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PES Performance are looking to the future as they further strengthen their engineering design team.

The appointment of Dean Gardner as Principal Engineer highlights the rapid development of the Advanced Manufacturing Park (AMP) based engineering solutions company in the past two years and its increasing involvement in larger engineering design projects.

Dean joins PES from his previous role as Engineering Manager at Atkins Energy where he looked after the fifty strong engineering team for the Nuclear Design function that designed mechanical handling equipment for various civil and defence nuclear programmes.

Dean’s career includes designing state of the art fly-by-wire controls systems for clients such as BAE Systems, NASA, Bombardier and Lockheed Martin, and supplying design services into clients including, Rolls-Rolls Tidal Generation (now GE Renewables) and GE Oil & Gas.

On his appointment Dean comments;

“What attracted me to PES was the enthusiasm of Mike and Dan for the success of their business. They never say no to any challenge, large or small.  They offer a level of one-to-one personal service with their clients that is difficult to achieve in larger organisations, due to the complexity at the interface between them. Ultimately having a small experienced team provides total flexibility to adapt to any client and their industry needs and so offer effective turnkey solutions.

“The variety of projects that PES have undertaken is extremely impressive and for an engineer this provides a broad diet of work and the opportunity to experience all aspects of the product life cycle.  Not only do you have the responsibility for delivering the work, you also get to do it!”

Dan Fleetcroft, Engineering Design Director at PES welcomes Dean to the team, saying;

“We have very specific requirements, as an engineering solutions business, operating in multiple environments, and it is difficult to find design engineers who have gained a broad level of experience before specialising.

“It has taken us over 12 months to find the perfect individual to join the team, and in Dean we feel we now have that person. In addition to his engineering design skills, Dean has the experience we increasingly need in terms of delivering larger, complex projects.

“Now we have the senior team in place we are better positioned to mentor, train, coach and develop the growing team. Dean brings new skills to the team and his experience operating in the nuclear design environment and managing projects in excess of £75m positions the PES brand for the future.

“As well as working with clients to explore concepts and develop appropriate solutions, Dean also has the experience to drive these large projects through the supply chain to ensure that they are commissioned and operational within required timescales.”

Performance Engineered Solutions (PES) Ltd is a high performance engineering solutions business, with a multi-disciplinary team of design and performance engineers. Its pedigree is born out of Formula One and the team delivers high quality and technologically advanced engineering design solutions to clients within aerospace, automotive, medical technology and energy generation amongst many other sectors.

The companies’ 3D Scanning team utilises CT scanning & 3D optical scanning system to deliver a number of specialised services for clients, including reverse engineering, quality inspection, design optimisation and planned preventative maintenance.

Engineering design business Performance Engineered Solutions (PES) Ltd has expanded its presence at the Advanced Manufacturing Park (AMP), following increased demand for its 3D scanning, quality inspection and reverse engineering services.

The PES Performance team have been involved in a number of projects over recent months, ranging from scanning a vintage aircraft and reverse engineering historic wood panelling from Winston Churchill’s room, to developing a new automotive product and using scanning to quality inspect components for the water and energy industries. The projects have taken them throughout the UK, to Europe and more recently to the US.

This increase in business has prompted a move into a larger unit within the AMP Technology Centre. The new separate office and scanning centre facilities, enables client’s products to be more easily scanned. Direct access to the workshop allows vehicles, aerospace components and large industrial parts to be accommodated without difficulty.

As Mike Maddock, managing director at PES Performance comments;
“Over the last 12 months, after we made an investment of £120k in a scanning and photogrammetry system, demand from clients for these services has increased significantly. We wanted to improve our facilities so that clients can choose whether to use our bureau scanning service here at the AMP or for our scanning team to visit their facilities.

“Our clients utilise 3D scanning in a variety of ways; some for reverse engineering and design optimisation; whilst others use scanning to undertake quality assurance and inspection processes, identifying potential manufacturing defects in components and in reviewing critical tooling, jigs and fixtures.

“Our clients are continually looking to drive efficiencies in manufacturing to deliver repeatable quality and control. Once they understand how the technology can be used as a key tool in their business and see the cost benefits of our inspection and reporting support, on individual or multiple parts, our services have been in great demand.”

Regarding the companies’ expansion at the AMP, Mike adds; “Initially it took some time to find the perfect facility for our requirements, but we have been determined to remain at the AMP. It is the ideal location for a high performance business like ours, working in an innovative and collaborative environment and we have many clients and partners located on the AMP.

“We are also able to access a wide range of the technical and support services we require on the Park and in the surrounding Rotherham / Sheffield area. We envisage further expansion of the business in the next twelve months, and having just appointed a key senior design engineer and we will be actively looking for the right people with the unique skills required to join our team.”

Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.
Runflat CBR, aims for success in global tyre market
Increased client demand prompts company expansion at the AMP
PES engineers help create custom Maserati for ‘Best of Italy’ event

Our 3D scanning team has helped produce a custom Maserati for Jodie Kidd’s participation in a celebration of Italian brands, food and wine.

The inaugural ‘Best of Italy’ Festival this will take place between September 16-18 in Castell’Arquato, Italy. Over 150+ Supercars and Motorbikes, as well as 500 top cyclists will take part in this celebration of all things Italian.

As part of this the event organisers commissioned GT Forte Ltd to produce an exclusive one-off custom Maserati, based on the 2001 Maserati 320S concept car, to be driven at the event by supermodel Jodie Kidd.

The base car used was a Maserati 4200 Spyder, redesigned to replicate the original ‘barchetta’ style of the 320S, with a small windscreen in front of the driver, a visible roll-over bar with aerodynamic fairing in the rear, and a closed passenger side without a seat.

Our PES Scanning team were asked by GT Forte to undertake a detailed 3D scan of the upper surfaces of the base car’s bodywork. This provided the necessary data which was used by the car’s project team to make the new modified body parts as accurately as possible, to ensure a perfect fit.

Mike, head of the scanning team commented; “This was a really interesting project and we were happy to support GT Forte in completing it. The car looked very good on its unveiling at Brooklands Museum recently, and we look forward to seeing it back in its Italian homeland this September.”

Find out more about the project here.

Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.
Runflat CBR, aims for success in global tyre market
Increased client demand prompts company expansion at the AMP
Using 3D scanning to help replace damaged wooden paneling in the Churchill Room, Hertfordshire
3D Scanning helps replace damaged panels in the Churchill Room
Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.

Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.

PES Performance engineers have helped Richard Lust and the Runflat CBR team to develop an insert that can be fitted into an ordinary wheel, and which maintains good drivability – the ability to steer, accelerate and brake efficiently – even if all four tyres suffer a blowout.

Beginning from a clean sheet, we worked with Richard to create an end-user ‘wishlist’, which incorporated more than 30 design and engineering challenges including to:

◊ Deliver world-beating performance for runflat tyre technology
◊ Deliver distance and speed performance well in excess of those currently available
◊ Develop an effective and lightweight anti-friction concept for longer runflat distances
◊ Incorporate a new ‘cantilever’ construction concept for lighter weight without compromising performance
◊ Develop the ability to absorb or deflect ballistic attack
◊ Ensure fitting can be carried out in less than 15 minutes
◊ Create a design concept to suit different wheel sizes so reducing manufacturing lead time
◊ Create a flexible product range so variations can be economically produced to fulfil special requirements of end-users.

Runflat CBR outgrew their original base in the AMP Technology Centre and have now taken a larger unit on the Advanced Manufacturing Park (AMP), ahead of the planned mass-manufacture of their products from the end of the year.

Richard, an engineer with nearly 30 years’ experience designing ‘runflats’, said: “We have now patented our revolutionary technology and are looking forward to sharing it with users across the globe from our new facility.”

See article in the Sheffield Star here.

See the Runflat video below;

The PES Performance Team, are delighted to hear that Yorkshire Man of Steel project has been awarded initial support from the Heritage Lottery Fund (HLF).

PES Performance have been involved in the project for the past four years, and we were immediately enthused by the Man of Steel concept from the first time we met Steve Mehdi & Jane in 2012.

We’re proud to be based at the heart of the Sheffield City Region, with the region’s heritage and reputation in the coal, steel and advanced engineering industries, and this is one of the key reasons why we decided to locate our business at the Advanced Manufacturing Park.

We therefore feel that it is entirely fitting that the Man of Steel celebrates the importance of the Yorkshire steel and coal industries, the lives of the men and women who worked in them and ensures that the next generations understand their local and Yorkshire heritage.

But it is not all about the past. The project also will showcase the best of the region’s current and future manufacturing technology, and as a high performance engineering design company this is what we are all about. It may appear to be a simple challenge; however the construction of the iconic Yorkshire Man of Steel will require the design engineering, manufacturing and construction expertise of the regional businesses, the ‘Team of Steel’ to deliver this unique and challenging project.

Not only will the Man of Steel put the region and Yorkshire firmly on the ‘international stage’ it will also profile regional expertise around the globe through this amazing and innovative sculpture. We are certainly very excited and our design team cannot wait to start the engineering design on the external structure of the Man of Steel.

We have been fully supportive of Steve as he pushed hard to offset the inevitable critics, who only saw the sculpture and not what it truly represents as an icon of the people, community and Yorkshire. Nothing could have cemented this more than the development and creation of the Heart of Steel; the first sculpture of which now sits proudly outside Rotherham’s Minster.

The Heart has already raised over £100,000 with thousands being given to the British Heart Foundation as part of the support for Rotherham as a ‘Heart Town’. All of the money being donated by the people, who in return will get their names placed on the second heart that will be placed inside the Man of Steel. Donations have not only come from Yorkshire but from around the world, showing the global reach of the project and pride of the region.

We have used our expertise in 3D scanning and engineering design to help bring the Man of Steel to life. The scanning has allowed the accurate reproduction of Steve’s 300mm high bronze maquette, and which has been scaled up to create the famous model now seen by thousands of people around the region. Eventually the scan data will help us to create the final 30m high piece.

It is important that the entire project will be designed and fabricated locally, harnessing a range of specialist skills and materials and showcasing the region’s renowned reputation for excellence.

Following the generous Heritage Lottery Fund donation, we look forward to working with Steve, Jane & the other companies in the ‘Team of Steel’ to bring the project to reality over the coming months; helping create a new Yorkshire Icon which will both celebrate the past and present, encourage people to visit and also help boost the region’s future economy.

Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.
Runflat CBR, aims for success in global tyre market
Increased client demand prompts company expansion at the AMP
PES engineers help create custom Maserati for ‘Best of Italy’ event
Using 3D scanning to help replace damaged wooden paneling in the Churchill Room, Hertfordshire
Using 3D scanning to help replace damaged wooden paneling in the Churchill Room, Hertfordshire

We were asked to help undertake the replacement of damaged wooden panelling in the Churchill Room, Hoddesdon, Hertfordshire


PES Scanning were asked by our Wood Routing partner, GCNC Ltd to support them in a project to help restore wooden paneling in the Churchill Room, at a former Conservative Club building in Hoddesdon, Hertsfordshire. The Club was housed in a Grade II-listed, 17th century house named “Stanboroughs” where it is believed Winston Churchill began his political career.

The Restoration Challenge

The upstairs of the building contains a number of special historical features, including a wooden staircase and the wood panelled room. The room itself was wooden clad on all the walls, excluding the ceiling, with simple, but ornate, carved features on the panels. The wood also ‘framed’ the large sash windows and traditional bay window, plus there was a large ornate fire place that required careful restoration and reassembly.

The developers worked with the local Heritage Trust office, to ensure the accurate restoration of the buildings listed features, and during the initial review of the building it was found that a number of the wooden panels needed to be replaced or repaired, ensuring any restored panels were an exact replication of the originals.

The first challenge was to accurately reproduce the wooden carved features, from the panels selected for scanning. The original panels were carved and our team wanted to ensure that the replacement panels would capture the original texture and individuality when reverse engineered.

Once the different panels were selected the PES scanning team captured the data by using a combination ofPhotogrammetry (and 3D Optical Blue light Scanning, using our GOM scanning system with a 300mm volume lenses to capture the original data to a high level of detail and resolutions.

The scanning data output is in the form of a polygon mesh (link to polygon mesh info). The mesh is imported into our CAD system so the data can be output into .stl file format which is compatible with GCNC Ltd’s CNC machine software ( Note there are a range of file formats we can deliver). The data was transferred to GCNC for manufacture.

Manufacturing the new pieces

Manufacturing in wood is a specialist process and we have always partnered with GCNC Ltd in all of our restoration projects that either require a manufactured solution in wood, stone or many other materials.

We provided .stl formatted data to GCNC which was used to programme their CNC system, enabling the manufacture of the panels. The process includes setting up the CNC programme to create the best cutting paths and tooling to ensure that the detail from the 3D scan data (.stl file) was best utilised.

Once the panels were completed GCNC marked out the panels to ensure this valuable ‘jigsaw’ went together perfectly when back in the room. The panels were reattached in the Churchill Room and now await redecoration.

Our client, Runflat CBR, aims to revolutionise runflat tyre technology and is expanding as they prepare for growth.
Runflat CBR, aims for success in global tyre market
Increased client demand prompts company expansion at the AMP
PES engineers help create custom Maserati for ‘Best of Italy’ event