Article summary: Our BTEC Project Day gave our Mechanical apprentices the opportunity to present their final projects to fellow learners, colleagues and industry partners, demonstrating their technical ability, problem solving skills and the tangible impact of their work in the workplace.
On Friday 20th February, we hosted our latest BTEC Project Day with our Mechanical apprentice cohort, who presented their completed projects to fellow learners, colleagues and employer representatives.
The event gave apprentices a platform to showcase the technical knowledge, practical skills and forward thinking approaches they have developed throughout their programme. Their projects ranged from hands on engineering improvements to smart solutions addressing genuine workplace challenges.
We were delighted to see such commitment and professionalism throughout the day. Many of the projects focused on strengthening safety standards, improving operational efficiency and promoting more sustainable practices, highlighting the meaningful contribution apprentices bring to their organisations.
Take a look below to hear directly from the apprentices about their projects and the impact they aim to create within their workplaces.
Charlie Johnson | DKW Engineering | CMM Automation Project
"My project is the automation of previously manual measurements. It is beneficial to my company because it allows for quicker and more precise measurements to be taken. The project also allows for parts to be fully measured by all members of the company, regardless of skill level."
Joshua Henvest | Dynamic Load Monitoring | Re-design of De-trenching Grapnel
"This project involved redesigning the de‑trenching grapnel to cut 70 mm cable. Achieving the final concept required applying multiple design methods, supported by simulations and calculations to validate its performance. Once completed, the design was submitted to the customer for approval, after which detailed manufacturing drawings were produced to get it made.
This project broadened our standard product range while also resolving a recurring problem in the original design. The improvements not only strengthened our ability to market the product but also improved our reputation and boosted overall customer satisfaction."
Max Gardiner | Cytiva | Multi-round Modernisation Project
"The project is a design‑focused initiative aimed at integrating advanced manufacturing technologies—such as orbital welding and 3D printing—into Cytiva’s product portfolio.
This project strengthens Cytiva’s portfolio by integrating modern manufacturing methods to improve efficiency, enhance product quality, and accelerate innovative design."
James Bath | Whitman Laboratories | Height‑Adjustable Puck Hold‑Down Guide – Line 19
"This project involved the design, manufacture, and installation of a height‑adjustable puck hold‑down guide on Line 19 to resolve ongoing issues with puck misalignment and H100 delta head collisions. I independently completed all stages of the project, from initial assessment and design through to fabrication, installation, and live production testing.
The final solution integrates seamlessly with the existing conveyor system, improves puck stability, and supports smoother, more reliable production flow. Designed and manufactured in‑house for under £400, the project delivered significant cost savings compared with the €10,300 external alternative, while also reducing downtime, manual intervention, and the risk of equipment damage.
Overall, the project provided clear operational and financial benefits to Whitman Laboratories while supporting continuous improvement and strengthening in‑house engineering capability."
Jack Pidgley | Prysmian Cables | Layup Wire Break Detection
"Wire break detection on our layup machine - To detect a wire break as soon as it occurs to reduce scrap and Cost of Poor Quality "
Dominic Embleton | Phoenix Systems UK Ltd | Design and development of an alternative PCB depaneling solution
"A project to investigate the current method of depaneling PCBs and how to improve the process in order to have a faster, more efficient and easier to maintain process through modernising equipment and streamlining production
The project allows for the operation of 3 pieces of equipment to be condensed down to a single machine and then what can be done in house through creating jigs and holders to improve the single piece of equipment used and adapt it to different products and customer requirements."
It was a great way to celebrate the learners as they move into the final stage of their apprenticeship journeys. Well done to everyone who took part!
See below the projects:
