate components serving a diverse range of industries. Meet the New Apprentices: Jack Needs is embarking on his apprenticeship journey as a CNC Machinist. Kane Howl has joined the team as an Apprentice Grinder. Both apprentices are committed to a comprehensive learning plan, combining on-the-job training at Erodexs' machining facility with structured off-site learning at Make UK Apprenticeships and Training in Aston, Birmingham. Director James Kirk expressed his pride in providing young, talented individuals with a launching pad for their engineering careers. He emphasised the importance of nurturing the next generation of skilled professionals, especially given the high precision and demanding nature of Erodex's engineering work. Kirk stated, "As with most engineering firms across the country, we see a shortage of skilled, time-served individuals that fit our profile, and we therefore accept that it is our responsibility to develop our own talent. We commit a significant amount of time to training our apprentices on the job and look forward to seeing them progress within the company." He added, "There will be opportunities for these individuals to grow within the business moving forward as we help them to develop the required skills. Everybody at the Erodex Group wishes them the best moving forward, and I am sure that they will all continue to enjoy successful careers with us." January 2023 marked the relaunch of Erodex's Apprenticeship Scheme, with external consultancy support from Next Gen Makers to ensure it remains at the forefront of best practice in the industry. The company is dedicated to providing an exceptional experience for its apprentices and is actively pursuing accreditation for the Make UK Engineering Apprenticeships: Employer Kitemark through Next Gen Makers. This prestigious recognition highlights Erodex as an excellent employer of engineering apprentices in the UK. Erodex is committed to attracting the next generation to its apprenticeship opportunities through innovative methods, including virtual reality outreach sessions for local college students. In the coming years, Erodex will offer apprenticeships starting at level 3 in various disciplines, including Engineering Technicians, across different departments within the business. Erodex's machining facility continues to be a driving force behind the significant growth experienced by the Erodex Group in recent years. The company has invested over £2 million in new machinery as part of its ongoing continuous improvement program. Founded in 1973, the Erodex Group recently celebrated its fifty-year milestone in business. It now employs 90 skilled individuals across two sites in the West Midlands, with its headquarters in Halesowen and a state-of-the-art machining facility in Wednesbury. ENDS.