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Volume XXVIII | Oct. 2026 www.etmm-online.com
TRADE FAIR
Fakuma Preview Friedrichshafen becomes the meeting place of the plastics industry
COVER STORY
Miniaturisation in injection moulding
Editorʼs Message
Turning research into better mould making
E
ven an established field such as tool and mould making still has room for development: higher part quality, more cost-effective production and more efficient use of materials remain key goals. Making further progress towards these goals needs specialist expertise and practical know-how. For mould design, this means understanding what happens inside the mould, how materials behave during processing and how design choices affect performance. This understanding helps researchers identify where improvements are possible. Several articles in this issue explore the close connection between science and engineering decisions. Research at RWTH Aachen University examines how hot runner valve gate pins can control cavity pressure in cascade injection moulding, while our miniaturisation feature from Mold-Masters shows how smaller melt channels help manage residence times when processing sensitive polymers. Other contributions examine AI-supported process optimisation and knowledge transfer in injection moulding, as well as the influence of internal defects on the performance of metal 3D-printed parts. Europe’s close connections between research institutions and industry provide a strong foundation for turning knowledge into practical improvements for mould makers and users. Sustaining these relationships requires continued investment in research, skills and cooperation. Both sides benefit: manufacturers gain access to scientific findings, while researchers find industrial partners who can identify practical challenges and help test new approaches under production conditions. Our Fakuma special takes this exchange between research and industry into the exhibition halls. The fair offers an opportunity to examine developments at different stages, from working prototypes to series products. Its new Innovation Award also recognises the importance of R&D. Discussions about their practical value can reveal both what they offer and which problems in production still have to be resolved. Sharing those challenges with fellow experts could help shape the next research project.
Alexander Stark, Editor, editor@etmm-online.com ETMM 4 | 2026
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COVER STORY
Miniaturisation in injection moulding p. 16 Advanced hot runners are replacing wasteful cold systems, boosting precision and efficiency in micro-moulding.
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NEWS NEWS STORIES 6 Salzgitter sells Desma to NMP 8 Incoming orders in German
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machine tool industry increase TRADE FAIRS
10 Fakuma 2026: The plastics
processing hub at the heart of Europe
12 Fakuma 2026: Hot-runner
ETMM Media ▪ media.vogel.de/etmm
innovations
14 Fakuma 2026: All-electric
injection moulding
REPORTS
MACHINING ACCESSORIES 26 The humanoid robots have already
arrived...
28 Optimising control processes with
robotic measurement cells
30 Grinding becomes a connected
manufacturing process
33 Cutting set-up times in giga-casting
presses
MACHINING EQUIPMENT 34 From aluminium to titanium:
Sustainable machining
36 Elevating lubrication to a strategic
advantage
38 Process reliability through fully
automatic presetting CUTTING TOOLS
HOT RUNNERS & TEMPERATURE CONTROL
42 New geometries raise machining
20 Balancing pressure in cascade
CAD/CAM & SOFTWARE
injection moulding
productivity
44 How AI is making CAD/CAM
smarter
The Cover Story from Mold-Masters takes a look at miniaturisation.
4 ETMM 4 | 2026
46 The perfect marriage between
CNC, robot and controller
48 AI predicts hidden defects in
metal 3D-printed parts
49 Teaching AI injection moulding
expertise
REGULARS 3 Editor’s Message 9 ISTMA World News 47 Masthead
TOP ONLINE Ranking The five most-clicked articles from the past month on etmm-online.com
Machining equipment: Temperchip Sensor 1. Tracks Machining Temperature in Real Time Hot runners: Stargate HRS: Innovative Hot 2. Runner System by Oerlikon HRS Flow control: Optimizing Manufacturing 3. Quality Process: Inspection at Point of Manufacture Materials: How Digital Sourcing solves material 4. procurement issues Machining equipment: KW Solution: Leading in 5. Automated Manufacturing and Robot Systems
ETMM 4 | 2026
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News
BUSINESS TRANSACTION
NEW SALES PARTNER
Salzgitter sells Desma to NMP
Stronger presence in Spain
TAKEOVER
Voltatron has signed an agreement with Prettl Beteiligungs Holding to acquire all shares in Kurz Elektronik. Based in Althengstett, Germany, the company develops and manufactures customised electronic solutions for industrial applications and the household appliance sector. The acquisition will extend Voltatron’s value chain with capabilities in cable assembly, plastic injection moulding and toolmaking. The company will also Voltatron expands manufacturing gain additional engineering expertise, electronic manu- capabilities through an acquisition. facturing services capacity and access to proprietary products and technologies. Kurz Elektronik contributes engineering resources as well as capacity for mediumand high-volume production. Its technology portfolio includes sensors, motor-control systems, battery management, user interfaces and Internet of Things applications. The acquisition will also add a Lithuanian manufacturing facility to Voltatron’s production network. The site provides capacity for volume production, while Kurz Elektronik’s engineering activities are concentrated at its technology centre in Althengstett. (ast)
Danish plastics manufacturer SP Group has acquired British injection moulder and box-build specialist OGM Moulding. The company will retain its name, management and approximately 190 employees while gaining access to SP Group’s international production network. SP Group has completed the acquisition of OGM Moulding and its subsidiaries for a fixed purchase price of approximately 21 million euros on a cash- and debt-free basis. A further earn-out payment of up to 7 million euros could become payable if OGM meets agreed earnings targets in 2027 and 2028. OGM reported Ebitda of approximately 5.1 million euros for the financial year ending 31 May 2026 and expects Ebitda of between 4.1 million and 4.3 million euros in 2027. Following the acquisition, SP Group has raised its 2026 growth forecast from 22–28 percent to 24–30 percent. Founded in Oxford in 1962, OGM manufactures injection-moulded precision components at facilities in Oxfordshire and South Wales. The two sites have a combined production area of approximately 10,000 m2. The company focuses on medical devices and diagnostics, protection and safety equipment, and industrial and transport applications. Many moulded components undergo further processing through OGM’s box-build operations, which cover assembly, validation, testing and packaging. OGM will continue to operate as a separate company under the management of Warren Berry. Former co-owner and chairman Paul Wightman will remain on its board for a transitional period of at least 12 months. (ast)
Salzgitter is selling Klöckner Desma Elastomertechnik to Name & Mawil Partners.
Source: free licensed
Voltatron acquires Kurz Elektronik
6 ETMM 4 | 2026
Source: Shibaura Machine LWB
INDUSTRIAL ELECTRONICS
Source: Salzgitter
disclose the sale price. Narith Meksavanh, CEO of the NMP Group: “Our strategic focus on quality and customer service has enabled us to achieve steady growth over the past ten years. In order to further meet our customers’ growing market demand, we are focusing on expanding our production capacity and our international sales network. We therefore view the acquisition of Desma Elastomertechnik not only as an opportunity, but also as a solution that will enable us to successfully address our industrial challenges by leveraging the capabilities at Desma’s locations. Our joint international sales networks will enable us to continue strengthening our market position, particularly in our growth-strong markets — the U.S., India, and China.” (ast)
Shibaura Machine Europe LWB is expanding its activities in Spain. Effective 2 September 2026, Puebla Vendrell Engineering System takes over sales of horizontal and vertical injection moulding machines for thermoplastic applications as its new sales partner. The partnership aims to strengthen the company’s position in the Spanish market. “With Puebla Vendrell Engineering, we have gained an experienced partner that has built a strong sales and service network for the Spanish market and is clearly focused on delivering real added value to industrial customers. Together, we aim to expand our market presence and make our injection moulding and automation solutions more accessible in Spain,” explains Dr Georg Holzinger, Managing Executive Officer of Shibaura Machine. Through the sales partnership, Shibaura Machine LWB aims to improve local sales coverage, accelerate customer support and open up new opportunities for injection moulding and Dr Georg Holzinger (left) and Emilio Modesto automation projects Puebla Vallina in Spain. (ast)
The Salzgitter Group has taken the next step in its active portfolio restructuring and sold Klöckner Desma Elastomertechnik to the German-French industrial group Name & MawiI Partners. The transaction is expected to be completed in the fall of 2026. The parties have agreed not to
SP Group acquires OGM Moulding for 18 million pounds
News
EXHIBITION PREVIEW
ADDITIVE MANUFACTURING
From 17 to 20 November 2026, Formnext will once again bring together the technologies and experts driving additive manufacturing. The event will showcase concrete industrial applications throughout the entire Additive Manufacturing valFormnext brings together the global Additive ue chain, featuring Manufacturing community. numerous use cases and business cases from a diverse range of industries. Visitor ticket sales are now open, with an early bird discount available until 22 October 2026. With around 800 expected exhibitors, the major players from across the global Additive Manufacturing ecosystem will be represented, covering the entire AM value chain. Throughout all four days of the exhibition, face-to-face networking, expert exchange, and practical application insights will remain at the center of the event experience. “Especially in the current market environment, the importance of exchange, market orientation, and access to innovation has become increasingly evident,” says Sascha F. Wenzler, Vice President Formnext at Mesago Messe Frankfurt. (ast)
On-demand manufacturer Quickparts announced its second major capacity investment in 18 months, bringing its total commitment to its Seattle Aerospace & Defense Center of Excellence to nearly 6 million dollars and adding twelve Stratasys Neo systems across its operations in the United States, France, Italy and the United Kingdom. The deployment modernises the company’s production fleet across all four sites, the latest in a series of milestones over Quickparts increases large-format throughput by 40 percent. the past year that included the November 2025 Seattle expansion and the February 2026 launch of its Durakor and Thermakor high-performance materials. “Quickparts’ investment reflects the growing role large-format additive manufacturing now plays in critical applications across aerospace, defense, and space,” said Dr Yoav Zeif, CEO of Stratasys. “We’re proud to partner with them as they scale their ability to support the world’s most demanding programs with proven industry-leading additive manufacturing technologies, materials, software, and services,” he added. (ast)
Quickparts expands capacities
Source: Quickparts
Source: Mesago / Marc Jacquemin
Formnext broadens programme
UPWARD TREND CONFIRMED
Incoming orders in German machine tool industry increase The recovery of the German machine tool industry is taking shape. Incoming orders rose by 12 percent in the second quarter of 2026 compared with the same period a year earlier. Following a 15 percent increase in the first quarter, order intake grew by 14 percent over the first half of the year. Domestic orders increased by 16 percent, while orders
from abroad rose by 13 percent. Performance continues to vary considerably across customer industries. Aviation and defence are showing particularly strong momentum, with demand also high in electronics and medical technology. Conditions remain more difficult in metal processing and mechanical engineering, while the automotive
Source: VDW
Machine tool industry Germany Upward trend confirmed – order intake grows by 12 percent in the second quarter
The positive trends experienced in the machine tool industry are continuing into the second quarter: incoming orders increased by 12 percent compared to the previous year.
8 ETMM 4 | 2026
industry and its suppliers continue to face the greatest challenges. The automotive sector’s share of total German machine tool sales fell to 23 percent in 2025. Mechanical engineering remained the largest customer sector, accounting for 27 percent. Aviation’s share, meanwhile, rose by five percentage points over two years to reach 11 percent. This recovery has not yet reached production. In the second quarter, calculations estimated a 6 percent drop on the previous year. In the first six months, production declined by a total of 7 percent to around 5.9 billion euros. However, the improved order situation should make more of an impact over the remaining course of the year. In the second quarter, exports remained 4 percent below the previous year’s level, although the decline was much less pronounced than in the first quarter. The US remained the industry’s largest export market and a key source of demand, with deliveries rising by 8 percent in the first half of the year. In contrast, exports to China, the second-largest market, fell by 24 percent. However, companies have recently reported a modest recovery in Chinese demand. (ast)
Istma
ISTMA World News & Events The International Special Tooling & Machining Association (ISTMA) is an international association representing 19 special tooling and machining associations throughout the world. Collectively, ISTMA member associations represent over 8,000 companies and over 40bn Dollar in annual sales. ISTMA World is in charge of the central coordination and organisation of all international activities
NETWORKING EVENT
Source: ISTMA
VDWF brings stamping professionals together Around 60 representatives of leading cutting and forming tool manufacturers attended the “VDWF Stanzer-Treff” on 29 and 30 June in Idar-Oberstein, Germany. The two-day meeting, organised by the Association of German Tool and Mold Makers (VDWF), was hosted by Wolfgang Loch, a producer of stamped, drawn and formed parts as well as welded and assembled components. The programme opened with a presentation by Tebis board member Jens Lüdtke on the current situation in tool and mould manufacturing. Subsequent technical talks covered software, continuous improvement processes and organisational efficiency in toolmaking. A tour of the Loch facilities followed, providing insights into stamping and assembly technology. The group then travelled by bus to a nearby gliding field, where participants were catapulted to 100 km/h in three seconds before a roughly 20-minute flight. “The glider flight was a very special highlight,” said VDWF Managing Director Ralf Dürrwächter. “Not only did we have perfect weather, but everyone was in fantastic spirits — an unforgettable experience!” A group dinner allowed further discussion. Ahead of a joint viewing of the World Cup match between Germany and Paraguay, referee Lutz Wagner sent greetings by video call and shared his predictions. Germany was eliminated; the toolmakers present agreed that the DACH region remained the technological world champion in their industry, but that cooperation with policymakers was needed to counter distorted international price competition.
The second day began with a tour of the toolmaking department at Wolfgang Loch, followed by a visit to cookware manufacturer Fissler in Hoppstädten-Weiersbach, where participants saw how products “made in Germany” are manufactured. A barbecue closed the event. “These kinds of informal gatherings are essential to an event like this — this is where the conversations take place that we often don’t have time for in our day-to-day business,” said Dürrwächter, describing the “VDWF meeting space” as a driver of cohesion within the industry. The next Stanzer-Treff is scheduled for 2027 at Vapic. www.vdwf.de
MEMORANDUM OF UNDERSTANDING
CEFAMOL and PtSA strengthen cooperation CEFAMOL, the Portuguese Association for the Mould Industry, and Production Technologies of South Africa (PtSA) have signed a Memorandum of Understanding on closer cooperation. The agreement between the two ISTMA member associations was concluded during a CEFAMOL institutional visit to South Africa from 31 August to 4 September 2026, which took in companies, training centres and industry organisations in Cape Town, Port Elizabeth, Durban and Johannesburg. The MoU sets out a framework for technical and business missions, market information, company contacts, innovation and R&D&I, training and participation in industry events. Both sides named tooling and engineering, automation, digitalisation and technical training as fields for future cooperation. ISTMA cites the agreement as a model for bilateral cooperation within its network and invites other members to follow suit. www.istma.org
MEMBERS Tool Factories Association www.svaz-nastrojaren.eu Estonian Special Tooling Association www.estatools.ee The Federation of Finnish Technology Industries www.techind.fi Association Française des Industries du Moule, Modèle et Maquette (AFIM) www.afim-france.com VDWF www.vdwf.de VDMA www.vdma.org
The Gauge & Tool Maker’s Association (GTMA) www.gtma.co.uk
Slovenian Tool and Die Development Center www.tecos.si
Szerszámgyártók Magyarorsazági Szövetsége (SZMSZ) www.szmsz.hu
Toolmaking Association of South Africa (TASA) www.tasaweb.co.za
Unione Costruttori Italiani Stampi e Attrezzature di Precisione (UCISAP) www.ucisap.it
Swedish Moulding and Press Tools Association www.sinf.se
Stowarzyszenie Techniczne – Tworzywa Sztuczne www.stts.com.pl
Swissmem www.swissmem.ch
Associação Nacional da Indústria de Moldes (CEFAMOL) www.cefamol.pt
International Mould Manufacturers Union www.ukub.org.tr
For information, contact: Mr. Manuel Oliveira Secretariat, Istma Europe c/o Cefamol Av. D. Dinis 17 Aptdo. 257 2430-263 Marinha Grande Portugal Tel. +351 244 575150 Fax +351 244 575159 istma-europe@istma-europe.com www.istma-europe.com
ETMM 4 | 2026
9
Fakuma
Source: P.E. Schall
Especially in economically challenging times, the industry meet is becoming increasingly important.
MAJOR TRADE FAIR IN AUTUMN
The plastics processing hub at the heart of Europe In October 2026, Fakuma will once again attract international visitors to the trade fair centre at Lake Constance. The exhibition will cover the entire chain of plastics processing, from raw material handling to injection moulding and 3D printing.
T
he Fakuma international trade fair for plastics processing will return to Friedrichshafen from 12 to 16 October 2026. The five-day event will mark its 30th edition and bring together exhibitors and trade visitors from across the international plastics industry. What began in 1981 with 76 initial exhibitors has evolved into a major European platform for the plastics processing industry. That’s why Fakuma is one of the industry’s must-attend events in the trade fair calendar. The focus on practical application is also stressed by exhibition advisory board member Dr. Friedrich Kastner. The CEO of the Next Generation Analytics Group (NGA) sums up the extraordinary success story of Fakuma, de-
10 ETMM 4 | 2026
scribing the trade fair as an event which has served as a reliable meeting place for decades, for an industry that’s undergoing constant change like few others. “Today, the trade fair is one of the most important plastics events in Europe, not only as a technology marketplace, but also as a source of inspiration for a sustainable, energy-efficient and digitally networked plastics industry.” Kastner points out that the issues shaping the plastics industry have changed over the years: “from the clearly linear value creation of the early years to a consistent circular economy. Energy efficiency, digitalisation, modern recycling technologies, the image associated with plastics and the shortage of qualified personnel are cur-
rently dominating our agenda.” Fakuma mirrors these developments and showcases practical solutions, holistic approaches and systemic methods for greater sustainability. Fakuma is no longer just an injection moulding trade fair, but rather a leading extrusion and recycling platform as well, that covers the entire spectrum of plastics processing. Industry players praise the special user benefits as well as the unique spirit of this practical trade fair with its lively atmosphere. “Fakuma is a special place for us: people meet here on equal terms, partnerships are forged and decisions are formulated that shape production strategies for years to come. Its informal atmosphere brings out the unique spirit of Fakuma,” adds Christopher Vitz, Regional President for Central Europe at Engel. Fakuma has always been an important European platform for the company: a place where plastics processing is not only showcased, but rather advanced collectively as well.
User-oriented, friendly atmosphere Industry events are particularly important in economically challenging times. As investment decisions come under closer scrutiny, companies are looking for solutions tailored to their specific requirements. Trade fairs such as Fakuma provide opportunities to compare technologies, exchange information directly and establish personal contacts. “Fakuma is about practical applications. Discussion takes place here on an equal footing. Numerous projects and developments are initiated in Friedrichshafen,” states Michael Wittmann, Managing Director of the Wittmann Group. “Fakuma has built up strong global momentum with this spirit, while retaining its local character and relaxed atmosphere. We have customers in Brazil who travel to Lake Constance to attend every Fakuma trade fair, because they value the combination of technological innovations and the relaxed atmosphere that provides space for in-depth discussions.”
Source: P.E. Schall
Fakuma
Industry players praise the special user benefits as well as the unique spirit of this practical trade fair with its lively atmosphere.
ETMM-TIP The Fakuma website provides up-to-date information on exhibitors, the supporting programme, tickets and travel arrangements to help visitors plan their time at the trade fair: www.fakuma-messe.de
The 30th Fakuma will take place from Monday 12 to Friday 16 October 2026, opening daily from 9:00 a.m. to 5:00 p.m. The trade fair will cover a broad range of plastics-processing technologies, including injection moulding, forming, extrusion, 3D printing, masterbatches and raw materials, as well as tooling, process technology and recycling. Exhibitors will also present processing machinery, peripheral equipment and automation solutions designed to address current and future requirements in plastics processing. A supporting programme will run throughout the fiveday event. It will include expert presentations in the trade fair forum and the third edition of the round-table discussion. Career Friday will highlight opportunities for young professionals, while the Paul Eberhard Schall Medal will be awarded for the first time. “We’re very pleased with the great interest expressed in the anniversary edition of Fakuma,” says Bettina Schall, Managing Director of P. E. Schall. (ast)
Fakuma
SURFACE TREATMENT
Longer life and consistent finishes
TOOLMAKING TECHNOLOGY
Standard components and services
www.borideabrasives.com
www.meusburger.com
MOULD AND HOT RUNNER TECHNOLOGY
NOZZLES AND VALVE GATES
Source: Meusburger
Meusburger will present new products, product expansions and digital solutions for mould, die, and jigs and fixtures construction. In the spotlight at the trade fair stand are high quality standard components, high-performance hot runner systems, solutions for cleanroom applications and digital tools for efficient design. In addition, the company invites visitors to take part in company tours at its Wolfurt site during the trade fair. A key focus of the trade fair stand is the comprehensive range of plates and mould bases. The raw materials that have been heat-treated for stress relief guarantee maximum quality and precision, and thanks to a high proportion of in-house production and enormous storage capacities, Meusburger ensures very short lead times. The standard parts manufacturer will also present its comprehensive range of high-precision components. As well as guiding elements, the range includes ejectors, slide systems, centring units and locks and hot runner solutions.
Source: Jacqueline Southby/ Boride
Boride has introduced its Ruby Dark Mold Polishing Stone, an aluminium oxide stone designed for applications requiring durability, controlled cutting and a consistent surface finish. It features a higher chromium content, resulting in a tougher, less friable crystal structure. Its blockier grain shape resists breaking down under pressure, helping the stone maintain its form and cutting characteristics for longer and extending its usable life. With a slower, less aggressive cutting action, Ruby Dark provides greater control during polishing. The abrasive grains do not break down as quickly or expose new cutting edges as frequently, making the stone well suited to precision applications where controlled material removal and surface consistency are important. The stone can produce a smooth, uniform finish over extended polishing cycles and has been used in demanding applications, including removing pores and achieving a smooth surface following the steel blasting process. Ruby Dark can be used by hand or with a profiler, with or without lubricant.
Oerlikon HRS Flow will highlight its cross-industry expertise in hot-runner injection moulding. This includes developments related to the needle-less Stargate HRS system and new applications for the Xp nozzle series in thick-walled containers. Visitors will also be able to experience hot-runner applications live at partner companies’ booths. Following its official launch at K 2025, the innovative Stargate HRS hot-runner nozzle concept, which uses a diaphragm-like mechanical system, will be presented for PP and r-PP applications to comply with the new PPWR regulations, as well as for processing resins such as PMMA and ABS, expanding its range of applications across market segments. Another highlight will be the new Xp series of valve gate nozzles, engineered for a wide range of applications and enhanced to meet the demanding requirements of the cosmetics industry. Accurate thermal control of the nozzle, combined with a new gate seal solution, ensures optimal injection quality for thick, transparent parts with shot weights up to 70 g.
www.hasco.com
www.hrsflow.com
12 ETMM 4 | 2026
Source: Oerlikon HRS Flow
Hot-runner innovations
Hasco will be presenting the latest product developments and solutions for tool and mould making. In the Mould Base area, Hasco will be showcasing solutions for efficient and reliable moulds. Among other things, the standard component manufacturer will be presenting a centering unit with a linear ball bushing, which is used for the precise centering of mould plates. In the field of temperature control, Hasco will be presenting new hoses as well as the innovative Z9911/... with the Z9911/... This protects the tool and peripherals in the long term because it reliably retains contamination. Another focus is on hot runner solutions. Visitors can use the H5055/... live. The design reduces shear, thereby preserving the mechanical properties of the plastic and reducing pressure loss to a minimum. This maintenance-friendly design allows coarse contaminants to be cleaned without the need for a pyrolysis oven, so the filter is ready for use again within minutes. In addition, products from the field of control technology will be shown. Source: Hasco
New mould components and more
Fakuma
INVISIBLE BACK INJECTION
New tunnel gate insert series
Life inline product marking
www.i-mold.de
www.rea.de
MATERIALS
FROM PACKAGING TO MEDICAL APPLICATIONS
Source: Rea Elektronik
little installation space in the mould. The spherical end of the sprue channel in the TGBL inserts provides exceptional flexibility. This ensures that, when contouring to the specific moulded part, the gate is always precisely circular, with its diameter increasing with the depth of material removal, regardless of the angle of the part’s surface. Due to their large deflection angles and narrow flow channel cross-section, TGBL inserts are ideal for processing thermoplastics with relatively low stiffness, such as polyolefins. The use of fillers and reinforcing materials, including talc or fibres, should be avoided.
The Digital Product Passport (DPP) and the growing demand for product traceability are presenting new challenges for manufacturers and pushing static coding and marking systems to their limits. Two joint projects by Rea Elektronik, Dr. Boy Spritzgießautomaten, and AF-Color will showcase practical solutions for the reliable and customised marking of injection-moulded products. The “Electric Barista” at the Dr. Boy booth combines injection moulding, laser marking and coffee preparation. Visitors order an espresso and enter their name at a terminal. A Boy 50 Electric then produces a cup from food-grade NAS30 containing AF-Color’s laser-sensitive masterbatch. After removal by a Boy LR 5 handling system, a Rea fibre laser marks the cup with the visitor’s name. A UR robot fills it with the selected beverage and hands it over. At the nearby Rea booth, a Boy machine similarly produces cutlery that is individually laser marked. In addition, Rea is showcasing further digital coding and marking solutions for thermoplastics, thermosets, and elastomers at its booth.
Source: I-mold
I-Mold will showcase the new TGBL series of its inhouse developed tunnel gate inserts, allowing the flow direction of the melt to be redirected by up to 270°. This provides a convenient way of moulding the edges of lids or caps from the inside, thereby avoiding gate marks on their visible side. The new TGBL inserts are suitable for shot weights of 35 g for size 1, 120 g for size 2, and 1000 g for size 3. Thanks to their compact, one-piece design, all three versions require very
PRODUCT TRACEABILITY
Together with Technotrans, Sumitomo (SHI) Demag will demonstrate how high-performance and cost-efficient production solutions can be achieved through the interaction of injection moulding machine, mould, temperature control, cooling and material. One of the highlights of the joint booth is the production of beverage closures on an Intelect S 280. The all-electric Intelect injection moulding machine manufactures the parts using a 48-cavity mould from HTW, demonstrating the performance and repeatability of its proprietary electric drive technology in a classic high-output packaging application while consuming less energy. The exhibit highlights the importance of a holistic process approach. Technotrans provides mould and machine cooling with an air-cooled weco 85 chiller using the natural refrigerant propane and a process-reliable high-pressure pump. Enesty supplies the cooling circuits through its Orca Plus water management system, while Eisbär contributes closure cooling and mould area dehumidification.
www.lehvoss.de
www.sumitomo-shi-demag.eu
14 ETMM 4 | 2026
Source: Sumitomo Demag
All-electric injection moulding
Lehvoss will highlight the cost benefits customers can achieve through its Smart Resourcing concept. According to the company, typical projects achieve savings of 10 to 20 percent without compromising quality, security of supply or technical service. This approach can also shorten development work and project lead times. Applications featuring Luvotech, Luvotech eco and Luvocom grades include an autonomous agricultural drone whose components are largely made from Lehvoss compounds. Its propeller blades use carbon-fibre compounds based on XCF technology, achieving a flexural strength of up to 527 MPa and a flexural modulus of 31 GPa. According to Lehvoss, they are up to 50 percent lighter than aluminium and 43 percent lighter than comparable PA66-GF50 solutions. The company will also display a work light made from Luvotech eco TC, a range of thermally conductive plastics based on mechanically recycled raw materials. Lehvoss states that the materials provide thermal conductivity of up to 18 W/mK and a carbon footprint up to 60 percent lower than comparable virgin materials. Source: Lehvoss
Smart resourcing of compounds
Fakuma
FOOD AND MEDICAL APPLICATIONS
Efficient injection moulding Source: Negri Bossi
Together with its parent company Nissei Plastic and automation specialist Sytrama, Negri Bossi will present two latest-generation injection moulding machines. Combined with robotic solutions and turnkey applications, the machines meet the requirements of a smart factory, reduce environmental impact and optimise injection moulding processes, the company states. With its presence at Fakuma, Negri Bossi wants to strengthen its position in the German market and present innovative applications for the stable, high-value food and medical sectors. One of the main exhibits will be the all-electric Nova5e110T H1540 injection moulding machine with a clamping force of 1,080 kN, equipped with a Sytrama S8 robot. In cooperation with hot- and cold-runner manufacturer Ewikon, the machine will produce a food-grade sleeve-shaped component in a four-cavity mould. The production cell integrates a silicone dosing unit from Binks Reinhardt-Technik and a packaging machine from Ravizza Packaging. www.negribossi.com
PLASTICS PROCESSING
Source: Arburg
Smartest factory concept Digitalisation, automation and smart production will shape Arburg’s presence at Fakuma 2026. Under the Smartest Factory theme, the company will show how machines, software, robotic systems and digital services can be combined across the plastics processing value chain to increase efficiency, improve transparency and reduce unit costs. With six Allrounders on its own stand and a further eight on partner stands, Arburg is showcasing a broad spectrum of solutions. Everything is on display, from standard machines through to automated micro and multi-component production cells, right up to complex turnkey systems for the medical technology sector. A highlight at the stand are two standard electric machines featuring the Gestica lite control system: The efficient production of LSR closures is demonstrated by a production cell centred around an Allrounder 1800 e Trend, equipped with a 64-cavity tool and a Multilift Select 16 linear robot system. An Allrounder Trend 1000 e demonstrates technical injection moulding by producing connector components for the electronics industry. www.arburg.com
ETMM 4 | 2026
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Cover Story
ADVANCED HOT-RUNNER TECHNOLOGY
Advanced hot runner technology enables precise, stable and material-efficient production of increasingly small medical components.
16 ETMM 4 | 2026
Source: © tilialucida - stock.adobe.com
Miniaturisation is rewriting the rule
Cover Story
s of injection moulding Micro-moulding demands more than simply making everything smaller. Precise thermal control, short residence times and stable melt delivery are becoming critical as medical and technical components shrink while their functionality increases.
The challenges created by miniaturisation The push toward miniaturisation presents several technical challenges for both mould makers and processors. OEMs are continually seeking opportunities to reduce device size while adding functionality. Components must often incorporate intricate geometries, thin wall sections and increasingly complex resin formulations. Lightweighting initiatives further reduce shot weights, often resulting in moulded part weights measured in tenths or even hundredths of a gram. At the same time, many of the engineering and medical-grade polymers used in these applications have relatively narrow processing windows. Maintaining material integrity throughout the moulding process becomes increasingly critical as part size decreases. Historically, these factors have led many designers to favour cold runner systems. Yet the disadvantages of cold runners become increasingly difficult to justify in modern manufacturing environments.
Why cold runners are losing acceptance The changing economics of manufacturing are causing many companies to reconsider traditional cold runner approaches.
In many small-part applications, the runner can weigh significantly more than the finished component itself. This creates an ongoing material cost penalty and generates waste that is difficult or impossible to regrind when processing medical-grade materials. Sustainability initiatives have become a key driver. Medical manufacturers are under increasing pressure to reduce waste streams throughout production. As manufacturers pursue aggressive sustainability targets and tighter margins, these inefficiencies are attracting greater scrutiny. Material costs also continue to rise for many specialty engineering resins. When expensive polymers are being converted into runner scrap rather than saleable components, the financial impact can be significant. Perhaps most importantly, cold runners inherently impose a cycle-time penalty. Every production cycle requires the cold runner to cool sufficiently for ejection. The additional cooling requirements reduce machine productivity and increase manufacturing costs. The result is longer cycle times, reduced productivity and higher cost per part. As a result, many processors are searching for alternatives that eliminate waste while maintaining the process stability required for high precision applications. Speaking of real-world scrap savings, an eight cavity cold-runner application that involved moulding a 0.15 g part produced about 4 g of scrap with each cycle. Transitioning to a hot runner system allowed them to double
WRITTEN BY
Thomas Bechtel Sr. Director, Global R&D Mold-Masters
ETMM-INFO
iFlow manifold technology
Source: Mold-Masters
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he trend toward miniaturisation continues to reshape the plastics industry. Across medical, diagnostics, electronics, drug delivery and high-precision consumer applications, manufacturers are increasingly challenged to produce smaller components with greater functionality, tighter tolerances and more demanding material requirements. What was once a simple moulded component is now frequently part of a sophisticated subassembly designed to integrate multiple functions into a smaller footprint. At the same time, pressure to reduce material consumption, improve sustainability and lower manufacturing costs has never been greater. For mould makers and processors, these market forces are creating a fundamental question: does it still make sense to mould small components with cold runner systems? For decades, cold runners have been widely accepted as the preferred solution for many micro and small-part applications. However, advances in hot runner technology are changing that perception. Advanced high-performance manifold designs that support significantly smaller melt channels are enabling applications previously considered impractical for hot runner systems.
Mold-Masters’ iFlow manifolds offers extensive flexibility to optimise melt flow for each application. Where conventional gun-drilled manifolds are limited to straight and 90-degree turns, iFlow manifolds gives designers the freedom to incorporate proprietary melt flow geometries, flow path options, and runner shapes, like curved flow paths, that avoid sharp corners and dead spots. For micro-moulding, this optimises flow behaviour, shear and residence conditions that helps maintain consistent part quality and improves overall moulding performance.
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Cover Story
Source: Mold-Masters
Manufacturers are continuously challenged to produce smaller components with more demanding requirements.
typically manufactured using gun-drilling processes. While effective, this method imposes practical limits on how small the internal runner channels can be made. Larger flow channels result in greater melt volume within the manifold and increased residence time. For applications involving extremely low shot weights, this can create processing concerns, particularly when moulding heat-sensitive or highly engineered materials. As a result, many moulders continued to view cold runners as the safer option for micro and small-part production.
Smaller channels open new possibilities
the mould capacity (16-cavity) and lowered cycle times by about 40 percent. Hot runner production eliminated cold runner scrap amounting to about 250,000 euros per year. The conversion to hot runner system for this specific application paid off within only four months.
“We don’t measure success by the size of the part; we look at the magnitude of the challenges we solve. By innovating with the customer in mind, it allows us to develop products that deliver lasting value.” Thomas Bechtel, Sr. Director, Global R&D, Mold-Masters The combination of increased output and reduced material consumption provides a powerful return-on-investment case for transitioning away from cold runner technology wherever possible. However, mould designers often face the reality that conventional hot runner systems have their limitations.
The limitation of conventional hot runner technology Despite the obvious advantages of hot runner systems, adoption in very small-part moulding has historically been limited. The primary challenge lies within the manifold itself. Conventional hot runner manifolds are
Mold-Masters’ iFlow manifold technology has the capabilities to address these specific limitations. Unlike conventional gun-drilled manifolds, iFlow manifolds can be manufactured with melt channels as small as 2 mm in diameter. This capability allows hot runner systems to be applied in applications previously reserved for cold runners. The reduction in melt channel size delivers several important performance benefits. Smaller channels reduce the volume of material residing within the manifold. Lower melt volume translates into reduced residence time, which can be especially beneficial when processing sensitive medical resins, engineering polymers or applications with exceptionally low shot weights. The smaller runner size capabilities of our iFlow manifolds are supported to the gate though our compact nozzle solutions are designed for small part weights. Custom solutions have been used on applications with part weights as low as 0.016 g and 9 mm pitches. Mold-Masters’ standard and custom solutions help support the flexibility necessary in gating locations for micro parts. Hot runner systems capable of incorporating smaller runner channels ensure residence time stays within acceptable tolerances. Depending on the material, the melt can start eroding within a short period of time. For certain grades of PBT, which can have thermal sensitivities, degradation starts after five minutes. To illustrate the differences on an application involving a part weight of 0.085 g, a conventional hot runner system would hold enough volume of material for up to 75 shots. At a 6 second cycle, residence time would be about 7.5 minutes. In a system with an iFlow manifold incorporating smaller runner channels, it would hold material for up to 24 shots with a residence time of only 2.5 minutes. This significantly improves residence times by up to 65 percent. Residence time is often critical to avoiding black spots or other defects of the part. This capability fundamentally changes the economics of small-part production.
Mold-Masters iFlow manifolds can be manufactured with smaller runner channel diameters than conventional gundrilled manifolds. Smaller runner channels reduce material volume in the manifold to help minimise residence time. A critical process variable for small parts.
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Source: Mold-Masters
Improving quality through better melt management Part quality remains the primary concern in medical and technical moulding. Reducing residence time helps preserve polymer properties and minimise the potential for material degradation. This is particularly important when processing high-value medical materials that require precise thermal control. The smaller melt volume within an iFlow manifold also improves process responsiveness and contributes to more consistent melt delivery throughout production.
The melt flow in micro moulding is extremely sensitive to thermal variations. Precise thermal control and uniformity is essential for producing high-quality micro moulded parts. Mold-Masters’ technology supports a stable and controlled pathway for the melt from inlet to gate. iFlow manifolds and Master-Series nozzles feature Mold-Masters’ Brazed Heater technology, which ensures optimal heat conditions for small part production. For moulders operating in highly regulated environments, consistency is often just as important as productivity. Stable melt conditions help reduce variability and support long-term process validation requirements.
Source: Mold-Masters
Cover Story
Manufacturers are under increasing pressure to reduce waste streams throughout production.
Proven for micro-part applications As miniaturisation trends continue, the industry increasingly requires technologies capable of supporting extremely small shot weights while maintaining process stability. Mold-Masters has successfully implemented iFlow systems in applications with part weights below 0.1 grams and mould configurations containing up to 96 cavities. Supporting these demanding applications is the Mold-Masters’ Master-Series nozzle platform. Designed specifically for small-part moulding, these nozzles feature smaller internal channel diameters and are particularly well suited to inside-gated applications commonly found in medical components. Together, the Master-Series nozzle and iFlow manifold combination provide mould makers with a practical solution for addressing the unique challenges of micro-moulding and high-cavitation small-part production.
When combined with iFlow hot runner technology, the E-Multi Mini creates a complementary solution for manufacturers seeking to push the boundaries of miniaturisation, functionality and production efficiency.
Looking Forward The medical moulding industry is entering an era where miniaturisation, sustainability and productivity are no longer separate objectives. Success increasingly depends on achieving all three simultaneously. Cold runner systems have served the industry well for decades, but the growing demand for smaller parts, higher cavitation, reduced waste and improved process efficiency is accelerating the shift toward advanced hot runner solutions. By enabling melt channels as small as 2 mm, supporting direct gating of extremely small components, and helping manufacturers reduce residence time, scrap and cycle time, Mold-Masters’ various technical solutions are helping to redefine what is possible in small-part moulding. For European mould makers competing in an increasingly demanding global market, technologies that reduce cost per part while simultaneously improving quality and sustainability represent more than a process improvement. They provide a competitive advantage that can help shape the future of medical manufacturing. (ast)
Miniaturisation is not limited to single-material components. Many medical devices increasingly require multi-material or 2K constructions to achieve enhanced functionality, ergonomics or sealing performance. To support this evolution, Mold-Masters also offers the E-Multi Mini. An all-electric, servo driven auxiliary injection unit which offers high-performance processing capabilities delivering excellent precision, repeatability, speed, and reliability. The E-Multi product line sets the benchmark for auxiliary injection units in precision 2K moulding applications. Purpose-built for the most demanding low-shotweight and micro-injection applications, the E-Multi Mini in compact 2K moulding environments. The E-Multi Mini is capable of shot volumes as low as 0.1cc. It offers the additional advantages that it processes standard resin pellets rather than specialised micro pellets, which simplifies material logistics, lowers operating cost, and provides greater flexibility for manufacturers. The E-Multi Mini has proven its ability to reliably process extremely small shot volumes using a wide range of technical resins, including materials that can be difficult to run on conventional injection moulding equipment, in various applications. This performance gives mould makers and processors greater freedom to develop increasingly sophisticated multi-material, micro-moulded, and medical components while maintaining process stability and part quality.
Source: Mold-Masters
Supporting the next generation of multimaterial medical devices
ETMM-TIP Explore Mold-Masters’ hot runner solutions for micro-moulding applications and advanced melt management at www. moldmasters.com
Processing temperature sensitive materials requires HR optimisation to ensure residence times are properly managed.
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Hot Runners & Temperature Control
VALVE GATE CONTROL
Balancing pressure in cascade injection moulding
Source: © dizfoto1973 - stock.adobe.com
Pressure imbalances can cause warpage and inconsistent part quality in cascade injection moulding. IKV researchers have investigated how variable valve pin strokes could stabilise cavity pressure during the holding phase and where the approach reaches its limits.
Researchers are investigating how valve pin movements can regulate cavity pressure during cascade injection moulding.
WRITTEN BY
M. Schöll F. Hankes Ch. Hopmann (see box for authors´ biographies)
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C
ascade injection moulding is the preferred process for the production of parts with large flow path/ wall thickness ratios, if visible weld lines are to be avoided or if the part cannot be filled using a single gate. It is used in particular when high demands are placed on the surface quality. For this purpose, hot runner nozzles are positioned along the flow path, which open sequentially after the flow front passed the gate. The nozzles can be opened depending on time, screw position or flow path using sensors. Like the conventional injection moulding process, cascade injection moulding is subject to unavoidable process fluctuations, such as the different closing of the non-return valve or the processing of varying proportions of recycled material. Therefore the process must be adapted to the current conditions. One way to achieve this is to control the cavity pressure, as this correlates with the part quality. However, the melt flow in the mould cannot be locally controlled using control approaches that use the screw movement as a manipulated variable, which is why cavity pressure control cannot be tailored to cascade injection moulding.
Another option is to influence the melt flow in the hot runner system by means of variable opening strokes of the hot runner valve pin. The different opening strokes influence the flow cross-section and thus the pressure transfer through the corresponding nozzles. This allows the melt flow in the hot runner to be regulated in a targeted manner. So far, this approach has been analysed for single-cavity moulds. However in cascade injection moulding the pressure transmission into the cavity can be influenced at each nozzle. For the development of local cavity pressure control during the holding pressure phase for cascade injection moulding, it is necessary to analyse, how the individual opening strokes must be adjusted in order to control the cavity pressure in the cavity. In the first step, the influence of individual pin movements on the cavity pressure curve is investigated. A strategy for controlling the cavity pressure is derived from this. In cascade injection moulding, the part is filled via several gates along the flow path in order to avoid weld lines. The pins are controlled in such a way that only one flow front appears in the cavity. Starting from one open hot runner nozzle, the flow front spreads out and the adjacent nozzles open shortly after the melt has flowed over them.
Influence of process fluctuations on part quality In order to achieve uniform filling of the individual part segments and an adapted holding pressure effect, the hot runner system can be rheologically balanced in addition to the variable opening strokes of the valve pins. The balancing is optimised with regard to a process point and material. However, the injection moulding process, and also cascade injection moulding, is subject to fluctuations that influence the flow processes in the cavity and also the part consequently properties. For example, the closing behaviour of the non-return valve varies when processing fluctuating viscosities and due to fluctuating positions of the pressure ring. Due to different closing of the non-return valve, varying amounts of material are injected into the cavity. As a result, the nozzles open with position-controlled opening at different filling levels. Fluctuations in viscosity can be caused by processing different material batches or fluctuating recyclate and
Hot Runners & Temperature Control
masterbatch proportions. The different flow properties influence the pressure gradient in the melt. In addition to varying part dimensions, viscosity fluctuations also cause different orientations in the part, which in turn influence the mechanical strength and dimensional accuracy. As the disturbances influence the part quality, there are approaches to compensate for the quality differences. These are discussed below.
Compensation of process fluctuations Due to the disturbances discussed, the filling level fluctuates when the individual gates are opened, meaning that local pressure peaks can occur. To avoid this, the opening of the nozzles can be controlled by the overflow of temperature sensors instead of depending on the screw path. The advantage of temperature sensors over pressure sensors lies in their faster response behaviour. Other systems for controlling cascade injection moulding, such as APC plus from Krauss Maffei Technologies, Germany, or IQ weight control from Engel, Austria, use the changes in injection pressure to detect viscosity fluctuations and different closures of the non-return valve to derive the opening times of the nozzles so that the pins open at the same filling level. The systems also adapt the switchover point to the holding pressure phase. They also adjust the holding pressure to compensate for the changed pressure gradient.
However, the injection pressure cannot be used to detect any faults within the mould, such as deposits on the flow channel surface or fluctuations in mould temperature. Furthermore, the changed material behaviour means that the adjustment does not work specifically for each individual part segment, as the hot runner balancing is optimised for one operating point. This can lead to overpacking of individual segments or to sink marks. Controlling the cavity pressure can increase process consistency, as this correlates with part quality. However, most control approaches use the screw movement as a
ETMM-INFO
Cascade injection moulding In cascade injection moulding, particular attention must be paid to the cooling of the melt during the injection phase due to sequential filling. As a result, the melt temperature at the switchover point is lower in some areas of the part, so the pressure transmission has a greater gradient. Therefore, during the holding pressure phase, variable opening strokes can only influence the pressure locally around the gates. The pins are therefore moved equally in order to regulate the cavity pressure and achieve a uniform pressure distribution in the cavity.
Hot Runners & Temperature Control
mould and process consistency has been demonstrably increased. In the future, the strategy is to be transferred to cascade injection moulding so that the cavity pressure is regulated both at multiple points and locally in the cavity during the holding pressure phase.
Source: IKV
Objective of the project
Figure 1: Schematic representation of the control loop for cascade injection moulding
Acknowledgements The research project 22805 N is sponsored as part of the “Zentralen Innovationsprogramms Mittelstand” by the German Bundesministerium für Wirtschaft und Energie (BMWE) due to an enactment of the German Bundestag.
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Methodological approach Source: IKV
Figure 2: Representation of the injection moulded part
In cascade injection moulding, the cavity is filled via several different gates, each of which has a valve gate nozzle. The melt flow into the cavity can be influenced at each of the nozzles by adjusting the opening strokes so that a large number of possible control variables are available, which can interact with each other. The problem is illustrated in Figure 1. For the implementation of the control system, it is necessary to specify, how the individual pins must be moved to compensate for deviations in the cavity pressure. Therefore, a weighting function should be used to specify how the individual pins should be moved to achieve balance. To develop a weighting function, the influence of different pin movements on the cavity pressure is first analysed based on simulations. Based on the analysis carried out, a control system is implemented which takes the weighting of different pin movements into account.
manipulated variable, so that the melt flow in the mould cannot be specifically controlled, for example to locally compensate for the problems discussed above. The Dynamic Feed from Synventive Moulding Solutions, Germany, is one way of locally influencing the melt flow in the mould, in which additional melt valves are used to regulate the melt pressure in each manifold of the hot runner. By influencing the melt pressure, the ideal pressure profile can be set for each part segment. The disadvantage of this system is that reference pressure curves are regulated in the hot runner manifolds, which does not correlate directly with the moulded part formation in the cavity. For example, the cooling behaviour of the melt is not detected. In cascade injection moulding, other systems influence the melt flow into the cavities during the filling phase by varying the opening speeds of the hot runner shut-off pins. By sequentially opening additional nozzles, the melt front is greatly accelerated due to the system pressure, which can result in flashes. The reduced opening speed increases the flow cross-section more slowly, which reduces the acceleration of the flow front and prevents the defect pattern. However, fluctuations in moulded part formation in the holding pressure phase cannot be compensated for in this way. A system developed at the IKV influences the melt flow during the holding pressure phase by means of variable opening strokes. As with the systems in the injection phase, the flow cross-section and thus the pressure loss in the flow channel is regulated by the different opening strokes, thereby controlling the cavity pressure. The system has so far been tested for a single-cavity
The used equipment for the tests and the implementation of the control strategy are explained below. The test procedure is described afterwards. The part under investigation has a spiral shaped geometry. The spiral is 2 mm thick and 75 mm wide, so that the cavity has a volume of 225.56 cm3. It is filled via three nozzles, with the first nozzle filling approximately 33.5 percent of the volume, the second 37.0 percent and the last 29.5 percent. The part is shown in Figure 2. The hot runner system for distributing the melt flow is naturally balanced and includes hot runner shut-off nozzles. A mineral-filled polypropylene (PP), type PP Compound 8500 from Sabic Deutschland, Germany, is processed as part of the investigations. The material is used in particular in the automotive sector for interior applications. In these applications, there are a variety of processes with multiple gates for filling the cavities, making it a representative material for possible applications of the control system in an industrial transfer. The simulations are carried out using Moldex3D software from Coretech System, Chupei City, Taiwan, with the 2024R1OR patch. Using this software, the pin movement can be modelled using adjustable pin stroke profiles. The hot runner system is created using line segments to which attributes are assigned for the geometry, the type of runner and the assignment to the corresponding nozzles. The geometry is automatically meshed on this basis, whereby a structured volume mesh of hexahedron elements is favoured due to the advantages in terms of convergence, robustness and stability. The meshing length of the surface mesh of the cavity is 3.75 mm. The volume mesh is generated based on the surface mesh. The boundary layer mesh (BLM) is used for this purpose. The volume mesh is generated with a three BLM. The influence of variable opening strokes during the holding pressure phase is analysed in the simulations.
Hot Runners & Temperature Control
On the one hand, individual open nozzles are taken into account. Furthermore, all combinations of the simultaneous opening of two or all three nozzles are included in the scope of the test. On the other hand, a complete opening of 10 mm and partial openings of 5 mm and 3 mm are analysed. During the injection phase, the process control is kept constant at all test points. The nozzles open sequentially when the melt front flows over the sensor 1.8 mm behind the nozzle. When the next nozzle opens, the previous nozzle is closed. From a volumetric filling level of 98 percent, the system switches to the pressure-controlled holding pressure phase. The test points discussed below have constant temperatures, injection volume flows, back pressure and back pressure time. The opening stroke is considered to be the complete opening to 10 mm and closed nozzles.
Influence of different opening strokes on pressure distribution in the part In the following, the influence of different opening stroke profiles (open to 10 mm or closed) of the hot runner shut-off pins during the holding pressure phase on the pressure distribution is simulatively analysed. Figure 3 shows the pressure distribution in the part for different points in time during the holding pressure phase when only the first nozzle is open. At the switchover point, the maximum pressure of 84.4 MPa is present at the third
Controlling the cavity pressure can increase process consistency, as this correlates with part quality. gate, which decreases towards the end of the flow path. The pressure also decreases towards the previous areas of the part. As the part is filled sequentially and the valve pins close when the next one opens, the part is only filled via one nozzle at a time. When filling via the last nozzle, the injection pressure already acts on the previous component sections as holding pressure. At 98 percent volumetric filling, the system switches to holding pressure phase so that the part is not yet completely filled at this point and the flow front is not yet compressed. From the switchover point, the third nozzle closes, whereas the first valve pin opens to 10 mm. As a result, the pressure is transferred through this nozzle during the holding pressure phase. Due to the open nozzle, the pressure in the part is maximised at this point. After a holding pressure time of 0.5 s, this drops from around 55.0 MPa to 9.8 MPa at the end of the flow path. The maximum pressure at the gate remains almost constant during the rest of the holding pressure phase. However, the
Republished This article is a secondary publication of the paper presented at the 33rd International Colloquium on Plastics Technology, Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University, 4 and 5 March 2026, Aachen.
Hot Runners & Temperature Control
Source: IKV
pressure gradient increases, so that after a time of 4.0 s the pressure only affects the area around the nozzle, which has already dropped almost completely over a distance of 100 mm. The effect of the pressure transfer is also summarised in the diagram on the left using the average pressures. Analogue to the pressure distribution, Figure 4 shows the temperature distribution in the part for the same test point. In contrast to the pressure, the maximum temperature occurs is at the flow front and thus at the end of the part. The melt temperature drops by 4.5°C towards the
Source: IKV
Fig. 3: Pressure distribution in the cavity with gate 1 open during holding pressure phase
Source: IKV
Fig. 4: Temperature distribution in the cavity with gate 1 open during holding pressure phase
Fig. 5: Comparison of the pressure and temperature distribution in the cavity with all open nozzles during the holding pressure phase
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third nozzle. The temperature is already lower in the previously filled component areas. Peaks can only be recognised at the nozzles. In the further course of the holding pressure phase, the temperature drops, whereby the distribution is shifted parallel to lower temperatures. After a holding pressure time of 1.0 s, the temperature between the first and second nozzle is around 159°C and between 181°C and 200°C between nozzle 2 and 3. After nozzle 3, the average temperature is around 224°C. The lower the melt temperature, the lower the pressure transfer in the melt. This explains the sharp drop in pressure in the part when only the first nozzle is open (compare Figure 3 ). The test point at which all pins are open during the holding pressure phase is analysed below. Figure 5 summarises the pressure and temperature distribution for the test point. As the injection phase is kept constant in all test points, the pressure and temperature distribution correspond to those of the previously discussed test point. However, at this test point the pressure is transferred into the cavity through all nozzles during the holding pressure phase. Therefore, the pressure distribution at the nozzles shows corresponding maxima. The maxima are comparable at the individual nozzles as soon as the nozzles are open. Furthermore, the pressures correspond to the values measured at the previously discussed test point. However, the pressure drops less between the nozzles. The minimum pressure between nozzle 1 and nozzle 2 after 0.5 s is 282 bar. Between nozzles 2 and 3 it is only 443 bar and after nozzle 3,331 bar. As the cycle time increases, the pressures between the nozzles continue to decrease. However, the pressure in the area of the third nozzle is more effective than with the other two nozzles, so that the gradient is lower. This is due to the different temperature distribution caused by the sequential filling. As a result, the melt around nozzle 3 is warmer after the switchover point than at the other nozzles. Due to the better pressure transfer, this also results in higher pressures. During the holding pressure phase, the temperatures become more and more homogenised, which is why the pressures also equalise.
Development of cavity pressure control Based on the identification of the influence of the individual pin movement on the local cavity pressure, the relationship between the individual pin movements and the compensation for control deviations is explained below. The implementation of the control strategy is then explained. Analysing the influence of different pin strokes and stroke profile on the pressure distribution shows that only the areas close to the nozzle are influenced - especially when the holding pressure phase has progressed. Therefore, the cavity pressure in part sections further away from a nozzle can no longer be regulated by variable opening strokes of the pin. At this point, the pressure can almost only be adjusted by the nearest nozzle. However, moving only one nozzle can cause large pressure differences in the part. If the other nozzles are closed, this effect is further intensified. The pressure differences cause locally different degrees of compensated shrinkage, which can result in warping. To minimise the pressure differences and thus increase the part quality, all valve pins are therefore moved equally when regulating the cavity pressure.
Hot Runners & Temperature Control
The pressure distribution in the cavity can be influenced by different opening strokes on the individual pins. For the practical validation, the control strategy is implemented on a cRIO-9074 from National Instruments (NI), Austin, Texas, USA, using Labview, a graphical programming language. Using different modules, both analogue and digital signals can be read in and output with the used hardware. This enables both the control of the hot runner pin movement and communication with the machine to be realised. During the practical validation, the pin movement during the injection phase is implemented as in the simulations. During the holding pressure phase, a comparison is made between the target and actual course of the cavity pressure. The target pressure curve can be calculated, for example, on the basis of pvT-optimised process control. In the event of deviations, the pin movement of all pins is adjusted using a proportional–integral–derivative controller (PIDcontroller). The control system should be practically validated in experimental tests.
Conclusions and outlook Variable opening strokes can be used to influence the pressure transmission into the cavity based on the adapted flow cross-sections. The influence of individual strokes on the cavity pressure was simulated in order to develop a control strategy for cascade injection moulding. The pressure distribution in the cavity can be influenced by different opening strokes on the individual pins. However, different opening strokes only affect the pressure distribution near the corresponding nozzle. Due to the cooling of the melt during the sequential filling process, the pressure transfer in the melt is so poor that the pressure distribution in component areas far away from the nozzle is not affected. Therefore, all pins are moved equally to regulate the cavity pressure. The control of the cavity pressure should be tested experimentally in further trials. Furthermore, the generalisation with regard to the investigated material and process should be analysed. (ast)
ETMM-INFO
About the authors Matthias Schöll, M.Sc. RWTH, is Head of the “Injection Moulding and Additive Manufacturing” Department at the Institute for Plastics Processing in Industry and Crafts at RWTH Aachen University. Fabian Hankes, M.Sc. RWTH, has headed the “Process Control in Injection Moulding” working group at the Institute for Plastics Processing in Industry and Crafts at RWTH Aachen University since September 2025. Professor Christian Hopmann, Dr.-Ing., is Director of the IKV and holds the Chair of Plastics Processing in the Faculty of Mechanical Engineering at RWTH Aachen University.
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Source: © Maksudul - stock.adobe.com
The core reason behind the adoption of humanoid robots in the manufacturing or tool and mould making industry is the lack of labour in these markets.
ROBOTICS
The humanoid robots have already arrived … The European manufacturing industry is increasingly recognising the potential of humanoid robots, particularly as the region faces growing labour shortages. Tool and mould makers are familiar with recruitment challenges and are therefore exploring possible applications. WRITTEN BY
Ahlam Rais Contributing Editor ETMM
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ovies such as RoboCop, The Terminator and I, Robot introduced broad audiences to fictional machines combining physical strength with human-like intelligence. Meanwhile, humanoid robots are now becoming one of the most visible manifestations of a much broader technological development known as Physical AI. Physical AI enables machines to perceive their surroundings, process information and act autonomously in the physical world. It combines sensor technology, decision-making models, simulation-trained behaviours and adaptive control. Humanoid robots give these capabilities a physical form designed to move, grip objects and navigate environments built for people. On the shop floors of tool and mould makers, machine tending and materials logistics are among the first potential applications.
Response to the labour problem Labour shortages are one of the main factors encouraging manufacturers and tool and mould makers to con-
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sider humanoid robots. A study by the international consultancy Roland Berger, entitled Humanoid Robots 2026 — The convergence moment for a new market, examines labour scarcity and possible automation measures. According to the study, more than 85 percent of German companies are already experiencing the initial effects of labour shortages in their operations. Vacant positions take an average of four months to fill. In manufacturing, around 45 percent of companies lack suitable candidates for open positions, while approximately 57 percent of metalworking companies report operational difficulties caused by staffing shortages. The figures draw on data from Oxford Economics, the ifo Institute, IfM Bonn, the United Nations and Roland Berger.
Humanoid robots in manufacturing Although the technology is still at an early stage, manufacturers are already examining humanoid robots for a range of applications. Repetitive tasks are one possible area of use, particularly where consistent handling or
Machining Accessories
inspection processes are required. AI-supported systems could also inspect large number of components according to defined criteria, potentially improving consistency and helping to identify defects. Unlike stationary industrial robots, mobile humanoid robots can potentially perform different tasks in several areas of a production facility. Their ability to work in environments designed for people could allow companies to automate selected activities without extensively modifying existing production layouts. Safe operation alongside employees, however, depends on the application, technical safeguards and the relevant risk assessment.
Initial applications in the industry Motion technology company Schaeffler plans to deploy thousands of humanoid robots across its global facilities by 2032 and integrate them into production operations. The initial rollout is planned for its German sites in Herzogenaurach and Schweinfurt. In Herzogenaurach, the company intends to develop a box-handling application under production conditions. Siemens has also tested humanoid robots for autonomous logistics tasks at its electronics factory in Erlangen, Germany. BMW completed a pilot project involving humanoid robots at its Spartanburg plant in the United States in 2025 and is conducting a further project at its Leipzig plant. There, humanoid robots are being integrated into existing series production, while BMW is examining additional applications in battery and component production.
Potential applications in tool and mould making One potential advantage of humanoid robots is their ability to move between different machines and work areas during a shift instead of remaining at a single station. This flexibility could be particularly relevant to tool and mould makers, whose production environments frequently involve varied tasks and small batch sizes. Possible applications include machine tending and the internal transport of materials and components. Machine tending: Machine tending involves loading raw materials or components into machines and remov-
ing them after processing. CNC machines and electrical discharge machining systems used to manufacture tools and moulds are possible application areas. Humanoid robots are also being examined for tending injection moulding machines, building on applications already performed by conventional industrial robots. Materials and component logistics: Humanoid robots could also support internal logistics by transporting materials, components and finished parts or by preparing workpieces for CNC and electrical discharge machining operations. The suitability of the technology will depend on factors such as component weight, precision requirements, production layout and safety considerations. These applications illustrate how humanoid robots could support practical shop-floor activities. Their development may therefore influence how work is organised in tool and mould manufacturing over the coming years.
The transition from pilot projects to production Humanoid robots are gradually moving from a largely experimental technology towards potential industrial use. Labour shortages are one reason for this development, while advances in AI, sensor technology and robotic control are broadening the range of possible applications. Pilot projects at manufacturing companies indicate that the transition towards deployment under production conditions has begun. For tool and mould makers, the ability to move between machine-tending, materials-handling and logistics tasks could offer greater flexibility than fixed, single-purpose automation. Widespread adoption will nevertheless depend on whether the systems can be integrated economically and safely into existing workflows. Physical AI — with humanoid robots as its most visible embodiment — could change how certain shop-floor tasks are performed. Tool and mould makers will therefore need to assess where the technology offers practical benefits and what technical, organisational and safety requirements must be met before deployment. Early movers are likely to gain the clearest picture of where it genuinely pays off. (ast)
Source: Mitutoyo
The robot handles the loading of the parts to be inspected into the storage area.
PRODUCT INSPECTION
Optimising control processes with robotic measurement cells Méca-Précis implements a robotic measurement cell to streamline its inspection processes. This solution combines a coordinate measuring machine from Mitutoyo with robotics solutions from Engineering Data, effectively removing bottlenecks in the parts inspection process.
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ome trades are passed down from father to son — ploys 45 people and operates a fleet of 25 machine tools, along with a passion for excellence. When Bruno 18 of which are CNC-controlled. Over the course of nearly half a century, the company — based in ChâtilMériaudeau speaks about the sophistication of the lon-sur-Indre (36) — has continuously strengthened components produced in his workshop, the sparkle in both its technical expertise and its produchis eyes and the enthusiasm in his voice, tion capabilities. tinged with pride, say it all. This affable and Méca-Précis has more than one string to its good-humored leader has clearly inherited a bow. It now specialises in prototype parts, deep appreciation for precision engineering. one-off components, small and medium proMéca-Précis was founded in 1975 by his faduction runs, and welded mechanical assemther, driven by a strong entrepreneurial spirblies. As a manufacturer of complex parts for it and a desire to put his expertise in highly the aerospace and satellite industries, the technical component manufacturing to company has also maintained, for 48 years, work. This expertise was honed during his the trust of a global leader in carton packagtime working for the military, where he deing machinery, for whom it produces parts signed and produced one-off parts tailored to Bruno Mériaudeau, Méca-Précis and complete sub-assemblies. While having highly specialised applications. His son the expertise and equipment to manufacture joined the company in 1982, at a time when sophisticated components is essential, enBruno Mériaudeau was the eighth employee suring these parts meet stringent dimensional requireof the family business. Today, he is preparing to pass the ments is equally critical. To this end, Méca-Précis opertorch to his own son, Nicolas, who took over the manates a standard measuring machine on the shop floor, as agement of Méca-Précis in 2023. The company now em-
“This solution brings us greater flexibility and allows us to significantly increase inspection capacity.”
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Machining Accessories
well as a coordinate measuring machine (CMM) housed in a thermally controlled environment. However, certain aerospace and space-sector clients require 100 percent inspection of all dimensions on every single part produced, both before and after surface treatment.
When inspection becomes a bottleneck “Dimensional inspection of a single pin takes just one minute — but there can be as many as 300 to check. At the other end of the spectrum, inspecting a single complex component for a satellite can require up to 80 hours,” explains Nicolas Mériaudeau. In this context, as production volumes increased and multiple palletised machining centres operated through the night, the coordinate measuring machine was no longer able to keep pace. “Our two inspectors were overwhelmed. To maintain a high level of service and manufacturing quality, and to ensure reasonable lead times for our customers, we needed to find a solution to eliminate the bottleneck in the inspection process. We therefore began searching for a way to automate and roboticise the inspection process,” explains Bruno Mériaudeau. As the manufacturer of the coordinate measuring machine (CMM) used by Méca-Précis was unable to provide a suitable solution, Nicolas Mériaudeau turned to Mitutoyo. The company proposed the design of a robotic measurement cell integrating the Mistar coordinate measuring machine, in collaboration with Engineering Data, a company specialising in fixturing solutions and the automation of machining centres.
Deployment of the robotic measurement cell ensures productivity Less than a year after the initial meeting between the teams from Mitutoyo, Engineering Data, and Méca-Précis — with both quality inspectors closely involved throughout the project — the robotic measurement cell was installed in the workshop. Following phases dedicated to developing part inspection programs, system commissioning, configuration, and technical fine-tuning, an additional six months were required before the system became fully operational. “We have effectively removed the bottleneck that was located in the quality control process. This solution brings us greater flexibility and allows us to significantly increase inspection capacity,” says Bruno Mériaudeau with satisfaction. “If we did not have this robotic measurement cell, we would not be able to cope with the growing production volumes of series-manufactured parts, which are highly demanding in terms of quality control. We now have a solution that fully meets our needs. Throughout this project, we benefited from the quality of exchanges, responsiveness, attentiveness, and geographical proximity of the Engineering Data and Mitutoyo teams,” adds Nicolas Mériaudeau. As a result, the pressure that had been weighing on Méca-Précis’ two inspectors has been significantly reduced. They can now rely on two measurement solutions to perform all the necessary checks in-house. The robotic cell has significantly reduced their workload by performing automated inspections during the day as well as overnight. Before leaving the workshop, they can load parts into the robotic system, which then carries out the inspections automatically in their absence. (ast)
ETMM-TIP For more information on the Mistar coordinate measuring machine and options for automated dimensional inspection, visit measure. mitutoyo.com
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THE FUTURE OF GRINDING
Grinding becomes a connected manufacturing process The future of grinding technology is connected, automated and data-driven. Manufacturers are integrating process chains with data-driven quality assurance and solutions that optimise the use of tools, coolants and peripheral equipment.
Source: VDW/ Uli Regenscheit
focus is shifting towards feeding process data, tool condition, machine behaviour and measurement results back into the system. This enables grinding processes to be performed more stably, efficiently and reproducibly, while treating them as integrated systems. As a result, innovation is moving beyond process design towards greater process control. To achieve this, manufacturers are developing more robust, digitally supported and, in some cases, adaptive process chains.
AI-powered wear analysis for efficient tool inspection and fully automated measurement systems for microtools.
WRITTEN BY
Tountzer Tsagkir Dereli, M.Sc. Institute for Machining Dortmund Technical University
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he grinding industry is under pressure from declining production, weaker exports, rising energy and material costs, and volatile markets. In response, manufacturers are shifting their focus from individual machines to more productive and resilient process chains that combine sensor technology, measurement data and digital feedback for process monitoring and quality assurance. Compared with previous years, Grindinghub 2026 showed that grinding is increasingly viewed as an integrated manufacturing process rather than a standalone operation. Machine tools, grinding tools, sensors, metrology, automation, data management and maintenance are becoming more closely interconnected. New developments therefore aim not only to improve individual process parameters, but also to enhance process stability, traceability, energy efficiency, operator support and quality assurance. This is reflected in integrated measurement and compensation systems, data-driven machine condition monitoring, automated tool manufacturing and dressing cells, and grinding tools designed for higher material removal rates with controlled thermal loads. One of the key trends in grinding is the functional integration of individual components. Increasingly, the
Flexible machine designs In addition to highly productive series production solutions, flexible machine concepts are gaining importance, as they cater to a wide range of workpieces, smaller batch sizes and easier operation. In this way, manufacturers are responding both to the shortage of skilled workers and to the increasing variety of product variants in many user industries. Machine concepts are no longer differentiated solely by the number of axes, size, or spindle power, but increasingly by their integration in process chains, automation solutions, and flexibility. Kellenberger, demonstrates this with two grinding machines — the K8 and the upgraded K10. The K8 is designed as a standardised, cost-effective CNC cylindrical grinding machine for entry-level applications as well as for small and medium-sized production runs. It deliberately omits certain configuration options, but provides a stable, high-precision foundation with a onepiece machine bed, friction-reducing coated V-flat guides on the Z-axis, and high-resolution Fagor measuring systems. Unlike the larger series, the K8 does not have a loader interface and is therefore positioned as a robust, easily accessible standard machine. The K10, on the other hand, expands the cylindrical grinding portfolio to offer greater flexibility and enhanced process support. The universal grinding head accommodates two external grinding wheels and a directly driven high-frequency internal grinding spindle with a grinding wheel speed of up to 60,000 rpm. In addition, there are longer X- and Z-axis travel ranges, an automatic B-axis, and an enhanced user interface. Features for structure-borne noise detection, semi-automatic balancing, quality measurement, and grinding time monitoring demonstrate that the machine is not only more versatile but is also designed to support guided operation, reduce setup time, and facilitate process monitoring.
Emag highlights the importance of coordinated process chains. Components are prepared during the preceding manufacturing steps so that only the amount of material that is actually necessary is removed during the grinding process. Grinding is therefore not viewed as an isolated corrective operation, but rather as a precision process used strategically within a production chain designed for economic and efficient operation. Particularly for high-precision functional components, this approach can help reduce machining times, tool wear and process costs without compromising the required dimensional, geometric and surface quality. This process chain approach can also be applied to new fields of application. The production of components for humanoid robotics is a particularly prominent focus here. Such applications require high-precision gear, shaft, screw, and actuator components, where motion precision, noise levels, load-carrying capacity, and service life depend directly on the manufacturing quality. This creates new demands for flexible yet cost-effective machining solutions that effectively integrate the various process steps, from rough machining to finishing. The key factor here is not just the specific machine concept, but the ability to handle a variety of machining tasks within a comprehensive manufacturing strategy.
Chucking systems for complex components This approach is also reflected in the clamping technology. Flexible process chains require chucking systems that can securely hold components with varying geometries, hardening distortion, or thin walls with minimal deformation. Emuge, a German clamping technology manufacturer based in Lauf an der Pegnitz, offers additively manufactured clamping sleeves designed for the flexible clamping of various components. Emuge manufactures these clamping sleeves using laser deposition welding and incorporates longitudinal, meandering clamping segments as well as honeycomb structures that would be difficult to produce using conventional manufacturing methods. These structures are designed using FEM to specifically adjust radial expansions for internal tension and radial contractions for external tension. This eliminates the need for separate rubber components, which are frequently used in traditional clamping systems. Grinding as a post-processing step plays a key role in the production of additively manufactured clamping sleeves, since it is only through the machining of the inner and outer surfaces that the surface topography required for precise clamping is achieved. This method is particularly suitable for hardened workpieces with hardening distortion, thin-walled components, and workpieces with varying geometries, where uniform force distribution and minimal clamping distortion are required.
Self-monitoring grinding processes, AI and sensor technology Based on these flexible chucking systems and machine and process chain concepts, another trend emerged at Grindinghub 2026. Manufacturers are increasingly designing grinding machines and related machining systems for autonomous production processes. The term “autonomous manufacturing” should be used with caution in a technical context. This does not refer to a ma-
Source: VDW/ Uli Regenscheit
Machining Accessories
chine capable of making its own decisions, but rather to a manufacturing cell that, once set up, can operate stably over an extended period of time, under supervision, and with minimal manual intervention. As a result, the operator’s role is shifting more toward process preparation, monitoring, and organisation and away from direct machine operation. Rollomatic, a Swiss machine tool manufacturer based in Le Landeron, addressed this trend with an automated tool grinding solution that combines a grinding machine, robotic handling, and a workpiece storage system into a manufacturing cell that requires minimal operator intervention. The focus was not on individual automation components, but rather on the ability to produce different tools in a reproducible manner over an extended period of time following an initial setup. From a technological standpoint, this illustrates the transition from automated individual machines to autonomous tool manufacturing cells. This form of low-labour manufacturing is becoming increasingly important, particularly in tool grinding, where there is a wide variety of product variants, a high demand for skilled workers, and stringent quality requirements. A similar approach is taken by Häberle of Laichingen — a German specialist in CNC technology and robotic automation — in its automated grinding wheel preparation process, developed in cooperation with Fanuc Germany of Neuhausen auf den Fildern, the German subsidiary of the Japanese automation specialist. This process combines spark-erosion dressing of conductive grinding wheel bonds with robotic handling, a setup station, and a digitally managed job sequence, thereby integrating it more fully into an automated manufacturing environment. Depending on the tool dimensions, this means that up to 100 tools can be prepared for use autonomously. This approach reduces downtime — especially when tools are changed frequently — and relieves the grinding machines of the need to perform dressing tasks beforehand. Wema Glauchau demonstrated another example of process control with greater feedback using the Wotan Dynamic Rest. The grinding of long, projecting components often involves deflections that can vary depending on the workpiece geometry and the grinding process. Steady rests are used to provide additional support for the workpieces. The dynamic steady rest not only supports long, slender workpieces, but also enables active tracking to compensate for minimal positional deviations during machining. This marks a step toward a
Idea-4X expands spindle technology to include data connectivity and digital condition assessment.
ETMM-TIP Plan your visit to the next edition of Grindinghub in 2028: www. grindinghub.de/en/
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Precision grinding and gear grinding for high performance drive components in robotics.
Source: VDW/ Uli Regenscheit
Source: VDW/ Uli Regenscheit
Machining Accessories
Additively manufactured clamping sleeves enable flexible, low-deformation clamping of various components through FEM-optimised honeycomb and meander structures.
more controlled component guidance process, moving away from a setup and support process that has, until now, relied heavily on experience. Technically speaking, this is a closed-loop approach for dynamic position correction in external cylindrical grinding. This is particularly relevant for long, flexible components, because the workpiece position, deflection, and roundness errors directly determine the achievable dimensional accuracy. The dynamic steady rest transmits the feedback directly to the workpiece’s support and positioning mechanism. The same approach is also evident in the identification and evaluation of machine and spindle conditions. The focus here is less on the direct mechanical compensation of individual deviations and more on the
Manufacturers are increasingly designing grinding machines and related machining systems for autonomous production processes. structured collection, processing, and utilisation of condition data as the basis for monitorable and, in the future, more autonomous manufacturing processes. With Idea-4X, GMN of Nuremberg took the concept of the sensor-integrated spindle a step further toward a networked spindle and data ecosystem. While Idea-4S laid the foundation for collecting spindle and condition data via a standardised IO-Link connection, Idea-4X expands on this approach by offering more highly networked analysis, communication, and service capabilities. Condition variables such as vibration, rotational speed, temperature, shaft growth, and operating data are thus no longer viewed merely as individual values, but are aggregated into an interpretable representation of the machine’s condition. The spindle is thus viewed more as a data-driven process module that supports monitoring, maintenance, digital documentation, and, in the future, process optimisation as well. Digital twins and digital product passports provide the spindle or machine with a digital identity, which allows technical char-
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acteristics, operating data, and service information to be presented in a more structured way. Idea-4X thus exemplifies the trend toward viewing grinding spindles not merely as primary mechanical components, but as data-bearing and network-compatible process modules. Neuron Soundware took a complementary approach by using acoustic AI to assess machine and process conditions based on characteristic noise signatures. This approach is attractive for grinding because spindle bearing conditions, incipient damage, or process anomalies are often accompanied by changes in vibration and sound patterns. Acoustic monitoring does not necessarily have to be installed directly in the working gap, but can be integrated into existing machine environments as an additional diagnostic layer. This expands condition monitoring to include a non-invasive method for the early detection of spindle and bearing abnormalities.
Grinding technology: The balance between process knowledge and system integration The future of grinding technology lies not in the isolated improvement of individual components, but in their targeted integration into stable, monitored, and cost-effective process chains. More powerful tools, more flexible chucking and support systems, optimised coolant delivery, process-optimised measurement technology, more autonomous handling solutions, and secure digital infrastructures are increasingly coming together to form a cohesive system. In this interplay, process knowledge, data, and automation are playing an increasingly critical role in determining productivity, quality, and resource efficiency. AI-powered and data-driven solutions complement this trend by making it easier to assess machine conditions, tool wear, process deviations, and quality characteristics. This lays the foundation for more closely monitored and, in the long run, more autonomous manufacturing processes. Progress in this area lies less in individual technological breakthroughs and more in numerous application-oriented, detailed improvements that make grinding processes more stable, more cost-effective, more transparent, and easier to integrate into end-to-end manufacturing strategies. (ast)
Machining Accessories
PRESSROOM EFFICIENCY
Cutting set-up times in giga-casting presses Large trimming presses for mega- and giga-casting require precise tool handling to avoid costly downtime. Automated die changing and hydraulic clamping systems help manufacturers complete changeovers in minutes while improving safety and process reliability.
Source: Stephan Auch/ Roemheld
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ocated in the German municipality of Moemlingen, Aulbach Automation ABK Pressenbau is a market leader in the manufacture of presses for trimming large castings. For more than a decade, it has relied on powered die changing systems, ball and roller bars, and die clamping elements from Roemheld. In modern mega- or giga-casting processes, a large, single-piece structural component is made of die-cast aluminium — anything from an individual subframe to an entire battery housing or a complete front or rear undercarriage. It replaces dozens of individual components, sometimes more than 100, that are normally welded together to form an assembly. The technology simplifies production, reduces weight and improves rigidity. However, the large component formats and heavy weights place extreme demands on post-processing operations. Aulbach Automation understands this well, as the 70-employee company specialises in the manufacture of trimming presses for the foundry industry. It has been working in the mega- and giga-casting sector since 2021 and by September 2025 had delivered 23 four-column presses for shearing off excess aluminium flash and other overflow material from castings measuring more than 3 x 2.5 metres. The main advantages of automated die changing, including for trimming castings, are reduced set-up times and increased reliability. The focus on the presses that Aulbach Automation supplies is on the accuracy of the changeover process. If dies are positioned inaccurately or clamped incorrectly, they can easily be damaged, or faulty components can be produced. In addition, with Roemheld products an operator benefits from high levels of ergonomics and safety. The table surface of an Aulbach Automation press incorporates Roemheld transport rails that feature hydraulic ball or roller bars that lift to allow the heavy lower part of the die set to roll in smoothly. Once it is aligned, the rails lower and the die rests flat on the press table. Set into the table are hydraulically-actuated, double-acting, swivelling clamping elements, also supplied by Roemheld. To avoid interference, the clamps are rotated out of the way at a 45-degree angle while the die is being rolled into place. Once sensors confirm the die is in the correct position, the clamps rotate through 45 degrees and move
Roemheld double-acting, hydraulically-actuated, swivelling clamping elements are set into the press table to secure the lower half of the trimming die.
ETMM-TIP Visit www.roemheld.com for application examples and product information on die changing and clamping technology.
downwards over the die edge with a force of between 60 and 412 kN. They are engineered to tolerate slight misalignments or edge variances of up to 1.5 mm. The upper half of the deflashing die must similarly be secured rigidly to the press ram. In this case, 90-degree hydraulic swivel clamps swing over the upper die and lock it to the ram surface, maintaining tight tolerances within a few tenths of a millimetre. As any slight misalignment with the lower die would cause catastrophic damage to the expensive tool and probably scrap the casting as the ram descends with typically 400 tonnesforce, the clamping system relies on a central Roemheld hydraulic unit equipped with electronic monitoring. Inductive proximity switches continuously monitor the precise physical location of the clamp, electronically verifying three distinct states: released, rotated, and clamped. If one sensor records a fault, the press is instantly locked out. The swivel mechanism is additionally protected by a spring-loaded overload device and a manual emergency control is in place in case of a sudden power outage. As downtime on mega- and giga-casting lines is costly, electronically monitored hydraulic clamping linked to a central control system enables multi-tonne die changes in minutes rather than hours, significantly increasing productivity. (ast) ETMM 4 | 2026
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DRY LUBRICATION
From aluminium to titanium: Sustainable machining Tool manufacturer HAM uses Knoll’s minimum quantity lubrication system to achieve high-quality machining results. The ultra-fine air-oil mixture provides cooling for materials ranging from aluminium to titanium while significantly reducing costs.
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inimum quantity lubrication (MQL) is still firmly embedded in many minds as a dirty and stickier process. A biased opinion, strongly contradicted by Raffael Eberle, who together with his parents Petra and Günter Eberle manage the business of the tool manufacturer HAM Präzision: “You can’t make such a statement. It comes down to the right MQL system. With the aerosol dry lubrication process provided by Knoll, an ultrafine air-oil mixture is generated that ensures the necessary lubrication and cooling during the machining process. Consumption is minimal; one shot glass of lubricant per hour is enough. No sticking or dirt can arise.” The trained production engineer knows exactly what he’s talking about: “After all, we are focussing intensively on machining as an area of application of our prod-
ucts.” HAM Präzision — Hartmetallwerkzeugfabrik Andreas Maier in Schwendi, Upper Swabia — has been producing solid carbide and polycrystalline diamond tools since 1969. “We have a standard range that covers many applications. But we primarily see ourselves as a solution provider for particularly demanding machining tasks. We help our customers optimise their processes, minimise cycle times and save on tool changes. To this end, we develop special and combination tools, which make up around 70 percent of our sales volume overall.” Raffael Eberle is enthusiastic about the process analysis and optimisation, which not only make in-house production more efficient. “Our experience in this regard is valuable for many customers, and it can be expanded in joint projects,” says the HAM Managing Direc-
Source: HAM
The solid carbide and PCD tools from HAM also have “mirror-smooth” surfaces and defined cutting edge preparations for catalogue goods so that the chip can flow off optimally. They are therefore perfect for minimum quantity lubrication.
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Machining Equipment
tor with conviction. But this requires a suitable test site and partner companies who are prepared to work on an optimised process chain. Against this background HAM decided in 2019 to look for partners and set up a Performance Centre with them that represents such a process chain — from the digital component and simulation through to the actual machining on the machine.
“We searched for and found suitable partners for the Performance Centre,” reports Raffael Eberle. “Today wellknown global players are represented here, such as Hermle, Knoll, Zoller, Solidcam, Lang Technik, Blum, Diebold and many more with whom we cover the entire process chain.” Together with these companies, HAM works on various projects and organises practical technology workshops on production optimisation several times a year. Managing Director Günter Eberle, who mainly looks after technical tasks, adds: “Of course, we also use the HPC ourselves to show customers our solid carbide and PCD tools in action and to demonstrate cutting behaviour and process stability. The HPC is also available to our partners for their own testing or for customer demonstrations.”
Various cooling and lubrication variants
Source: Knoll
Representing the entire process chain
Raffael Eberle discusses with Ralf Spöcker, Regional Sales Manager at Knoll, how the Aerosol Master can be used for deep-hole drilling.
from other MQL systems in the particularly fine atomisation of the lubricant.” Benjamin Hailfinger, Knoll Product Manager for the Aerosol Master, clarifies: “Our patented procedure ensures that a very fine, stable aerosol is generated from a synthetic oil and air, which we apply directly to the cutting edge, also at high speeds. If the oil droplets were bigger — as is the case with many other MQL systems — they would be hurled outwards by the rotation with the effect that they land not on the cutting edge, but on the machine wall. Our fine aerosol lubricates in the right place and virtually evaporates.”
Some of the key elements of the Performance Centre include a Hermle C 12 U 5-axis machining centre and its Open to changes cooling lubricant supply. This is supplied by Knoll Maschinenbau with a cooling lubricant-emulsion filtra- “Especially in the current climate where there is cost tion system and the modern MQL system Aerosol Master pressure and CO2 reduction is required, every machine operator should consider this 4000 ATS. HAM application cooling lubricant alternative,” engineer Marc Schäfer, who was involved in the setup of the says Raffael Eberle. “Because if Performance Centre from the one dispenses with emulsion, outset, clarifies: “In order to be which makes up at least seven able to meet current and future to ten percent of the costs of production challenges, it is imthe machining process, there is more savings potential than portant that we are able to repwith the tool that gives rise to resent and compare the machining process with different four to six percent of the macooling lubricant variants.” chining costs.” Knoll products have been HAM Präzision has now designed its standard catalogue playing a role in HAM’s own production for many years tools with MQL suitability. In now. Almost all machining addition to the geometric decentres are equipped with filsign, they also have the speciftration systems and chip conically developed HSF (Hybrid Marc Schäfer, Application Engineer, HAM veyors from the company Surface Finish), cutting edge based in Bad Saulgau. “When it preparation, as well as surface comes to perfect cooling lubricant supply and filtration, polish. This reduces the force transmission and heat deKnoll is our first point of contact,” highlights Raffael velopment, ensures optimal chip transport and avoids Eberle. The persons responsible at HPC gladly responded built-up edges. “These characteristics are important in to the recommendation of Ralf Spöcker, the responsible every type of machining process; particularly however Knoll Area Sales Manager, to also install the Aerosol in minimum quantity lubrication,” says Raffael Eberle. Master on the Hermle machining centre in the Perfor- HAM drilling tools for MQL machining also have a spemance Centre. “It wasn’t too complex,” confirms Marc cial shank chamfer, which completely seals the tool opSchäfer. “The Aerosol Master is only a relatively small posite the mounting. Raffael Eberle explains: “The low box. Hermle provided the required interface, and the rest pressure of only 10 bar, with which the Aerosol Master was virtually plug & play.” works, does not allow any parting or sinking of the meThe experiences HAM has gained with the aerosol dry dium. With our modified shank chamfer the aerosol lubrication are very positive. “This is an extremely inno- fully reaches the cutting edge and achieves the desired vative technology,” reports Marc Schäfer. “It is different success.” (ast)
“On our Hermle C 12 U we are able to move with emulsion, but also machine with air — i.e. completely dry, or simply with the aerosol dry lubrication system ATS from Knoll.”
ETMM-TIP Further information on the Hermle C 12 U machining centre used in HAM’s Performance Centre is available at www.hermle.de/en
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Machining Equipment
Source: Exxon Mobil
Effective lubrication helps CNC machines maintain precision while reducing friction, heat and wear.
EFFICIENT MACHINING
Elevating lubrication to a strategic advantage Europe’s metalworking industry faces cost pressures, foreign competition and skills shortages. For SMEs with limited investment budgets, effective lubrication offers a way to get more from existing equipment by improving productivity while reducing operating costs.
WRITTEN BY
Thomas Bergmann Senior Lubrication Field Engineer Exxon Mobil
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achining demanding alloys to tight tolerances, running unattended production and sourcing costly CNC replacement parts leave manufacturers vulnerable to downtime and scrap. Effective lubrication helps control friction, heat and wear, extending oil change intervals, cutting fluid life and tooling life while supporting precision and productivity. The benefits of a premium lubrication mindset are illustrated particularly clearly in one of the most demanding, high-precision manufacturing environments in the world: Formula 1 engine construction. At Oracle Red Bull Racing’s Red Bull Ford Powertrains facility in Milton Keynes, machine tools are regularly pushed harder than those in a typical commercial environment, both in terms of spindle speeds and round-the-
clock utilisation. The team asks its equipment to perform far beyond OEM specifications, placing immense pressure on both component reliability and machining precision. When everything functions seamlessly, lubrication can easily be taken for granted. But a minor lubrication-related problem can quickly become a machine-performance issue, directly impacting asset availability, longevity and part tolerances. The spindle represents a CNC machine’s most sensitive and valuable component, operating at extreme rotational speeds and severe thermal loads. Maintaining an effective fluid film is critical to supporting spindle performance and protecting against fatigue and wear. To protect these critical components in its 24/7 machining operation, the Red Bull Ford Powertrains team relies on
Machining Equipment
Mobil Velocite spindle oils. Formulated specifically for high-speed operation, these oils help maintain the appropriate fluid film and heat management under demanding operational cycles. Achieving micron-level accuracy depends not only on cutting tool quality, but also on the ability of the machine to make controlled, repeatable movements. Irregular actions caused by friction fluctuations known as ‘stickslip’ can disrupt repeatability and ruin tight tolerances. Red Bull Ford Powertrains uses Mobil Vactra Oil No. 2 for slideway lubrication to ensure smooth movement and rapid separation from metal working fluids, preventing the formation of contaminated tramp oil that degrades cutting fluids and accelerates tool wear. From Formula 1 to standard machine shops, reliable, defect-free production depends on controlling friction, heat and wear while maintaining repeatable movement. Lubrication plays a key role in meeting these requirements.
cations. Microscopic wear and friction can reduce the effectiveness of, or damage, any machine component. Adopting a “Zero Trust” approach to lubrication means proactively deploying premium oils and greases across all high-value, heavily-loaded and critical assets. This approach also addresses the shortage of qualified maintenance staff by reducing the need for oil changes and interventions, while securing unattended production runs against machine failure. The Process: Even the most advanced lubricant can perform poorly if it is stored or handled incorrectly or becomes contaminated. A premium lubrication strategy means moving away from a “set-and-forget” approach in favour of clean storage, contamination control protocols, and structured oil sampling. Like a blood test, regular lubricant analysis can provide an early warning indicator, helping teams identify wear, detect contamination and initiate predictive maintenance before any failure occurs.
Three ways to improve lubrication For European machine shops looking to adopt a more strategic, F1-inspired lubrication mindset, optimisation should focus on three key pillars: the product, the application and the process. The Product: Advances in lubricant formulation mean that premium products can offer performance characteristics beyond those of standard lubricants, including superior oxidation resistance and consistent viscosity across wide temperature range. In machining applications, these properties translate directly into extended oil, tool and cutting fluid life, reduced maintenance interventions, enhanced end product quality, and improved resource efficiency. The Application: In the IT world, a ‘Zero Trust’ architecture assumes security threats exist everywhere and extends protection to every single asset. Historically, machine shops have not used advanced lubrication solutions on a large scale, or reserved them for niche, appli-
ETMM-TIP For more information on industrial lubricants and their use in metalworking, visit www.mobil.eu
Making lubrication a bigger part of the picture Poorly managed lubrication is like running outdated software: a hidden operational vulnerability that can open the door to costly unplanned downtime. Just as cyber security evolved from a back-room IT concern to a boardroom resilience priority, lubrication should be seen as a critical risk-mitigation tool. By taking inspiration from Red Bull Ford Powertrains, commercial manufacturers would do well to shift their mindset from short-term purchase price to long-term total cost of ownership. This is not about spending more on lubricants. It is about thinking differently about them. By selecting lubricants based on technical performance, protecting high-value assets with a ‘Zero Trust’ approach, and monitoring fluid condition proactively, commercial manufacturers can transform lubrication from an overlooked maintenance expense into a powerful driver of precision, resilience, and profitability. (ast)
Machining Equipment
TOOL PRESETTING TECHNOLOGY
Process reliability through fully automatic presetting Berg Spanntechnik is optimising its production operations with Haimer’s Microset VIO linear tool presetter. The system delivers precise measurement results and enables a continuous flow of data.
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Sales Manager Christian Wenge explains: “We are specialists in sophisticated clamping technology that cannot be bought off the shelf. We manufacture almost exclusively customised solutions designed specifically for each customer’s particular application.” Accordingly, Berg clamping systems range from small to large and are
Source: Haimer
odular clamping systems for metal-cutting and forming machine tools form the core of Berg Spanntechnik’s portfolio. The company divides its solutions into four application areas: tool clamping, workpiece clamping, special applications and forming technology.
The machining center receives all actual tool data digitally from the tool management system.
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Machining Equipment
used in medical and energy technology, the automotive industry, general mechanical engineering and many other sectors. Based in Bielefeld, Germany, the company draws on more than 100 years of experience in developing, manufacturing and assembling sophisticated clamping technology. “What matters most to us is consistently delivering the highest quality so that our customers can also manufacture high-quality products,” says Christian Wenge, adding: “To achieve this, we operate state-of-theart production equipment that we are increasingly automating and digitalising — right down to the smallest detail.” Tool management plays an important role in this process. In 2021, Berg brought its system up to date by implementing the Coscom Eco system. Since then, all tools and tool holders have been stored in the system as digital twins. In recent years, however, one element was still missing for complete digital integration: direct data exchange with the tool presetter.
Tool presetting as an important element of machining production CAM programmer Oliver Oberkoch points out that Berg has been benefiting from tool presetting since the 1980s: “Back then, we still used manual devices to set and measure our tools before the machining process. Almost 20 years ago, we invested in a partially automated Microset Uno tool presetter, which already offered a certain degree of data transfer. Our current highlight, however, is the fully automatic Haimer Microset Vio linear tool presetter acquired last year, which also supports bidirectional data exchange with our tool and data management system.” Oliver Oberkoch, who is also responsible for digital tool management and coordinating tool presetting at Berg, explains the fundamental advantages of tool presetting: “Because the exact tool data is already available when the tool is loaded into the machine, we reduce machine downtime, increase precision and minimise rework and scrap. This gives us consistent and repeatable processes.” He adds: “Ideally, the presetter receives the target data directly from the tool management or CAM system and can then digitally transfer the measured actual data to the machine. That is exactly what we achieve with our new Haimer Microset Vio linear tool presetter.”
Choosing the high-end solution It quickly became clear that Berg would invest in a Haimer Microset unit. The production team had already been highly satisfied with its previous Microset devices. “Haimer shares our philosophy of quality,” says Oliver Oberkoch. “Ultimately, the decisive factor in our purchase was the outstanding quality of the technology offered.” The Microset Vio linear is designed as a complete solution in the field of fully automatic high-end presetting systems. Berg uses the standard 20/50 model, which is ideally suited to its requirements. According to Oberkoch, the 400-millimeter height capacity of a new Microset Uno — which was also considered — would not have been sufficient. By contrast, the VIO 20/50 can measure tools up to 500 millimeters in length, which Berg requires for applications including deep-hole drilling. ETMM 4 | 2026
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The Haimer Microset VIO linear 20/50 not only delivers highly accurate measurement results, but is also capable of exchanging digital data with a wide range of data and tool management systems.
Source: Haimer
Source: Haimer
Machining Equipment
Paperless manufacturing: Via the industrial PC’s touchscreen, the operator can digitally transfer the tools’ actual data to the machine, among other functions.
Thorsten Böker, Haimer’s responsible technical sales representative, highlights several technical details that are crucial to the unit’s quality: “The machine features an FEM-optimised, thermally stable gray cast iron construction that offers exceptional rigidity. As a result, there is virtually no distortion, even under the maximum permissible load. The linear drive is unique and ensures fast, quiet and highly accurate positioning. With a repeatability of ±2 micrometers and spindle runout
accuracy of 2 micrometers, the Vio linear meets the highest precision requirements.” Another important element is the ISS Ultra high-precision spindle. It uses the same clamping system as the production machine, enabling highly accurate measurement results that closely reflect actual operating conditions.
Open data exchange with a wide range of tool management systems A further decisive advantage of the Haimer Microset system is its openness to communication with third-party systems. Haimer Microset offers more than 50 interfaces to systems from various providers, underlining its flexibility and customer focus. “A key criterion for us was that our new presetter had to be able to exchange data with the Coscom software,” emphasises Oliver Oberkoch. “Haimer provided us with a perfectly functioning interface and also offered tremendous support by programming new postprocessors for our machining centers.” To make working with the Haimer Microset Vio linear as easy as possible, those responsible opted to install two monitors instead of one. This allows employees in the tool presetting department to view the tool assembly on one screen while the measurement software runs on the other. This ensures optimum workflows and gives the operator a direct overview of all relevant information.
Source: Haimer
Continuous digital workflow
The partnership with Haimer extends beyond the Microset presetting devices. Berg Spanntechnik also uses the Power Clamp shrink-fit machine, various shrink-fit holders and extensions, as well as other Haimer products.
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Sales Manager Wenge confirms: “With the Haimer Microset Vio linear and its connection to the Coscom software, we have taken a major step toward Industry 4.0 and simplified our system landscape around these two elements.” The improved digital integration significantly reduces the potential for errors. “Previously, it was still possible to import the wrong tool data by mistake. Today, that is almost impossible,” adds Oliver Oberkoch. “The NC program, along with all production-relevant information and tool data, is transferred through a standardised interface, resulting in an exceptionally high level of process reliability.”
Source: Haimer
Source: Haimer
Machining Equipment
Quality unites: Berg Sales Manager Christian Wenge (right) and Thorsten Böker, Haimer’s responsible technical sales representative, agree that high product quality is an important success factor for both companies.
This is how the end-to-end digital process works: When a new production order is received, the component is programmed in the CAD/CAM system. The tool data, or the digital twins of the tools, can be imported via the tool management system. Once programming has been completed, the tool data is transferred to the tool presetting department. The responsible employee retrieves this data and then knows exactly how the tools must be assembled for the program to run correctly. The employee then measures the tools using the Microset software and stores the tools’ actual data on the server via a Haimer postprocessor. At an IPC terminal located in the immediate vicinity of the machine, the machine operator can then retrieve the data sheet for the component to be manufactured and import the program. Using the same interface, the operator sends the tool data to the machine control and starts the machining process. Oliver Oberkoch points out that the fundamental advantages of tool presetting continue to apply. Oberkoch supported the introduction of the new Microset Vio linear from start to finish and has high praise for Haimer as a partner: “The support was excellent, whether in relation to the interface with our existing tool management system or the programming of the post-
At Berg, CAM programmer Oliver Oberkoch is responsible, among other things, for digital tool management and coordinating tool presetting. The Haimer Microset VIO linear ideally matches his vision of digital tool management.
“We also save time during setup, although the exact amount cannot be quantified because it varies depending on the particular production application.” Oliver Oberkoch, CAM Programmer, Berg Spanntechnik
processors. It was exactly the level of service we have come to expect from Haimer in other areas.” Berg Spanntechnik also uses many other Haimer products, including the full range of shrink-fit technology — from the Power Clamp shrink-fit machine to various shrink-fit holders and extensions. Berg also uses additional tool holders and shell mill arbors and is currently testing tools with a Duo-Lock interface for reaming hard materials. Oliver Oberkoch concludes: “It is a major advantage for us that Haimer is a full-system supplier covering the entire tooling environment around the machine tool.” (ast)
ETMM-INFO
Microset Vio Linear Tool Presetter The Haimer Microset VIO linear is a fully automatic tool presetter designed to measure cutting tools outside the machine tool and transfer the data digitally to production systems. Berg Spanntechnik uses the VIO 20/50 model, which can measure tools up to 500 millimetres long and achieves repeatability of ±2 micrometres. Its thermally stable grey cast iron construction, linear drive and ISS Ultra high-precision spindle support accurate measurements under conditions close to those in the production machine. Connected bidirectionally to Berg’s Coscom tool management system, the presetter receives target data and returns the measured actual values through a continuous digital workflow. This reduces manual data entry, setup-related machine downtime and the risk of incorrect tool data, while improving process reliability and measurement repeatability.
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Source: Dormer Pramet
Modern cutting tools are designed to improve machining efficiency, process reliability and component quality.
METALWORKING
New geometries raise machining productivity New cutting-tool developments from Tungaloy, Horn and Dormer Pramet address different stages of the machining process. Common development priorities include reliable chip control, fewer tool changes and stable machining under demanding conditions. WRITTEN BY
Alexander Stark Managing Editor ETMM
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F
lat surfaces on non-ferrous components are often machined using the end cutting edges of general-purpose solid end mills. However, their dish angles can make it difficult to achieve the required surface finish. Small-diameter tools also tend to have relatively few flutes, limiting productivity in high-volume applications such as D-cut and H-cut machining on sliding-head lathes. Tungaloy is addressing these requirements by expanding its Tung Meister exchangeable-head end-mill range. The system comprises more than 45 head geometries and several shank materials, covering diameters from 5 to 32 mm. The manufacturer offers more than 25,000 head and shank combinations for different machining applications. The latest addition is a face-milling head developed specifically for non-ferrous metals. Its geometry includes a wiper on the peripheral cutting edge to improve the resulting surface finish. A positive rake angle and sharp cutting edges are intended to reduce cutting resistance, while enlarged chip pockets help prevent chip accumulation.
Although the new series starts at a diameter of 12 mm, each cutter has six cutting edges. This allows higher feed rates than conventional four-flute solid end mills, according to Tungaloy. The tools are intended for high-volume production of small components, including D-cut and H-cut operations on sliding-head lathes. The compact cutters can also machine mating surfaces and internal seats in components such as motor housings. Operations that would otherwise require both a large face mill and a smaller tool can therefore be performed with a single cutter, reducing the number of tool changes.
Chip control for small turned parts With a new product, Horn is focusing on process reliability during grooving and parting off. The company has introduced its 1A chip breaker geometry for the 274 carbide insert system used on sliding-head lathes. The geometry is pressed into the green insert blank before sintering and is designed to control chip forma-
Cutting Tools
tion during turning. It can be used with different workpiece materials and is available in cutting widths of 1, 1.5 and 2 mm. Depending on the version, the maximum grooving depth ranges from 3 to 6 mm. Inserts are offered in the PVD-coated carbide grades TH35 and IG35, together with holders for different sliding-head lathe configurations. Accurate centre height is particularly important when machining small-diameter turned parts, as even minor deviations can affect workpiece quality. The operator should ideally be able to index an insert without having to readjust its position. Horn specifies repeatability of less than 0.02 mm after the double-edged insert has been turned and reclamped. The company attributes this to the combination of peripheral insert grinding and a stable insert seat.
Broader ranges for milling, drilling and turning Dormer Pramet is taking a broad approach with several additions to its portfolio, presented at AMB 2026 in Stuttgart. These cover solid-carbide end milling, micro and deep-hole drilling, as well as external and internal turning. The expanded S9xx solid-carbide end-mill range comprises 204 new square-end and corner-radius cutters. Metric and imperial dimensions are available, together with different flute lengths. Intended for machining steel, stainless steel and cast iron, the cutters combine a TiAlN coating with an optimised flute geometry. Dormer Pramet has also extended its Force drilling range. The additions include Force X Generation 2 solid-carbide drills for ISO P, M and K materials, Force Micro Drills in diameters from 0.7 to 2.95 mm and Force Deep Hole Drills for depths of up to 20 × D. The latter are designed to support chip evacuation and positional accuracy in deep-hole applications. For external radial turning, the company has introduced Polygon Shank Coupling holders. The modular holders are compatible with existing BS blades and can be assembled in either right- or left-hand configurations, allowing users to retain their current blades. New ISO S holders extend the range for internal turning. They feature an integrated coolant supply and are available in
longer versions for deep holes and difficult-to-access internal geometries. “These new turning and solid end milling products reflect our continued focus on performance, reliability and practical innovation. By combining advanced materials with intelligent design, we are helping manufacturers machine with greater confidence and control,” said Brian Davis, Vice President of PM and R&D at Dormer Pramet. Together, the developments show how cutting-tool manufacturers are addressing productivity at different points in the machining process. The approaches range from consolidating several operations in one tool to improving chip control and expanding solutions for specialised milling, drilling and turning tasks. (ast)
ETMM-TIP Discover further cutting-tool developments, applications and industry news in the ETMM topic section: https:// www.etmm-online.com/ cutting_tools
CAD/CAM & Software
INDUSTRY TRENDS
How AI is making CAD/CAM smarter AI has moved well beyond the buzzword stage, and the tool and mould making industry is no exception. Manufacturers are increasingly weaving AI-powered solutions into core production workflows and CAD/CAM is where much of that transformation is now visible.
Contributing Editor ETMM
A
rtificial Intelligence (AI) is moving beyond experimental applications in tool and mould making. Manufacturers are increasingly integrating AI-supported functions into production workflows, with CAD/CAM systems emerging as one of the principal areas of application. Software providers including Siemens, Mastercam and Open Mind Technologies have introduced AI-based tools intended to support design, programming and machining processes.
AI is steadily working its way into CAD/CAM systems to make design and manufacturing workflows faster, smarter and less dependent on manual trial and error.
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AI has developed rapidly across a wide range of industries, taking on tasks that previously depended largely on human judgement and expertise. According to market research company Grand View Research, the global AI market is projected to reach 3,497.26 billion dollars by 2033, representing a compound annual growth rate of 30.6 from 2026 to 2033. Within CAD, or computer-aided design, and CAM, or computer-aided manufacturing, Artificial Intelligence
Source: ©LA Stock Vision - stock.adobe.com
WRITTEN BY
Ahlam Rais
CAD/CAM & Software
can help automate individual tasks, provide technical guidance and reduce the need for manual trial and error. For tool and mould makers, these capabilities could shorten programming times and make specialist knowledge more accessible.
AI assistants in CAD/CAM CAD/CAM technology is used to support precise design processes, automate workflows and prepare CNC machining operations. AI assistants integrated into these platforms can draw on software documentation, training materials and production data to provide guidance in natural language. These tools can help new users become productive more quickly while allowing experienced programmers to spend less time searching through menus, manuals or internal documentation. This could be particularly relevant to tool and mould makers facing shortages of skilled programmers and machinists. On the design side, Siemens offers its natural-language Designcenter Copilot within the Designcenter CAD software. The conversational assistant draws on existing information to answer technical questions, explain recommended practices and help users locate relevant documentation. Siemens also integrates several AI-supported functions into Designcenter X Solid Edge, its 3D CAD software for small and medium-sized manufacturers. These include a generative AI assistant and the Magnetic Snap Assembly tool, which accelerates component placement by applying constraints automatically. According to Siemens, the Automatic Drawings function can generate up to 80 percent of the required 2D drawing views with limited user input. These can include orthogonal, broken and isometric views with dimensions.
AI support for CAM programming On the manufacturing side, US-based CAD/CAM software provider Mastercam has introduced Mastercam 2026.R2. The release includes GPU-accelerated simulation and AI-supported assistance through Mastercam Copilot. According to Mastercam, the assistant allows machinists to adjust feed rates and spindle speeds across several operations using voice or text commands. Confirmation prompts are incorporated into the process, while the system supports approximately 200 toolpath types. It can also create machine groups based on verbal descriptions. A hands-free mode is activated using the keyword “Copilot”, enabling users to operate the assistant without using a keyboard. The system can also search the myMastercam video library and provide timestamped links to relevant sections of training videos. Siemens has meanwhile expanded its cloud-based NX X Manufacturing platform with the introduction of NX X Manufacturing 2606. The release adds a generative AI capability to the AI Make Machining Suggestion function, which uses large language models to recommend machining strategies for particular applications. Earlier versions based their suggestions on historical machining data and existing tool libraries. The new function can also produce recommendations without
relying on this history. According to Siemens, this allows users to examine alternative machining strategies that could improve efficiency or surface quality and reduce tool wear. While individual AI assistants support specific programming and information-retrieval tasks, some software providers are combining AI with rule-based automation, digital twins and other technologies to cover a broader proportion of the CAD/CAM workflow.
Combining AI with other smart technologies AI is increasingly being combined with complementary technologies to support more consistent CAD/CAM programming. One example is Hypermill Intelligence from
Within CAD/CAM, AI can help automate individual tasks, provide technical guidance and reduce the need for manual trial and error. Germany-based software developer Open Mind Technologies, which was presented at this year’s Mach engineering and manufacturing exhibition and trade show in the United Kingdom. The solution combines AI, rule-based processes and automation within a single platform. It is intended to address repetitive work, tooling errors, processing risks and the loss of specialist knowledge. Rule-based automation uses predefined parameters to perform recurring CAD/CAM tasks. Tool-based automation incorporates digital twins to help ensure that suitable tools, machining strategies and parameters are available in both CAM and manufacturing execution systems. These functions are supplemented by machine-based optimisation and the Hypermill Chatbot, which provides contextual guidance during programming. Together, the technologies are intended to support a more consistent workflow from planning to production.
AI becomes part of the CAD/CAM workflow AI-supported CAD/CAM functions can assist tool and mould makers with training, information retrieval, machining recommendations and routine programming tasks. Current developments from companies such as Siemens, Mastercam and Open Mind Technologies show how software providers are integrating conversational assistants, generative AI and rule-based automation into their platforms. The practical value of these functions will depend on the quality of the available data, their integration into existing processes and the ability of users to review AI-generated recommendations. Artificial Intelligence is nevertheless likely to become an increasingly common component of CAD/CAM workflows as manufacturers seek to address skills shortages and improve programming efficiency. (ast) ETMM 4 | 2026
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CAD/CAM & Software
AUTOMATION
The perfect marriage between CNC, robot and controller CNC Solutions has developed a Technology Package that seamlessly integrates CAM, motion control and robot execution. The system is said to deliver predictable multi-axis performance and significantly reduces commissioning time.
O
Integrating robot execution with CNC control connects offline programming with machining on the production floor.
n paper, a robot is just a set of joints and motors. On a production floor, however, it becomes something entirely different. CNC Solutions in Belgium learned that the hard way years ago, when teach-in methods that worked for simple pick-and-place began to crumble under CNC-class workloads. In milling, sanding, laser or plasma cutting paths, the motion isn’t a few hundred points; it’s millions. “For CNC processes you’re talking millions of points — you can’t teach a robot that; you need CAM,” recalls Managing Director Lander Debruyne. CNC Solutions had been building CNC-based paths since the 1990s and delivering turnkey cells long before “robot CNC” was fashionable. But as jobs grew more demanding — multi-axis milling, abrasive sanding, highspeed trimming — the usual controller-centric approach
buckled. The team needed a flow that started in CAM, simulated the real cell, and then drove the robot like a CNC — deterministic, predictable, and fast. Over more than a decade of projects (and hard-won lessons with Stäubli robots), they accumulated the know-how to do exactly that. What made Stäubli the constant? Precision and repeatability, yes — but also sealed construction that shrugs off dust and chips, and the ability to interface a CNC-style motion layer to the robot cleanly for trajectory execution. For abrasive work like grinding and milling, that combination proved decisive. The turning point was deciding to package the method, not just repeat it. CNC Solutions codified everything into a Technology Package: one stack that bundles the software layer, the motion control layer, and the robot — ready for an integrator to extend with their own PLCs, fixturing, and process equipment. The processes (milling, welding, sanding, laser cutting, and more) arrive predefined and tuned to the machine, so teams start from a validated baseline instead of a blank page. Under the hood are three pillars. First, Ency Robot, an offline programming (OLP) software, that accurately calculates toolpaths and simulates the entire cell for industrial robots. Second, a Beckhoff motion controller that commands the robot like a standard CNC — feeds, modes, frames, the works. Third, a Stäubli robot that executes those paths with the accuracy and duty cycle that production demands. That stack didn’t materialise overnight. As Debruyne explains, the team “deepened its expertise step by step,” optimising robot axis motions until the commissioning process behaved more like a CNC machine than a bespoke experiment. The result is a productised nucleus that other integrators can now drop into their cells.
Source: Ency
Why Ency became the accelerator
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CNC Solutions anchored the offline robot programming layer on Ency. Instead of spending hours on online programming with the robot idle, Ency simulates the whole cell, checks axis limits, avoids singularities, and runs full collision control — so commissioning time turns into production time. It is genuinely all-in-one: design, technology setup, toolpath calculation, and simulation in one environment, with a zero-code digital-twin builder and libraries of post-processors and robot models. In
CAD/CAM & Software
“Robots only pay back when you build a real solution around them.”
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short, the CAM you trust becomes the robot’s language — cleanly, predictably, repeatably. “Start from a familiar CNC environment and translate CAM strategies to robot motion” — that’s how the team describes the philosophy. The choice of Ency reflects that pragmatism: broad functionality for simple two-axis jobs and complex multi-axis cells, with code paths and models managed in-house so behavior stays transparent. Out-of-the-box processes include milling, grinding, deburring, polishing, blasting (wet/dry), plasma and laser cutting/welding, waterjet cutting, cladding, painting, cleaning, gluing, and more.
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Plug-and-play, in the literal sense The Technology Package goes beyond software. Plugand-play wiring means the Stäubli robot ties to the controller over a single cable; the package arrives with predefined processes specific to the cell. CNC-style modes (Auto, Manual, Home), feed overrides, and emergency-stop logic are standard. The system exposes process I/O and communication hooks for the plant network and supports speed control during automatic runs. Even the encoder-wheel-style manual moves are accounted for. And because every real cell drifts from spec, the details that usually chew up a month are already in the box: absolute/TCP/frame calibration, singularity handling, OPC UA connectivity, real-time path adjustments, and toolwear compensation. The most telling measure is how quickly integrators can move from “robot installed” to “first good part.” With Ency removing online robot teaching and the motion layer behaving like a CNC, teams skip the fragile handoffs and focus on fixtures, tools, and process windows. That change — compressing risk and time where it matters — turned CNC Solutions’ project know-how into a product. When the company brought the Technology Package to EMO Hannover 2025, it did so on two fronts: at Stäubli, where the package ran live, and at Ency, where the latest generation of the software demonstrated the exact CAD-to-cell workflow behind it.
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What made this package convincing High-accuracy robot CNC isn’t pick-and-place. Paths are dense, physics is unforgiving, and production hates surprises. Without offline programming tied to a CNC-style motion layer, you pay in idle robots, creeping timelines, and inconsistent quality. The Technology Package eliminates those penalties by making the robot behave like the machine your operators already trust — so you stop babysitting a pendant and start shipping parts. Debruyne sums up the journey without fanfare: “Robots only pay back when you build a real solution around them.” The Technology Package is that solution for CNCclass robot work — engineered, tested, and validated — born from a decade of production and the right combination of tools. (ast) ETMM 4 | 2026
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CAD/CAM & Software
QUALITY CONTROL IN AM
AI predicts hidden defects in metal 3D-printed parts Internal defects remain one of the biggest challenges for industrial metal 3D printing. Research teams from Korea and Germany have jointly developed an AI model that predicts how pore characteristics influence the mechanical performance of printed components. A breakthrough in quality assurance and part reliability.
A
ETMM-TIP
morphology and mechanical performance. The approach enables potential internal defects and their effects on component performance to be predicted during the process design stage, providing a new framework for defect-aware process design and quality management.
Reference: Data-Driven analysis relates mechanical properties to pore morphology in laser powder bed fusion; Acta Materialia; DOI:10.1016/j. actamat.2025.121751
Pore morphology matters more than porosity in metal additive manufacturing
An AI model predicts how internal defects affect the quality and reliability of metal 3D-printed parts.
Source: AI generated/ DallE
research team led by Dr Jeong Min Park of the Nano Materials Research Division at the Korea Institute of Materials Science (Kims), in collaboration with Dr Jaemin Wang and Prof Dierk Raabe of the Max Planck Institute in Germany, has developed an artificial intelligence (AI)-based model capable of assessing the likelihood and characteristics of internal defects during the process design stage. The research breakthrough is expected to improve the reliability of metal additive manufacturing components and support their wider adoption for industrial-scale production. Metal additive manufacturing has attracted attention as a next-generation production technology capable of creating complex, high-value components. However, its wider industrial application has been constrained by microscopic internal defects generated during the process, which can lead to component failure and reduced performance. Conventional quality assessment has focused mainly on simple indicators such as porosity. In practice, however, the impact on mechanical performance depends significantly on the shape, size, location and distribution of defects. To address these challenges, the researchers developed an explainable AI model capable of systematically analysing and predicting the relationships between metal additive manufacturing process conditions, defect
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The core feature of the developed AI model lies in its ability to analyse and predict internal defects generated during the laser powder bed fusion (LPBF) process in metal additive manufacturing based on morphological characteristics — such as shape and distribution — rather than simply the number or volume fraction of defects. By using microstructural images, the model automatically analyses pore size, non-circularity and spatial distribution, and directly correlates these factors with mechanical properties, enabling a quantitative explanation of how defects influence actual performance. In particular, the model is designed to explain why defects increase and performance deteriorates under certain process conditions, distinguishing it from conventional “blackbox” AI models whose decision-making processes are not transparent. The research team comprehensively analysed process conditions, powder characteristics, defect images and mechanical property data across various metal additive manufacturing materials, including steel, aluminium alloys and titanium alloys, and used these datasets to train the AI model. Through this approach, they established an integrated framework capable of stepwise prediction — assessing how process variables and powder characteristics influence defect formation, and how defect morphology subsequently affects mechanical performance. This technology could significantly improve the quality and reliability of metal 3D-printed components and accelerate their use in the production of high-value parts. In particular, it can support process optimisation and quality control in metal additive manufacturing for industries requiring highly reliable components, such as aerospace, defence and mobility. By reducing defect rates as well as material waste and rework costs, the technology is expected to enhance overall production efficiency. (ast)
CAD/CAM & Software
AUTONOMOUS PROCESS INTELLIGENCE
Teaching AI injection moulding expertise
Source: AI generated/ DallE
As skilled workers retire and factories become more global, manufacturers risk losing critical know-how. A new AI system combines generative and large language models to optimise injection moulding and transfer expert knowledge to operators.
I
njection moulding is a highly efficient manufacturing process, but also sensitive: even minor changes in temperature, humidity or material behaviour can lead to defects. For decades, maintaining stable quality has therefore depended largely on the experience and intuition of highly skilled operators. As many of these experts approach retirement and manufacturing sites become increasingly international, concerns are growing that critical process knowledge could be lost. Researchers in South Korea are now addressing this challenge with an AI-based approach. A team at the Korea Advanced Institute of Science and Technology (Kaist) has developed what it describes as the world’s first generative AI technology capable of autonomously optimising injection moulding processes, combined with a large language model (LLM)–based system designed to transfer manufacturing knowledge directly to the shopfloor. The work was carried out by a team led by Professor Seunghwa Ryu at the Department of Mechanical Engineering’s Innocore Prism-AI Center and has been published in the Journal of Manufacturing Systems. The first component of the research is a generative AI–based process inference technology that automatically determines optimal process settings in response to changes in environmental conditions or quality require-
Artificial intelligence is increasingly taking on a central role in process optimisation and knowledge transfer in injection moulding.
ETMM-TIP Publications: Paper 1: “Development of an Injection Molding Production Condition Inference System Based on Diffusion Model,” DOI: https://doi.org/10.1016/j. jmsy.2025.01.008/ Paper 2: “IM-Chat: A multi-agent LLM framework integrating tool-calling and diffusion modeling for knowledge transfer in injection molding industry,” DOI: https://doi. org/10.1016/j.jmsy.2025.11.007
ments. Until now, adjustments to factors such as temperature, humidity or target product quality have typically required repeated trial-and-error interventions by experienced workers. To overcome this, the team implemented a diffusion model–based approach that works in reverse, inferring the process conditions needed to achieve a desired quality outcome. The model was trained using environmental data and process parameters collected over several months from a real injection moulding factory. In parallel, the researchers developed a surrogate model that can stand in for actual production, allowing product quality to be predicted without running the real process. This approach reduced prediction errors to just 1.63 percent — well below the 23 to 44 percent error rates reported for established methods such as generative adversarial networks (GANs) and variational autoencoders (VAEs). Real production trials confirmed that AI-generated settings could reliably produce parts meeting quality requirements.
Natural-language support The second achievement is the IM-Chat, an LLM-based knowledge transfer system designed to address skilled worker retirement and multilingual work environments. IM-Chat is a multi-agent AI system that combines large language models with retrieval-augmented generation (RAG), serving as an AI assistant for manufacturing sites by providing appropriate solutions to problems encountered by novice or foreign workers. When a worker asks a question in natural language, the AI understands it and, if necessary, automatically calls the generative process inference AI, simultaneously providing optimal process condition calculations along with relevant standards and background explanations. For example, when asked, “What is the appropriate injection pressure when the factory humidity is 43.5 percent?”, the AI calculates the optimal condition and presents the supporting manual references as well. With support for multilingual interfaces, foreign workers can receive the same level of decision-making support. This research is regarded as a core manufacturing AI transformation (AX) technology that can be extended beyond injection moulding to moulds, presses, extrusion, 3D printing, batteries, bio-manufacturing and other industries. (ast) ETMM 4 | 2026
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Impulses
GOOD TO KNOW
events 2026 for the industry
7 8
CONGRESS
B2B Communication Days Würzburg, www.b2bdays.de
OCT
28 29
CONGRESS
Industrial Benchmark Summit Würzburg, www.industrial-benchmark-summit.de
OCT
SYMPOSIUM
User meeting on machining – Aerospace Würzburg, www.anwendertreff-zerspanung.de
3
DEC
Source: Stefan Bausewein Fotographie
Moments from past events
50 ETMM 4 | 2026