Haas investment supports Blacksand Bronze manufacturing growth
For more than 25 years, Blacksand Bronze has continued to evolve the way it makes things, with Haas CNC machining becoming an important part of the Waiheke Island company’s move towards greater in-house manufacturing capability.
But the manufacturing story began well before CNC machining became part of the workshop.
Blacksand Bronze founder and designer Matthew von Sturmer trained as a jewellery maker and explored multimedia, while his wife Carmen worked in interior design. Over time, the objects they produced grew in scale from jewellery into lighting, furniture, sculpture and homewares.
“In the 1990s architects and designers were hungry for locally made objects with character, particularly in an enduring material like bronze. They started asking us to make ‘jewellery for the home’. This began our move into hardware without either of us coming from a traditional hardware or engineering background,” says von Sturmer.
Working as both designers and makers exposed the couple to the processes and alloys involved in popular finishes requiring electroplating and fine polishing. It also prompted them to reconsider the materials and processes they wanted to work with.
“We also saw that many simply didn’t endure. This led to a self-audit guided by three questions: What is good for us to make? What is good for our customers to use? What is good for the environment?”
The answer was silicon bronze.
There is no secondary plating or coating, with the finish being the material itself, naturally ageing and developing a patina through touch, use and environment. Using a single alloy also supports a closed-loop process, with bronze swarf and offcuts collected and remelted rather than becoming waste.
Over the years, Blacksand Bronze developed its understanding of the technical requirements and explored different pathways including subcontracting, tooling for drop forging, polishing and electroplating. Eventually, the business made the decision to move towards an in-house manufacturing model and direct-to-market approach.
Investment in digital design and the growing ability to control more of its processes in-house meant the business could operate from almost anywhere, with Blacksand Bronze making the move to Waiheke Island.
“A move to Waiheke Island made no sense to anyone but ourselves. Our investment in digital design and growing ability to control more of our process in-house meant we could move almost anywhere. Waiheke was far away, yet so close.”
The couple’s youngest daughter, Trelise, later joined the business, bringing her background in brand, marketing and business development and helping grow Blacksand Bronze into international projects.
Von Sturmer says the New Zealand industry is often divided between small artisan workshops and large manufacturers, while Blacksand Bronze has looked to combine elements of both.
“We believe there is a third path, combining artisan skill and handcraft with digital tools, systemised workflows and modern manufacturing technology.”
The move towards CNC machining initially began with a desktop Roland MDX-540. Blacksand Bronze was soon cutting metal, but with a maximum depth of cut of less than 0.5mm, the limitations of the machine soon became clear.
The business turned to Haas as it looked to increase its machining capability.
“Our local Haas team assisted with advice on how we purchased our first machine and what our growth might look like in the future. Our TM-2P has now been a reliable workhorse for over 10 years and, having grown organically, we have recently installed our second Haas, a VF-4SS.”
Von Sturmer says the introduction of Haas CNC machining was pivotal to bringing together the different elements of the company’s manufacturing approach.
“The decision to include Haas CNC machining was a pivotal step in making this path possible. Working within the constraints of technical function and repeat manufacturing creates a unique poetry of compromise between digital design, computer-aided manufacturing, sand-casting and hand finishing. When a piece ‘works’, these constraints disappear, allowing a balance between form and function.”
Alongside the installation of the VF-4SS, Blacksand Bronze undertook a ‘CNC health check’ with Bruce Burns from OneWorks. The process identified opportunities to further optimise production, with the business implementing recommendations around integrated CAD/CAM using Fusion 360, workholding and cross-compatibility between the VF-4SS and TM-2P.
The VF-4SS is now central to the next phase of the company’s growth, with faster rapids and tool changes and 30-tool capacity. It is being partnered with a new vise pallet system and fourth-axis rotary.
“Our next phase of growth will be fuelled by the advanced features of the VF-4SS, including faster rapids and tool changes and 30-tool capacity. Partnered with our new vise pallet system and fourth-axis rotary, and supported by a team of expert collaborators, our small production team is looking forward to doubling our output with half the effort.
“‘Doubling and halving’ is our current workshop motto. Doubling our machining capacity while looking for ways to halve setup time, handling and unnecessary processes.”
For von Sturmer, the way Blacksand Bronze makes things continues to evolve, but the attraction remains much the same.
“Real material, with inherent strength, durability and natural beauty, made into objects designed to be used and to endure.”
Sponsored content: For more information phone 0800 422 769, email sales@haascnc.co.nz or visit www.haascnc.co.nz.