Manufacturing Solutions

Flecknoe provides integrated technologies to improve your manufacturing process.


Flecknoe manufactures and distributes a large range of machinery and tools for all aspects of Thermoforming, Plastic Fabrication, Composite Fabrication, Pattern Making, and Nested Base Manufacturing. We also support other manufacturing processes using our technologies. All of our products complement each other in their ability to improve the performance of your manufacturing.


Flecknoe, with technology partner Monark USA, is the first high-end manufacturer of cut-sheet thermoforming equipment, virtually 100% produced in Australia using agile, innovative Australian design concepts.

Flecknoe thermoformers:

Flecknoe's vast experience in the Australian Thermoforming Industry and Monark's diversified experience in the US ensures state-of-the-art technology for Australian and Asian industries.

Flecknoe can design and manufacture thermoforming processes and equipment with capacity for basic to advanced forming techniques. Flecknoe can advise you on:

From a simple Single Station Drape Former to High Speed Twin Sheet Six Station Rotary Thermoformers, incorporating PLC Control with HMI Interface, and the accuracy of full infrared sensing.

The quality design and construction of the equipment means:


Flecknoe offers the best and most cost-effective option to buying used, unwarranted machinery or rebuilding out-dated machinery. Flecknoe can design and manufacture vacuum forming equipment with capacity for basic to advanced forming techniques.

Examples of vacuum formed products:

Example machine used for making concrete paving moulds.

Used for forming the rear of buses and motor-homes.

Laboratory machine for experimental purposes.

The Most Important Point of Vacuum Forming

Heating the sheet is one of the most important points of vacuum forming. Together with the Raytek scanner and the Flecknoe heater zoning system you can get proper heating every time over the entire sheet. All machines are fitted with single point non-contact infrared sensors that are used to read sheet temperatures during the heating cycle and also during the cooling cycle on the mould for part consistency every time.

Clamp Frames

Flecknoe machines are fitted with either aluminium extruded clamp frames or the heavy duty pin bar design. Aluminium extrusion clamp frames are the standard on all of our small to medium machines ensuring lighter, easy to handle equipment. Pin bar clamp frames are used on larger or more specialized machines. The pin bar design has two major advantages:

 Flecknoe are specialists in the design, manufacture and retro-fitting of aluminium extrusion and pin bar pneumatically operated clamp frames.


Vacuum Formers for Schools

As a senior member of the Society of Plastics Engineers, Philip Kitney recognizes the need to promote the knowledge and education of plastics and polymers worldwide.

Flecknoe has two machines ideally designed for the education sector:


With its ease of operation and simple setup, the HS430 is an entry level machine ideal for high schools for all of those industrial design projects.

SDF 860

The SDF 860 machine is fully PLC controlled with all of the Flecknoe controls included, making it the choice of colleges with a need for an industrial style machine for their more demanding education program.

CNC Routers

Thermwood CNC routers are in action all across Australia and New Zealand with more and more being used in all industries from cabinet making to thermoforming to boat building.

Flecknoe has over 10 years experience in supplying and installing Thermwood 3 and 5 Axis CNC Routers throughout Australasia including New Zealand, Singapore, China, and Australia. Flecknoe has factory-trained specialists available to support any installation in any market.

Thermwood manufactures three-axis, four-axis, and five-axis CNC routers. They built the first CNC router in the world, and since then have spent millions of dollars developing the latest CNC router technology. Thermwood offers over thirty features and capabilities not available from anyone else. The Thermwood five axis CNC offers full five-axis simultaneous motion, five-axis tool length compensation, constant tip speed, and built-in CAD path generating capability.

Thermwood offers complete systems for every aspect of woodworking from nested based manufacturing of cabinets, closets, and other products made from sheet stock to a wide variety of architectural millwork applications, store fixtures and furniture. Thermwood’s unique approach results in systems that are highly productive, extremely easy to use, yet are among the lowest cost.

Thermwood machines use engineered structures designed using the most advanced CAD/CAM and structural analysis. All weldments are fully stress relieved and the final machine is laser calibrated to assure accuracy, including three-dimensional volumetric compensation, a feature not available from other systems in this market.

Five axis CNC Routers have become the accepted method of trimming three dimensional plastic parts. CNC Routers increase productivity, reduce cost and improve quality. The only draw back has been that a decent machine has been expensive... until now!

Thermwood specializes in three-axis and five-axis CNC routers. They built the first CNC router in the world and have since spent millions of dollars developing the latest CNC router technology. Thermwood offers over thirty features and capabilities not available from anyone else. The five axis offers full five-axis simultaneous motion, five-axis tool length compensation, constant tip speed and built-in CAD path generating capability.

Thermwood offers two basic types of five-axis CNC routers. The moving table  fixed gantry machines Models 67and 90 or the fixed table table moving gantry machine Model 70.

Programs developed offline with a CAD/CAM system are only as good as the ability of the router to execute them. The Model 67 is laser calibrated to assure the highest level of position accuracy. Laser alignment and calibration is generally reserved for multimillion dollar aerospace machines.

Router Bits

Flecknoe knows that the quality of the cutter is the single most important factor in reliably trimming and machining plastic products.

Fecknoe is an Australasian distrubutor of Onsrud router bits supplying more than 1,000 line items to ensure that you have the best cutter solution available for your routing applications. 



Onsrud manufactured the first router bit in 1920. Onsrud specializes in tooling for CNC routers for the world's most demanding industrial users. The tools cut aluminum, composites, honeycomb, plastics, as well as natural and man-made wood materials.

Tight tolerances, high production, and long life are the features of Onsrud bits. Onsrud recently introduced three new exciting cutting tools designed to tackle even the toughest composite milling/routing applications.

These tools are designed to dramatically improve the machining of carbon graphite and aramid fibre materials. They use a solid-carbide burr with a unique finishing edge designed to equal the cutting performance of a burr tool, but with a much better edge finish.

The geometry of these tools increases the amount of effective cutting flutes, resulting in superior performance over a standard burr. Special clean-out flutes aid in the dissipation of chips, and a chisel design cutting edge extends tool life and productivity. The line includes the Carbon Graphite and Fiber Metal Router with modified geometry to cleanly cut aramid materials and fiberglass.

CAD CAM Software

 Flecknoe is a distributor, service and training agent for KeyCreator, NCG CAM, and CIMCO Integration software. Flecknoe has 15 years experience with Computer Aided Design and Manufacturing.



Key Creator


KeyCreator is award-winning CAD/CAM software that takes a real geometry approach to 3D modelling. The product earns equal praise for its ability to quickly create design concepts from scratch, make changes to any model in any format, extract and modify geometry in real-time on imported CAD models.

Easy to use and fast results are the backbone of this powerhouse package.




NCG many innovative features including automatic 3D roughing. This is suitable for all types of forms, creating an optimised and smooth cutter motion for HSM machining, while helping to extend tool life, minimising wear on the machine tool and producing parts with excellent surface finish.

Easy to learn and use – learning curve of just 1 day.



CIMCO Edit is the editor-of-choice for professional CNC programmers who demand a full-featured and reliable cost-effective professional editing and communication tool.

Best of all it is completely configurable and easily adapted to any existing CNC program editing environment.

CIMCO Edit includes graphical simulation of 3/4/5-axis milling and 2-axis turning programs, including solid visualisation (milling only) with tool holder and rapid collision check.



Flecknoe Pty Ltd is a member of the Australian Manufacturing Technology Institute (AMTIL).

Flecknoe director, Philip Kitney, has been a senior member of the Society of Plastic Engineers (SPE) since 1994, and regularly attends the Thermoforming Conference in the USA.

Philip Kitney - Director


Phone +61 8 9354 9393
Fax +61 8 9354 5643
Mobile 0419 928 469

22 Kembla Way Willeton
Western Australia 6155