ETMM 02/2025

THE WHOLEWORLD IN YOUR HANDS!

REALTIME MOULD TRACKING

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Begin the journey to betterprofitability today. Visit us online or emailfromthe QRC below to receivea proposal that achievesyour goals for the future.

Mouldingthe wayforward

Springusuallybringsabreathoffreshair—andtheworldofmould makingisnoexception Yetthisyear,thebusinessclimatefeels particularly volatile. Still, let’s start with some encouraging news: Moulding Expo and Plastpol, two key industry events, are just aroundthecorner.ThesetradefairswillbringtogetherEurope’sleadingmouldmakersandplasticsspecialists,highlightingthecontinent’s pivotal role in global industrial sectors

However, there is no ignoring the growing turbulence in transatlanticrelations.U.S tariffsonsteelandaluminiumarealreadyleaving a noticeable mark on international business dynamics Ironically, it is American mould makers who are among the first to feel the repercussions Rising raw material costs are pushing up production costs — a move from the White House that is backfiring As I write this, a looming25percenttariffonallvehiclesnotmanufacturedintheU.S. threatenstofurtherdisruptthesector,withpotentiallysevereconsequences for suppliers and mould makers across Europe

What remains is a troubling mix of uncertainty and a slow erosion of trust that took years to build. Partnerships once seen as stable are nowfaltering—ordissolvingentirely Thesedevelopmentsunderscore theurgencyforEuropetostrengthenitsinternalnetworksandleverage its own capabilities In the field of mould making — a cornerstone of industrial value creation — Europe possesses tremendous expertise, innovationandquality Andthisstrengthextendsfarbeyonditsown borders.EventheUnitedStatesdependsonEuropeanprecision.Europe mustnowembracethisstrategicadvantage–withconfidence,unity, and foresight.

Thecurrentclimateisawake-upcall:theEUanditsmemberstates must take decisive action. Fair competitive conditions must be demanded, competitiveness must be reinforced, and Europe must take a firm and united stand. The upcoming trade fairs offer the perfect platform — not just for the exchange of ideas, but also for aligning shared interests Because one thing is certain: in a rapidly changing world,Europ uld ki i t ly tofthe olutio it is a driver of p

AlexanderStark, Editor, alexander.stark@vogel.de

COVER STORY

Compact injection mouldingp. 18

Promatrix uses Hasco's Streamrunner for precise earplug moulding, offering compact, defect-free production with quick delivery and flexible orders.

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NEWS

BY THE NUMBERS

6 Trends in key plastics markets

NEWS STORIES

8 Timtos: AI & robotics lead the future

TRADE FAIRS

10 Moulding Expo showcases innovative strength

14 Moulding Expo: Trade fair preview

16 Plastpol: Global plastics industry converges in Kielce

REPORTS

COMPONENTS

22 How Groth masters complex demoulding tasks

PLASTICS PROCESSING

26 Hansgrohe turns defective parts into premium products

28 Machine vision ensures perfect caps every time

30 Advanced moulding cell boosts production

Promatrix uses this 4-cavity injection mould for the production of earplugs.

CAD/CAM & SOFTWARE

32 Schunk ensures process reliability with NC simulation

MACHINING ACCESSORIES

36 Nano cooling lubricant boosts deep-hole drilling

39 Versatile robot for tough jobs

MACHINING EQUIPMENT

40 Turning centres drive innovation at Diamond Precision

42 One setup, endless possibilities

CUTTING TOOLS

44 Horn USA expands with own coating systems

46 The decisive role of efficient chip removal

QUALITY CONTROL

48 Rapid inspection of large, tighttolerance components

With the Streamrunner multi-component injection moulding solution, different plastic components and colours can be distributed in a very small space.

EDM EUROPE

EDM EQUIPMENT & SUPPLIES

34 Neptune Injection embraces EDM for unmatched precision

REGULARS

3 Editor’sMessage

49 Masthead

50 ISTMAWorldNews

Ranking February/March’s most-clicked articles on etmm-online.com

1. Machining Accessories: Koller Formenbau enhances performance with nano coolant

2. Management: Trelleborg expands aerospace portfolio with acquisition of Aero-Plastics

3. Markets: Tool and mould making in China is growing stronger

4. Additive manufacturing: 3D printing market: a look at the economic challenges

5. Software: EMO Hannover 2025 highlights smart data in manufacturing

Trendsinkeyplasticsmarkets

Globaldemandforplasticadditivesin2023–splitbyapplications

According to the latest market study by Ceresana, about 36.7 million tonnes of plastic additives are already consumed worldwide each year. The report predicts that sales of plastic additives will grow by an average of 3.3 percent per year until 2033.

Source: Ceresana

Source: https://www.precedenceresearch.com/automotive-plastics-market

AGILITY® CMMs

Renishaw’srangeofAGILITYCMMs is designed to maximise the advantages of theaward-winning REVO® 5-axismulti-sensor CMM system:

•Automated infinite positioning with surface finish, vision, ultrasound and dimensional inspection sensors

•Turnkey solution with afull range of expertservicesfrom Renishaw

•5-axis technology typically delivering 50% time savings and greater returnonQAcapital investment

INTERNATIONAL MACHINE TOOLS SHOW Timtos:AI&roboticslead

welcomed 4,163 international buyers from 90 countries.

thefuture

The Taipei International Machine Tool Show (Timtos 2025),co-organizedbyTaitra and Tami, concluded successfully. The six-day event hostedover1,000exhibitors across 6,100 booths at NangangExhibitionCenterHalls 1&2andTaipeiWorldTrade Center Exhibition Hall 1. Timtos welcomed 4,163 international buyers from 90 countries, a 5.1 percent increase from the previous edition. The top five buyer countries were India, Japan, China, South Korea and Malaysia,withdelegationsfrom Japan, India, Vietnam, the Philippines, Malaysia, Brazil and Mexico attending.

Timtos 2025 showcased six major industry trends: precision machinetools,keycomponents,full-scaleautomationandsmartmanufacturing,digitaltwin-drivenintegration,additivemanufacturing and expanded cross-industry applications. Innovations from Taiwan’smachinerysectorweredisplayedacrossaerospace,automotive, medicalandconsumerindustries,reinforcingTaiwan’sleadingrole inprecisionmanufacturingandintelligentautomation.Timtoswill return in March 2027 (ast)

ADVANCEMENT OF PUR FLOODING EngelandCannoncooperate

Engel and Cannon have entered a strategic partnership

The aim of this cooperation between two partners is to further develop innovative technologies for PUR flooding and enable industrial applications with even higher quality and efficiency

Engel refers to this technology as clearmelt and has decades of experience with it, as well as a multitude of customers and references. With the clearmelt process, components are coated with PUR directly in the machine after the injection moulding process. Now, Engel is strengthening its position through the partnership with Cannon. This cooperation combines long-standingexpertiseandisintendedtoleveragesynergiestocontinue offering customers forward-looking solutions. Engel contributes its expertise in injection moulding technology, while Cannon, with its expertise in PUR processing, optimises process reliability andefficiency Theclearmelttechnology,whichcoatsthermoplastic components with a durable PUR surface, is to be further developed and optimised through Cannon’s know-how. (ast)

INJECTION MOULDING

SapaacquiresMegatechIndustries

The Italian injection moulding specialist Sapa has announced the 100 percent acquisition of Megatech Industries, a European company specializing in plastic injection molding for the mobility sector Sapa aims to expand its position in the field of plastic injection moulding and to expand its international customer base and presence.

The deal marks a significant milestone in Sapa’s international growthstrategy,expandingitspresenceinkeymarketsandreinforcing its industry leadership The company plans to combine the strengths of both companies and further scale its one-shot technology Withthisacquisition,Sapaissettoapproach700millioneuros inannualrevenue,nearlydoublingitspreviousturnoverof360millioneurosfor2024.Thecompanywillconsolidateitspositioninthe Iberian Peninsula and Poland, while establishing a new presence in Czech Republic, Germany and Brazil. The acquisition also strengthens Sapa’s relationships with major OEMs, including Volkswagen Group, BMW Group and Stellantis (ast)

MANAGEMENT NEWS

HuskywelcomesnewCOO

Husky Technologies announcedtheappointmentof Balaji Suresh to Chief Operations Officer (COO). With over two decades of experience in global manufacturing, supply chain, and operational leadership, Suresh brings a wealth of experience to Husky at a pivotal moment in the company’s growth journey.

Suresh joins Husky from L3 Harris Technologies, whereheservedasVicePresidentofGlobalSupplyChain, leading enterprise-wide operations and supply chain initiatives. His career is marked by a strong commitment to operational excellence, digital transformation and strategic growth. He has implemented lean transformations, optimized complex supply chains and driven customer-focused solutions in dynamic industrial environments. As COO,hewilloverseeHusky’sglobalmanufacturingandsupplychain operations, ensuring seamless integration of digital solutions and lean manufacturing principles to enhance efficiency and customer experience. He will play a crucial role in strengthening Husky’s operational resilience and reinforcing its industry position. (ast)

Timtos

Balaji Suresh is Husky’s new Chief Operations Officer (COO)

Sour ce : Husky

Marco Volpato (left), President & Chairman of Cannon and Stefan Engleder, CEO of Engel

Sour ce En gel

Sapa completes the acquisition of European firm Megatech Industries.

Sour ce : Sapa

Control the opening sequence in your mold

EXTERNAL SUPERIOR PLATE SEPARATOR

2different options:

Three plate mold: Designed to make apre-opening movement in the mold cavity,before opening the mold to eject the part.

Leading double ejection: System to control 2sets of ejector plates when the injection machine actuates the upper setofejector plates.

Simple external installation, enables easy adjustingand maintenance.

EXTERNAL DOUBLE EJECTION

TRAILING DOUBLE EJECTION:

Double ejection system to control 2 sets of ejectorplates when the injection machine actuates the lower set of ejector plates.

EXTERNAL SYNCHRINIZED PLATES

SYNCHRONIZED PLATES:

Designed to allowsynchronized mold plates openings, regardless of their location. With acustomizable first stroke opening, and afree second movement.

Moulding Expo brings together the best that high-quality European tool, pattern and mould making and its supplier companies have to offer

STUTTGART TO HOST INDUSTRY LEADERS

MouldingExposhowcases innovativestrength

From 6 to 9 May 2025, Moulding Expo in Stuttgart will showcase cutting-edge innovations in tool, pattern and mould making. Industry leaders will present new technologies, smart manufacturing solutions and the latest in precision tools to drive global competitiveness.

From6to9May2025,theindustrywillmeetinStuttgart to discuss the latest developments in tool, pattern and mould making and to strengthen its competitiveness in economically challenging times As the toolandmouldmakingindustryfacesrapidtransformations,MouldingExpo2025emergesasapivotaleventfor showcasing cutting-edge technologies and fostering globalcollaboration.Withkeyindustryplayersunveiling their latest advancements, the trade fair serves as a crucial meeting point for decision-makers, suppliers and innovators.

Volker Nonnenmann, Managing Director of Nonnenmann,emphasisestheimportanceofMouldingExpoas akeyplatformforpresentingnewproductsandstrengthening global competitiveness: “Like the German industry, tool and mould making in the DACH region is also undergoing radical change and must overcome old procurementstructures.Worldmarket-leadingknowledge alone is not enough to remain globally competitive MouldingExpooffersanimportantplatform,especially

now.Wearepleasedtobeabletoshowournewproducts atthetradefair,whichwearelaunchingbeforethefair.”

The importance of continuous development is also emphasised by Hufschmied Zerspanungssysteme. At the trade fair, the company is presenting innovative technologiesandtools.ChristelHufschmied,Managing Director of Hufschmied Zerspanungssysteme, summarises: “Continuous innovation and the development of customer-specific solutions are crucial to remaining competitive as a European toolmaker With patented solutions such as the Graftor, we are increasing production capacity, quality and cost-effectiveness. Visitors to our stand can find out about our latest developments and tools.”

For Sodick Deutschland, the presentation of its high-precision eroding machines is the main focus at MouldingExpo Visitorscanseethemachinesinaction atthe99-square-metrestand.SalvatoreCocco,VicePresident of Sodick Deutschland, emphasises: “Moulding ExpoisoneofthemostimportantGermantradefairsfor

tool,patternandmouldmaking Sincethebeginning,we have used the trade fair to present our latest developments. When choosing an EDM system, accuracy, performance, energy efficiency and the cost per hour are themainfactors—andthisispreciselywheretheSodick + series comes in. Visitors can see the latest Sodick machines for themselves at Moulding Expo.”

ForWerkzeugbauWinkelmühle,MouldingExpoisan importantindustryeventforpresentingexpertiseinthe field of precision tools and modern production technology Tom Berthold, Managing Director of Werkzeugbau Winkelmühle, says: “Moulding Expo is one of the most importantdatesinourtradefaircalendar.Wearefocusing on important impulses in the field of smart manufacturingintoolmaking,theassociatedsuppliertechnologies and prospects for related research fields. As early as2023,wewereabletousethetradefairtosuccessfully positionourselvesasatoolmakerforindustrialprocesses and, at the same time, as a supplier of stamped, bent and plastic parts.”

MouldingExpopresstripshowcases Poland’sToolValley

PolandwasthedestinationfortheMouldingExpopress trip which marked the restart of international trade pressconferences.Followingthetripstohotspotsinthe tool,patternandmouldmakingindustryinPortugaland Slovenia, the focal point this year was the Bydgoszcz Industrial Cluster Tool Valley. During company visits, Shapers Poland and Intemo provided insights into tool construction and mould making in Poland

PiotrWojciechowski,ManagingDirectoroftheBydgoszcz Industrial Cluster Tool Valley, stated the following: “Our Cluster comprises 170 members, including universities, business environment institutions and 140 companies from tool construction and plastics processing that supply high-quality moulds and tools to the automotive industry, the medical industry, the cosmetics industry or manufacturers of household devices.”

The Polish Cluster will be represented at Moulding Expo for the first time on a joint stand. Wojciechowski continued: “After our visit in 2023, we will be delighted to present the quality and diversity of our Cluster this year with five to six companies on our joint stand.”

StephanBerzisthenewPresidentofISTMA Europe

The ISTMA Europe Meeting was held at the same time astheMouldingExpopresstrip.StephanBerzwaselected as the new President of ISTMA Europe during the Meeting and made the following statement: “Tool construction is an essential cog in European industry The current structural change calls for adaptation — from customer profiles and procurement and production cooperation agreements through to digitalisation. After more than thirty years in the industry, I want to use my experience and my global network to provide positive momentum and help shape the future.”

The focal point was a visit to the Bydgoszcz Industrial Cluster Tool Valley. The company Intemo was visited.

ETMM-TIP

More information about Moulding Expo is available at the event’s website at www.messe-stuttgart.de/ moulding-expo

Impactofeconomicsituation

AroundtablewiththepartnerassociationsofMoulding Expo and the ISTMA Europe Meeting provided insights into the current economic situation. Bob Williamson, President of ISTMA World, summarised: “The world market for tools and moulds is estimated to be 260 billiondollarsandisforecasttoincreaseto500billiondollars by 2033. Current challenges such as the shortage of skilled workers and supply chain problems are a reflection of global changes. Emerging markets in Asia representgrowingcompetitionforthewesterntoolconstruction industry This means that there is a need for action in terms of innovations and automation. Regional networks will also become more important in future.”

The European tool, pattern and mould making industryanditssuppliersarealsofacedwithmajorchallenges The current consumption and investment restraint can be clearly felt among tool construction companies, which depend to a large extent on the model cycles of their customer industries, and pose a great challenge.

Markus Heseding, Managing Director of the VDMA Precision Tools Association and the VDMA Measuring and Testing Technology Association, emphasised the importanceofMouldingExpoinviewofthecurrenteconomic situation: “Moulding Expo is the ideal platform in the heart of Europe to network with relevant decision-makers along the metal and plastics value-added chainsinregardtotoolconstructionandmouldmaking,

InjectionMolding Pioneer

discuss future projects and find innovative solutions. The trade fair offers a valuable international network and information which are extremely important, especially in difficult market conditions.”

“Itisimportanttorecogniseinthisrespectthatthetool constructionandmouldmakingindustryintheD-A-CH area is inexpensive,” said Prof Dr.-Ing Thomas Seul, PresidentoftheAssociationofGermanToolandMould Makers(VDWF):“Theworkoftoolmakersisgoodvalue for money! Although their tools and moulds are not cheap,theyactuallyofferrealvalue-addedwhichsuppliers from low-wage countries cannot afford: the large number of small and medium-sized enterprises in the industrysupplyvalidmeansofproductionfortheindustry—withprocessreliability,inaccordancewiththelaw and without unexpected risks.”

Strongtogether:JointstandsatMEX

All in all, trade visitors to Moulding Expo can obtain information, be inspired by innovations and exchange ideaswithleadingcompaniesfromvariouscountriesat numerousexhibitionstands,includingfourjointstands.

TogetherwithITsystemproviders,CNCmachinemanufacturers,materialdistributorsandcompaniesthatuse AIintelligencefornewmanufacturingprocessesinmodelandmouldmaking,theGermanAssociationforModel and Mould Making will be represented at Moulding Expo Helmut Brandl, Chairman of Marketing at Bun-

Inthisdossier,youwillfindallrelevantETMM articlesonthenextindustrialrevolution. www.etmm-online.com/tooling-industry

desverbandModell-undFormenbaue.V.:“Wehavebeen atMouldingExposincethefirstedition Thetradefairis regardedasanindicatorofthelatesttrendsinhigh-quality European model, mould, tool and jig construction andoffersanidealplatformforexchanginginformation onmaterialsandsoftware.Atourjointstand,wewillbe showcasing innovative technologies and materials that meet high quality standards and will shape the production of the future.”

The Bydgoszcz Industrial Cluster Tool Valley is home to a large number of companies from the tool and plastics processing industry and is considered the most important toolmaking centre in Poland Piotr Wojciechowski,ManagingDirectoroftheBydgoszczIndustrialClusterToolValley,says:“Wearelookingforwardto demonstrating the high quality of Polish companies at Moulding Expo No tool is too sophisticated for us — from injection moulds to extrusion heads and tools for thermoformingandrotationalmoulding,ourmembers offer a wide range of solutions. I am convinced that visitors will find a reliable partner at our stand.”

At the Cefamol joint stand, nine Portuguese toolmaking companies will be presenting state-of-the-art technologiesandprovidingvaluableinsightsintoPortugal’s strong manufacturing expertise. Manuel Oliveira, Secretary General of Cefamol, says: “Moulding Expo is a must for anyone interested in the future of the tool and mould making industry It provides access to ground-breakinginnovationsandleadingplayersinthe industry ThePortuguesecompaniesattheCefamoljoint stand will showcase cutting-edge technology and integrated and customised solutions based on decades of international experience.”

“Truetothemotto‘thinklocal, actglobal’,MouldingExpomakesit possibletoshowcaseyourselfto internationalcustomers.”

Ralf Dürrwächter, Managing Director, VDWF

In addition to toolmakers, suppliers, contract manufacturers and software providers will also be presenting their products at the VDWF joint stand.

Ralf Dürrwächter, Managing Director of the Association of German Tool and Mould Makers (VDWF), summarises: “Over 40 companies will be exhibiting at the VDWF joint stand. True to the motto ‘think local, act global’, Moulding Expo makes it possible to showcase yourselftointernationalcustomers.Asa‘Europeanhub’, the trade fair offers visitors a valuable platform to experience the performance and expertise of the industry.”

FlorianNiethammer,HeadofExhibitions&Eventsat Messe Stuttgart, also provided some important key figures about Moulding Expo 2025: “In May we are expectingover200companiesfrom16countries.36percentof exhibitorscomefromabroad.Afteroursuccessfulpress trip in Poland, we are really looking forward this year to welcoming tool construction companies from the Tool ValleyClustertoMouldingExpohereatMesseStuttgart at the start of May.” (ast)

Stephan Berz is the new President of ISTMA Europe.

TOOL CHANGER

Compact,scalabletoolchangingsolution

Machine engineering company Zimmermann has introduced the ZIM Rack tool changer, a compact and modular solution designed for its portal milling machines. This innovative rack magazine allows for the storage of up to several thousand tools without requiring additional space, offering a customisable system that adapts to individual production needs.

The development of the ZIM Rack wasledbyJonathanLutz,aseasoned mechatronics engineer at Zimmermann, who played a crucial role in refiningthesystem.Havingworkedextensivelyonmillingheadsandautomationsolutions, Lutzfoundhispassioninoptimisingtool-changingsystems.Assistingintheassemblyand installationisPeterWelchner,whobringsnearlythreedecadesofexperienceinmechanical assembly and international machine installations

The ZIM Rack provides optimal tool storage while occupying minimal space. The system minimises downtime by preparing tools while the milling machine operates. Unlike conventional chain-based systems, the ZIM Rack moves only the required tools, reducing overall wear and maintenance.

ThebasemodeloftheZIMRackoffers60slots,expandableinincrementsof30,ensuring manufacturershavetheflexibilitytheyneed.WithZimmermannprovidingboththemilling machine and tool changer, customers benefit from an integrated system with streamlined service and support.

Hall 6, Stand D40

PRECISION MEETS PERFORMANCE

PCDmillingcuttersforaluminium

Cutting tool specialist Horn has expanded its DM range of polycrystalline diamond (PCD) cutting tools by adding a range of mills specifically aimed at manufacturers looking to machine aluminium efficiently. The cutting geometries of a variety of tools, from simple end millstocomplexandmodularcombinationtools,havebeenoptimisedtomeetthechallengesofmachiningaluminium,takingintoaccountfactorslikechipformation,cuttingforces and surface finish

The tensile strength, elongation, hardness and yield strength of aluminium can be influenced by alloying elements such as silicon, magnesium, copper, zinc and manganese. The material can become soft during machining due to the development of heat, causing it to adhere to and even destroy the tool. It is therefore important that the cutting feed rate and spindle speed, as well as the type and quantity of coolant, are properly matched to the material. Horn's engineers can provide advice on selecting the correct machining parameters for specific aluminium alloys

The DM range is also suitable for processing other non-ferrous metals and technical plastics. The PCD grade consists of an advanced mixture of diamond grains of different sizes. As the volume percentage of diamond increases, so do the effectivehardness,toughnessand edge quality Strict quality standards are in place at the Tübingen factory to ensure that the tools, with their precision-lasered cutting edges, deliver a high level of performance and long service life.

Hall 6, Stand F5

TEMPERATURE CONTROL

Flexible,fastandsimple—magneticquick-holderformulti-couplings

Component supplier Nonnenmann offers users a broad product portfolio and solutions for temperaturecontrolandtubing Inordertocoverallapplications and customer requirements, variousseriesofmonocouplings, temperature-resistanthosesand accessory parts, as well as multicouplings, play an important role in daily customer contact.

Depending on the size of the machine, the dimensions of the mould, the number of temperature control circuits and the frequency of the set-up processes, multi-couplings are part of the standard equipment of contract injection moulders and companies with their own injection moulding department Multicouplings enable several temperature control circuits to be coupled quicklyandwithoutconfusionwithjustone movement.Usingthese,upto12circuitscan be coupled in a single step, which corresponds to a total of 24 monocouplings for

supply and return This speed enables significantly faster set-up times and ensures higher machine utilisation in injection moulding production. Process reliability is also increased because the couplings are permanently assigned to the temperature control circuits and can no longer be con-

nected incorrectly during the set-up process.

Since the beginning of the year, Nonnenmann has been offering users a new option for attaching the multi-coupling to the tool with the Magnet-Quick-Holder,whichmakes assemblyeasier,fasterandmore flexible. The magnetic quick-holder can be ordered directly from the supplier as an accessory when purchasing a newmulti-couplingorasaretrofit kit.

The company offers the magnetic quick-holder suitable for the common multi-coupling series M009, M090, M109, M152 and M155. The standard mounting accessoriesofthemulti-couplingsarereusedduring assembly and supplemented by the magnet holders. This magnet solution can be used up to a temperature of 80 °C at the contact surface on the tool.

Hall 6, Stand D60

YourPartnerinSmallPitch,HighValueMoulding

ThenewMX09Nozzleisidealforsmallpitch,highvaluemoulding forthepackaging,capsandclosure,andmedicalmarkets.

Withaminimumpitchof20mm,apocketof14mm,anutdiameterof7mm andarangeofextendedtipsavailable,theMX09canfitintoverytightspaces.

MX09nozzlehasimprovedreliability,excellenttemperatureprofileandthermal stabilitybyincorporatinganadvancedmicrocoilheaterandthermocoupledesign.

Talktotheteamtodayaboutourwiderangeofhighperformancehotrunner andcolddecksolutionsbackedbyindustryleadingglobalserviceandsupport.

VisittheMastipteamatChinaplas2025onBooth#9F31 andlet’sdisussyournextproject!

WRITTEN BY AlexanderStark

Managing Editor

ETMM

Hundreds of companies from over 30 countries across Europe, Asia and the Middle East have confirmed their participation at Plastpol

PLASTPOL

2025

Globalplasticsindustry convergesinKielce

Kielce’s upcoming Plastpol exhibition serves as a key platform for showcasing groundbreaking global solutions, including live demonstrations of machinery. This increasingly international event plays a significant role in fostering new business opportunities.

From 20 to 23 May 2025, Targi Kielce again turns into a working factory when the latest technologies and solutions are presented at Plastpol Expo The latest plastic processing machines, including injection moulding machines, extruders blow moulding machines and recycling lines for plastic packaging production,willbeoperatinglive.Plastpolisalsoapresentation of companies involved in producing and distributing raw materials whose expo stands offer visitors the possibility to learn about the range of polyethene and polypropylene granulates, regranulates, various dyes and additives for plastics — including ecological ones

The organisers are convinced that making business decisions is much easier when observing machines working live and seeing latest technologies in action.

“Increasedprecision,energysavingsandintegrationwith

intelligentmanagementsystemsarethemostapparent trends. The new products presented recently highlight thesefeatures.Therewillundoubtedlybeanabundance of premiere machine demonstrations,” says Kamil Perz, Director of Plastpol at Targi Kielce.

Recordbreakingglobalparticipation

Cooperation and exchange of the latest technological ideasarecrucialforthedevelopmentoftheglobalindustry—thisistheessenceoftheInternationalFairofPlastics and Rubber Processing Plastpol. “Faced with the challengesfacingEuropeancompanies,weareworking to make our International Fair of Plastics and Rubber Processingmoreinternationaltoattractnewcompanies worldwide. We create an increasingly global business

spacetoprovideopportunitiestoestablishnewcontacts and conquer new markets. We have marked our presence at many industry events in Europe, Asia and the Middle East. In May 2024, over 600 exhibitors from 31 countries presented their offers at Plastpol. There are manyindicationsthattheMay2025expowillyieldeven better results,” says Kamil Perz.

Over 15,000 industry visitors from around the world are expected to attend. “The international character of the show is conducive to arrange new supply chains, contract negotiation, and networking and contacts establishment Leadsbecomecontracts.ThepreviousPlastpol abounded with agreements that boost companies’ developmentandenhancetheentireindustry The29th expo promises to be equally impressive,” emphasises Kamil Perz, adding: “Indeed, there is great interest in participating in the event. The Targi Kielce and Plastpol brands are well known, and companies trust them and wanttopresenttheirproductshere.Plastpol’sexhibitors’ listincludesmanynewcompanies,includinglargeones, fromaroundtheworld.Icanrevealthattheywillputup impressive expo stands.”

Innovation,sustainabilityandinsights

Duringthefourdays,theeventwillspotlighttechnology, rawmaterials,andbusinessmeetings,whiletheagenda is further enriched by conferences focused on sustainable development and recycling in the plastics industry Aspartoftheplasticsprocessingexpo,theprogramalso includes a conference organised by the Plastics Europe PolskaFoundation.ThePlastechInfoTechnicalSeminar welcomes representatives of important companies, top-players on the global market; Tworzywa.pl in cooperationwithTargiKielcearetheseminarorganisers.(ast)

Your guide to Plastpol

Visitors can purchase tickets online (9 Euros) or at the venue (18 Euros). A full-event ticket for all days is available for 90 złoty (20 Euros) online. For visitors purchasing tickets on-site, the prices are 80 złoty (18 Euros) for a single day and 200 złoty (44 Euros) for all days. Group tickets for school and university groups are also offered.

Parking is available at the venue. The expo will be open from 10:00 to 17:00 on May 20-22, with visitor registration and ticket purchases closing at 16:30 On May 23, the event will run from 10:00 to 15:00, with ticket purchases available until closing

Visitors can reach Targi Kielce by public transport using MPK bus routes 21 and 25 (stopping at Zakładowa or Targi Kielce) or routes 54 and 112 (stopping at Batalionów Chłopskich III). Those traveling by car can refer to the official event website for directions. www.targikielce.pl

Shapethe Future of Tool andDie Making

Experience unparalleledadvantagesatIndia’slargest exhibition fortool anddie makers.Connect with industryleaders,expandyour customer base,and showcase your innovations to acaptivatedaudience.

Organised by

TOOL ANDGAUGE MANUFACTURERS ASSOCIATION-INDIA

96534 27396 /97694 07809 tagma.mumbai@tagmaindia.org www.diemouldindia.org

Offeringa full line of world-renownedpolishing stones, diamond compound, andaccessories that will take youfromstart to final finish.

Compactinjectionmouldthanksto

The compact Streamrunner design optimises space while minimising melt volume and dwell time.

HascoStreamrunner

The Dutch mouldmaker and injection moulder Promatrix is specialised in aluminium moulds for prototyping and small to medium serial production of plastic parts. Hasco’s Streamrunner enabled the company to produce 0.15 g earplugs in a compact 4-cavity mould.

More than 25 years ago, Promatrix was one of the first Dutch companies to produce aluminium moulds, mainly prototyping moulds for automotive parts Today, these kind of tools still make up about 95 percent of the Promatrix mould portfolio The parts produced with these moulds are mainly used by theOEMsorTier-1companiestovalidatethedesignand test the parts, e.g. for crash resistance, paintability, etc.

Initsowninjectionmouldingdepartment,Promatrix produces half prototypes for the automotive industry andhalfarticlesforawiderangeofapplications,including for offshore customers. This includes components for bicycles, robot lawn mowers as well as 2K-applications, such as earplugs made of ABS, PA, TPE and much more

On its premises in Bodegraven, the Netherlands, the company has 18 injection moulding machines with clampingforcesfrom150to13,000kNforpartsassmall asearplugstoasbigascompletefrontbumpercoversor feeding troughs in livestock stalls. “So, we can produce everything in-house,” Rubin Klein, Team Leader of the EngineeringDepartmentatPromatrixpointsout.“From designingandmakingthetoolsthroughtheproduction of individual parts and even assembling complex units As we mainly use standard parts, we benefit from fast delivery times and can guarantee short lead times inhouse thanks to short distances.”

“Aswemainlyusestandard parts,webenefitfromfast deliverytimes.”

Rubin Klein, Team Leader Engineering Department, Promatrix

Promatrix customer service begins in the design phasetodeterminethebestoperationalsolution,based on product drawings and the process flow. The experts alsoconsiderthemanufacturabilityofeachproductand offer advice about potential modifications.

Prodevelop is a sister company of Promatrix and the client of the mould in which the Streamrunner is used. Prodevelop is responsible for the product development

of the hearing protection and automation around the production and assembly process

Since the beginning, Promatrix relies on hot runner technology from Hasco for most of its moulds, and for the serial production moulds for its own use, they also use a variety of Hasco standardised components, such as bushes and sleeves and much more.

Defect-freemouldingfortinycomponents

Forarecentapplication,aspecialassemblysurfacefora filter insert in an earplug, Promatrix decided to use a Hasco Streamrunner, due to the proven advantages of thishotrunnersystem,suchastheeliminationofblind spots, a particularly gentle material flow and thus a noticeable reduction in pressure losses.

The additively manufactured Hasco Streamrunner offers innovative hot runner solutions.

Source:Hasco

The main reason are the very small cavities in the 4-foldmould,thatmadeitnecessarytousethistechnology.Thecavitiesareinclined,whichmakesitevenmore complex. After injection moulding, the first part of the

With the Streamrunner multi-component injection moulding solution, different plastic components and colours can be distributed in a very small space.

earplug from 0.15 grams of transparent ABS the part is transferredintoanotherinjectionmouldingmachineby arobot.Hereamagnetandthefilterfabricareautomaticallyinsertedandfinallythepartisover-mouldedwith a polyamide ring to hold the actual filter in place.

“WeareusingtheStreamrunner,astheassemblyspace is really small,” explains Rubin Klein, “and since we processatransparentABS,wedon’twantanyblackspotsin the part.”

The compact design of the additively manufactured Streamrunner not only saves a considerable amount of space, but also, thanks to the gentle passage of melt through the optimised melt channel geometry, the amount of melt held can be kept to a minimum, minimisingthedwelltimeofthemelt,thusreducingtherisk of thermal degradation.

The additive manufacturing technology (selective laser sintering — SLS — of steel powder) used for the hot runnerdistributoroffersmaximumdesignfreedomand canbedevelopedindividuallyforeachspecifictaskand designed to be rheologically optimal on the basis of filling simulations.

Promatrixelevatesmouldproductionwith Hasco’sStreamrunner

“We are very grateful to Hasco for bringing the Streamrunner to our attention,” says Rubin Klein, “we were indeed not familiar with this system. Hasco helped us to solvethatproblemofthedesignlimitationswehadwith this application. And certainly, the fast reaction and delivery times helped us a lot. This is true for all Hasco products, as they have most of it in stock And should there be an issue, the copmpany is always available to solve it.”

“By the way, even 2K parts can be produced in one mould,” Gwen Bude, Area Sales Manager Benelux adds, “byusingaStreamrunnersystemwithtwodifferentflow channels, one for each material.” Source:Hasco

From left: Stefan Reich, Key Account Engineer Hasco hot runner and Arjen van der Linden, Technical Sales Engineer Hasco Mould Base with Rubin Klein, Team Leader Design at Promatrix in their production halls.

Promatrix uses this 4-cavity injection mould for the production of earplugs.

Sour ce Hasc o

The application of Hasco’s Streamrunner lifts Promatrix to a new level to create added value for its clients. Experience, technical knowledge and passion for makingarehiddeninthethreeimportantpillarsofthecompany: expertise, quality and machine park. In practice, this means that Promatrix can fulfil every wish in the field of moulds, injection moulding and prototyping.

“A good thing is, that we are rather flexible,” Rubin Klein explains, “most injection moulders don’t want ordersforjust3,000or5,000parts.Weareinapositionto meet such requirements This helps customers with a soft launch into the market for a certain product and after they made their first profits, they can invest in a serial production mould.”

Withabout45employeestoday,Promatrixisconstantlygrowing.Justrecentlytheymovedintoanewbuilding

ETMM-INFO

“WeareusingtheStreamrunner,as theassemblyspaceisreallysmall.”

Rubin Klein

andthenextbuildingtoexpandstoragespaceisalready in the construction phase

From the initial idea to the last shot of the injection mould,experiencedplasticsengineers,moulddesigners andmouldmakingexpertsfromtheHascoteamaccompany and support customers all over the world. (ast)

Innovations in hot runner technology: The Streamrunner revolution

The hot runner technology has made significant strides in recent years, and one of the most remarkable innovations is the introduction of the Streamrunner. This state-of-the-art technology has revolutionised the way manufacturers approach injection moulding, offering unparalleled precision, efficiency, and versatility

The Streamrunner is distinguished by its smooth material flow, ensuring an even distribution of molten plastic within the mould. This leads to improved quality of the final products and significantly reduces the risk of defects.

The Shadowfree Streamrunner is a notable variant that addresses a common issue in injection moulding: the formation of shadows or streaks on the surface of moulded parts. Conventional valve gate applications can cause such defects in sensitive plastics. The Shadowfree Streamrunner, however, utilises a special form of material flow within the hot runner that eliminates these imperfections, resulting in flawless, aesthetically pleasing components. The material flow is split into two or more sub-channels within the hot runner and merged when the valve pin enters the melt stream. This eliminates blind spots that typically form behind the valve pin. This makes it an ideal choice for applications where surface finish is critical, such as in the automotive and consumer electronics industries. Another exciting development is the Multicolour Streamrunner, which allows for the simultaneous injection of multiple colours or materials within a single mould. This capability opens up new possibilities for product design and customisation, enabling manufacturers to create complex, multi-coloured parts without additional assembly steps. The Multicolour Streamrunner is particularly beneficial for the production of consumer goods, toys and medical devices, where visual appeal and functionalit mount.

In addition to its technical advantages, the St runner also offers significant economic benef reducing cycle times and minimising materia manufacturers can achieve higher productiv lower production costs. The low height and re mould dimensions lead to cost savings due to energy requirements and the use of smaller chines.

Overall, the Streamrunner represents a majo forward in hot runner technology Its innovativ features, including the Shadowfree and Multic our variants, provide manufacturers with the high-quality, visually appealing parts with gr the industry continues to evolve, the Stream in shaping the future of injection moulding.

Source: Hasco

HowGrothmasterscomplex demouldingtasks

When it comes to demoulding complex undercuts, mould makers often use multilevel tools to clear elements that obstruct the demoulding direction. At Groth, mould makers rely on high-quality latch locks from their standard parts partner, Knarr, to drive such tooling solutions.

The latch lock controls the movement sequence of the individual moulding plates when opening an injection mould to eject the products.

WRITTEN BY

RichardPergler

Journalist

Pergler Media

The Claus Groth company, based in Vlotho, East Westphalia, Germany has been manufacturing complex and technically sophisticated injection moulding tools since 1948. In addition, the plastics specialists produce injection-moulded products in their inhousemouldingfacility Asafamily-runbusiness,Groth isareliablepartnerforclientsintheautomotiveindustry, mechanical engineering, furniture construction as well as transport technology

The company’s production experts can respond flexiblytocustomerrequirements—fromjustafewhundred parts per year to production volumes of up to two million. “We manufacture injection moulds up to a size of 800x600mm,”explainsJensStrate,ManagingDirector of the company located in the Lipper Bergland region. “Our injection moulding machines operate with clamp-

ingforcesofupto300tonnes Andforover30years,we havealsobeensupplyingourcustomerswithassemblies and plastic-metal composites.”

Themajorityofproductsaretechnical components

The mould maker currently employs 32 staff members. Inproduction,sixspecialistspershiftoverseethe20machines,whichoperateintwoshifts.Fourspecialistswork intoolmaking,whilefiveexpertsareresponsibleforthe assembly of the mould tools. The material receiving, storage and shipping departments each have two employees. The remaining staff members work in sales, management and administration. For design work, the companyreliesonexperiencedexternalspecialistsand

electrode manufacturing is also handled by trusted external partners.

The toolmaking department primarily processes standardtoolsteels,aswellascase-hardenedmaterials and occasionally stainless steel. Typically, the mould specialistsmanufacturetoolswithfouroreightcavities, designed for continuous operation and almost exclusivelyusedintheirowninjectionmouldingfacility The toolsareengineeredforhighprocessreliabilityandstability, meeting stringent quality standards. Tolerances of 10 µm or less are the benchmark.

Creativesolutionsforcomplextasks

The majority of injection-moulded products are technicalcomponents,manyofwhicharemadeofpolyoxymethylenes (POM). These high-molecular, partially crystallinethermoplasticsaregenerallyusedfortheproduction of precision parts, not least because of their high rigidity, low friction values and good dimensional stability However, other technical plastics are also processed on a large scale in Vlotho

TheteamaroundStrateoftenfindscreativesolutions for their clients. Especially when the workpieces have geometries that place high demands on the injection mould and especially on the demoulding. For example, when complex geometries with undercuts in the demouldingdirectionaretobeproduced.Thenthetaskof demoulding such parts quickly and gently is often a real challenge. Generally, tool and mould makers use slidersorjawswhenundercuts,notchesoropeningson injection moulded parts cannot be reliably demoulded using conventional mould separation.

Projectwiththreedifferentdiameters

Inarecentproject,theplasticsspecialistsmanufactured threeverysimilarcomponentsforchassisapplications, differingonlyintheirdimensions.Thediametersmeasure 62, 67, and 68 mm.

For this task, the toolmakers built three four-cavity mouldswithmultiplepartinglines,enablingthesimultaneousinjectionmouldingoffouridenticalblackPOM components per cycle. The exact order quantities are yettobedeterminedbytheclient,butGroth’smoulding facilityisfullypreparedforseriesproductionandexceptionally well-equipped.

The parts just before ejection. Before this step, undercuts must be cleared, and cores pulled. For this, the plate is moved on the nozzle side — the gap in the mould on the right illustrates the travel path before the opening at the parting line.

Thisalsohelpstopreventunwantednoise,amongother things.”

One challenge in the injection moulding and subsequent demoulding is the deep ribbing of the products —butalsotheundercuts,whichcouldnotbedemoulded withaclassicopen-closemoulddesign.“Theseareasare partly located in the depth of the cavity of the injection mould,” says Strate, outlining the challenge for the toolmakers. “We therefore decided to free the undercuts of theseplasticproductswiththehelpofunderfloorslides. In addition, an inner core must also be pulled out for demoulding.”

Safeejectionforcomplexcomponents

Underfloor slides are slides, but also core pulls, that the mould maker has installed below the parting line. They ensure that the undercuts are released just before the mould is actually opened. Underfloor slides are often moved with hydraulic cylinders, especially in larger tools.However,thistypeofdriveistoocomplexandalso toopronetoerrorforsmallermoulds Othervariantsare generally used here.

“WithKnarr,wehaveaverycooperative businessrelationship.Wecanrelyonthe highqualityandlongevity.”

Jens Strate, Managing Director, Claus Groth

“We then complete these parts in the assembly with anO-ringsealmadeofsofter,moreelasticTPEmaterial, which is firmly affixed to the POM part using adhesive dots,”saysStrate “TheO-ringsealisincontactwiththe metal of the vehicle and absorbs any small relative movements of the components to each other, which may arise, for example, due to vibrations when driving

“A proven method of pulling the slide gates in particularbeforedemouldingistodrivethemviaanadditional plate in the mould,” explains Strate “This is activated beforethepartinglineisopenedandtheresultingmovementensuresthattheslidegatesreleasetheplasticparts. This means that they can be easily removed from the nozzle-side mould half when the mould is actually opened at the parting line.”

Twolatchlockscontrolthemovement

Fouridenticalpartsareproducedintheinjectionmould with each shot. The cycle times are around 55 seconds. In the project for the three moulds for the chassis component, the moving plate is precisely controlled by two latch mechanisms, which are installed in the centre at the top and bottom of the injection moulding tool.

“The two latch units ensure that the mould’s parting line initially remains closed until the platen that drives the underfloor slide gates has reached its end position,” explainsStrate “Onlythendothetwolatchslidesrelease the opening of the tool at the actual mould parting line, the injection-moulded part is demoulded on the nozzle

The chassis components can be removed as free-falling parts or defined by robot extraction — for both options, Groth is well-equipped. Here, an employee is currently mounting the appropriate gripper

sideandfinallyejectedontheejectorsideandremoved by a robot.”

ThelatchlocksforallthreetoolscomefromthestandardpartsspecialistKnarr,basedintheFranconiantown ofHelmbrechts Knarroriginallyspecialisedinejection technology While still a leader in this area, it has since expandeditsportfoliotoofferacompleterangeandhas been able to convince many users, particularly in the East Westphalia region.

“We’ve had a very collaborative business relationship with our standard parts partner Knarr for many years,” emphasises Strate “The close contact with the field service plays an important role here, but above all, it’s the high quality and durability of all components. We can rely on that. We can be sure that wear and tear on the latch lock units will not be a problem in the foreseeable future.”

For the precise control of the movements in this tool, thehigh-qualitylatchlocksfromKnarrarethekeyfactor. The compact, pre-assembled unit enables the toolmakers to install it quickly and easily into the injection

Technical parts made from a wide variety of plastics are the speciality of the plastics specialists at Groth in Vlotho. For this, 20 injection moulding machines, mostly from Krauss Maffei, operate on a two-shift basis.

mould. Depending on the application, the control elements are available in both an on-mounted and pinned version as well as a recessed and inserted version The team at Groth opted for the on-mounted solution for these three tools.

In product development at Knarr, the developers placedgreatimportanceonsensibleinstallationdimensionsandpracticalstandardsizedefinitions.Knarrconfigures the control bracket and latch bar to customer specificationsintermsoflengthandwiththenecessary mounting holes. For the standard sizes, the standard parts manufacturer delivers the latch locks completely ready for installation.

“In processing, it becomes clear that Knarr supplies high-qualitycomponentshere—yougetagoodfeeling working with their products, you can feel the quality This applies to both the material and the precise workmanship Andtheaccompanyingdatafitsexactly.Then there’s the ease of handling during mounting — as the latchlockisalreadypre-assembled,Knarreliminatesthe otherwiselaborioustaskofassemblinga‘latchlockkit.’”

High-qualitycomponentsensureoptimal function

Latch Lock

The latch lock is a purely mechanical control element. It controls the movement sequence of the individual moulding plates when opening an injection mould to eject the plastic products. With a robust latching system for the latch locks, Knarr supports high process stability for the user — the latch lock securely locks the intermediate plate in absolute position accuracy. Collisions are inherently excluded. A significant advantage, especially for assembly and disassembly, is that Knarr has firmly integrated the internal components of the latch housing — it cannot accidentally fall out and does not need to be “assembled” first. This is particularly beneficial in complex assembly situations.

Withcarefullycoordinatedmaterialsandcoatedcomponents,Knarrguaranteesminimalwearofthelatchlocks, optimised service life, and thus significantly reduced maintenance. The fast opening and closing of the injectionmouldinapurelymechanicallydriventoolsolution alsoallowsfortheminimisationofcycletime.Alatching system on the latch lock, which locks the backing plate in position and thus prevents possible collisions, ensures a stable production process

“We can rely on the high quality of the standard parts, the ability to deliver and the professional advice from our standard parts partner Knarr,” summarises Strate “Although we also source material from other suppliers, Knarrisourgo-tofull-servicesupplier,especiallyforour smaller tools. We know that everything is taken care of and everything will fit, and we feel in good hands with our standard parts partner.” (ast)

Sour ce : Pe rg ler

Media

Hansgroheturnsdefective partsintopremiumproducts

Hansgrohe pioneers sustainability with a cutting-edge recycling system at its Offenburg plant in Germany. Developed with Impulstec and Getecha, the automated line reprocesses chromated injectionmoulded parts, achieving 98 percent raw material reuse.

The Hansgrohe Group is not only considered a leadingmanufacturerofpremiumbathroomandkitchenproducts,butalsoapioneerinthetechnological implementation of sustainability principles. A current exampleofthisisthecommissioningofafullyautomated recycling line for processing metallised faulty parts from the injection moulding production at the Offenburg plant. It was developed in close collaboration with the high-voltage experts from Impulstec and the mill manufacturerGetecha.Thankstotheinnovativesystem, analmostseamlessrawmaterialcyclecouldberealised. For some time now, the management at Hansgrohe have been putting their trust in granulation technology from Getecha. So when, Project Manager David Zapf, in his role as Specialist Surface Technology at Hansgrohe,

was setting up the development of a new recycling systemforthereprocessingofchromatedfaultypartsfrom the injection moulding production, he once again turnedtosystemsolutionsfromtheGermanmillmaker This time, an RS 30060 granulator and a GA 500 S extractionsystemwerechosenastheidealsolutionforthe newrecoverylineaftervarioustestruns.Theycoverthe processstagesofpre-shreddingandcleaningtheground material, including exhaust air filtering Their performance is of decisive importance for the level of quality that can be achieved in the subsequent stripping of the injection-moulded parts and the separation of the raw materials into a plastic fraction — in this case ABS — andametalfraction—hereamixofnickel,copperand chromium.

To implement the recycling system, David Zapf intensified his collaboration with Getecha and brought the high-tech company Impulstec on board.

Directrecyclingofrawmaterials

The chromating of the moisture-proof products (e.g showerheads)notonlyservestorefinetheirappearance, butalsotomaintaintheirvalue,asitprotectsthesurfacesfromcorrosionandmechanicaldamage Inmostcases, this involves a thin layer of only about 40 µm, which can account for up to 15 percent of the product weight. However, only injection-moulded parts with absolutely flawlesschromatingsurvivethestrictqualityassurance oftheelectroplatingprocessatHansgrohe,whichiswhy a constant volume of defective parts routinely accumulates. In view of the positive experiences that the company has already had with its in-house raw material cyclesfornon-metallisedscrap,thedesirearoseabouttwo yearsagotoestablishsuchacycleforthechrome-plated ABSmouldedpartsaswell.AccordingtoDavidZapf,the clearobjectiveherewas“todemetallisethecoatedproducts in such a way that the plastic content can be reintroduced into the company’s own new part production, while the highly concentrated metallic content can be sold on the market.”

Toachievethis,thesurfacetreatmentexpertnotonly intensified its collaboration with Getecha, but also brought high-tech company Impulstec on board. The reason for this is that the Radebeul-based special-purpose machine builder has developed a high-profile processbasedonhigh-voltagepulsetechnologythatmakes itpossible,amongotherthings,toseparatemetallicthin layers from chrome-plated ABS components using an electro-hydraulic shock wave treatment. An important prerequisite for achieving optimum efficiency here is thereliableshreddingofthegalvanisedfaultypartsinto ahomogeneousgroundmaterialwithalowdustcontent. “Gradually, our plan for the new recycling plant took shape as a highly automated processing line in which thecontinuouslyfedfaultypartsprimarilypassthrough three process stages: First, systematic pre-shredding with dust extraction, then separation of the chrome layer using the shock wave process, and finally magnetic separation,sothatweobtaintwopureplasticandmetal fractions, which we can then send for granulation and marketing,” reports David Zapf

Granulatoranddustextractionfroma singlesource

As with previous projects, Hansgrohe’s Project Manager placed the pre-shredding stage of the process in the capable hands of Getecha. This meant that the Aschaffenburg-based plant manufacturer not only provided the granulator — in this case a RS 30060 granulator — but alsothedustextractionandexhaustairsystemforcleaning the granulate. “This proved to be optimal. It meant we could directly connect the process engineering components of our material-selective electrohydraulic shockwave technology — such as the liquid medium

Sour ce : Hansgr ohe/ Impulst ec

The new recycling system is an automated processing line in which the galvanised defective parts first undergo a pre-shredding process with dust extraction, then a shock wave process, and finally magnetic separation.

“Thedemetallisedproductscanbe reintroducedintoourownproduction.”

David Zapf, Specialist Surface Technology, Hansgrohe

reactor At the same time, it ensured that our process could always work with perfectly conditioned ground material,” emphasises Stefan Eisert, Managing Director of Impulstec.

The RS 30060 from Getecha is a compact funnel mill with a modular design, featuring a 640 x 410 mm grindingchamberopeninganda300mmrotorcuttingcircle. Basedonthescissor-cutprinciple,3x2rotorbladesand two stator blades granulate the supplied scrap, which may have a diameter of up to 500 mm and a wall thickness of up to 8.0 mm. The rotor turns at about 420 rpm1 and is driven by a 15 kW three-phase motor in IE3 design. The special quality features of the granulator include, among other things, the external rotor bearing, whichrepresentsasignificantincreaseinsafety,andthe geometricprecisionofthecuttingcircle,whichensures consistently homogeneous granulation. Other design highlights are the segmented rotor structure, the solid belt pulley — which provides additional flywheel mass —andtheoverallgoodaccessibilityofallimportantcomponents.

Highlyinnovativewithgreatpotential

When the recycling plant went into operation in mid2024, it was clear to everyone involved that this was a highlyinnovativeandperhapsevenuniquesystemsolution.Thankstothenewprocessingline,Hansgrohecan currently reuse almost 98 percent of its raw materials. “Ontheonehand,wereceiveahighlyconcentratedmetalfractionthatprimarilycontainscopperandnickeland issoldforsmelting Thismeansthat100percentofthese recyclable materials are returned to the raw materials cycle. We also get the decoated ABS, which we use to manufacture new parts. This allows us to close the materials cycle at the site,” says Pascal Dengler, who is responsible for the smooth operation of the recycling plant.

Incidentally, since the new recycling system is designed for the demetallisation of up to 100 tonnes of chrome-platedplasticperyear,ithasnowenabledHansgrohe to create a hand shower product line for the premium Hansgrohe brand that uses only recycled granulate. (ast)

quality control system

PRODUCTION OF BOTTLE CAPS

Machinevisionensuresperfect capseverytime

Machine vision provides advantages in various applications, including quality assurance. It offers accuracy, speed, flexibility, and reliability. K&S Anlagenbau has implemented this technology for inspecting bottle caps.

Theproductionofbottlesandbottlecapsinthebeverage industry is highly automated. The reason is simple:largequantitieshavetobeproducedquickly and reliably. It is important that the processes keep pace with the speed but also with the quality requirements.“Ouraimistomakeautomatedprocessesassafe and reliable as possible. This is the lever for being able to operate a process at high speed in the long term. Our approachistotakethehecticoutofproductionprocesses Todothis,werelyonstandardisedtoolsthatallowus to manufacture reproducible products reliably and quickly. Based on machine vision, we have developed a solution for inspecting porcelain bottle caps,” says ThomasKelz,responsibleforqualitytechnologyatK&S Anlagenbau.

ThecompanyfromLengenwang,Bavariahasbeendeveloping automation solutions for the electrical, automotive,medicalandconsumergoodsindustriesforover

30years.Theengineeringcompanyspecialisesinstandardised modules with the option of individual adaptations. Together with the consulting firm Computer Vision Solutions Consulting & Research, they developed an application for the quality inspection of bottle caps for beverage bottles. This is primarily used to check the print image of the bottle caps. The consulting company was called in by K&S Anlagenbau because the team around Managing Director Dr Markus Heber has many years of experience in the implementation of sophisticated applications that are implemented with machine vision technologies.

Maximumflexibility,minimumofstops

Thechallengeindevelopingthenewsolutionwastoimplement a quality control system that quickly and reliablydetectsfaultsinafullyautomatedprocess,butisalso

Sour ce : K&S

The

performs inspections inline using the machine vision software Halcon

low-maintenance. Low maintenance means that the systemcanquicklyandeasilybeswitchedtootherproducttypesanddeliversreliableresults.“Automationonly brings decisive added value, if the customer has little effortinmaintainingthesystem,”saysDr.Heber Inthe newly developed system, quality control is carried out inline.Todothis,thecameratakesapictureofthebottle cap to be checked. The image of the imprint on the top of the cap is then checked using the algorithms of the machine vision software MV Tec Halcon

Thechallengewithprintimagecontrolisthevariability of the print images on the one hand and the requirement to create a clear operating concept for the system operator on the other hand. Possible print image errors could be, for example, incorrect or out-of-focus colours orimprintsthatarenotcompletelyvisible The“central” position of the print image on the bottle cap is also checkedandevaluatedasaqualitycriterion.“Oneofthe major challenges during implementation was that the number of different-looking print images is theoreticallyinfinite.Thisappliestoboththegood,i.e.,“OK”prints, andthefaulty,i.e.,“NOK”prints.Ourtaskwastherefore to ensure that the software was trained in advance to make the right decision at all times and for different prints,”explainsDr Heber Fortraining,theimageofan OK print, also known as a “golden sample”, is saved in Halcon. This “good image” serves as a template against which each image is compared during the inspection process.VariousparametersinHalconcanbeusedtoset thedegreetowhichdeviationsfromthe“goldensample” are still considered OK

Simplecontrolviagraphicaluserinterface

Animportantcomponentofthesystemisthegraphical user interface (GUI) The GUI is the operating unit with which,ontheonehand,theentiresystemcanbevisually displayed and overviewed and, on the other hand, changesandconfigurationsoftheprocesscanbemade.

The requirement for the GUI was that it can display severaldifferentappsdynamically.Theappsshouldalso beabletobecontrolledbothviatheGUIandthePLC.In the finished system, the setting options now include variousdisplayoptionsandconfigurationmodes,aswell

as different user levels This means that it is possible to assign rights and thus determine which employees are allowedtocarryoutwhichactivities.Troubleshootingor adjustments can also be made via the GUI. One adjustment,forexample,istosimplychangethetestprogram, e.g., if a different print needs to be tested.

“Thesystemruns flawlesslyasrequired andcanbeoperated highlyautonomously.”

Dr. Markus Heber, Managing Director, K&S Anlagenbau

One of the core components of the system is Halcon from MV Tec. Halcon is a machine vision library that is integrated into the K&S Control software using H-Dev-Engine. “I have been working with Halcon for over ten years. It is the industry standard in the field of image processing software and, with its large library, it is not limited to just a few algorithms,” explains Dr Heber H-Dev-Engine acts as an interpreter designed to dynamically load and execute the machine vision algorithms. H-Dev-Engine also enables changes to the machine vision processes on the fly without having to recompile or recertify the entire application. H-Dev-Engine acts as the image processing backend and communicates with the GUI in the background. System operators have little or no contact with it. This is because they operate the system via the GUI they are familiar with.

In addition to flexibility and stabilityinoperation,itwasofcourse also important for K&S Anlagenbau to guarantee robustness and high detection rates. ThisisalsoensuredbythemachinevisionsoftwareHalcon.ThisnotonlyincludesH-Dev-Engine,butalsomany image processing methods that are used to check the print images. In total, the Halcon library contains more than 2,100 different operators. Matching technologies, classification and blob analysis are used in the specific application.

The system ensures accurate defect detection in bottle caps using advanced technologies, including matching, classification and blob analysis.

IntheK&SAnlagenbauplant,classificationisusedfor qualitycontrol.Possibleerrorsincludecolourdeviations, missing edges, incorrect edges, or structures. Correspondingdeviationsaresegmentedandanalysedusing blob analysis. For this purpose, features are extracted fromconnectedpixelswithsimilarbrightness,theblobs. In this specific case, errors and deviations of a previously defined size are recognised as such.

If the machine vision technologies described find an error, this is displayed in the GUI. The corresponding area is detected by the blob analysis and highlighted in colour This also allows users to recognise the nature of the defect. If the imprint is “OK”, the bottle cap is processed further

Systemfulfillsrequirementsinuse

The system is already being used by customers. “The feedback we have received from the customer has been verypositive Thesystemrunsflawlesslyasrequiredand can be operated highly autonomously,” says Dr. Heber Specifically, the system can test 120 bottle caps per minute.Asaresultofthesuccessfulimplementation,Dr HeberisalsoworkingwithK&Sonnewmachinevision or 3D vision topics of this inspection application. The special feature is that each system is customised and adapted to the customer's requirements — just in line with K&S' claim to be a special-purpose machine manufacturer (ast)

INJECTION MOULDING

Advancedmoulding cellboostsprecision

Precision tool manufacturer PB Swiss Tools relies on Sumitomo (SHI)

Mathias Gerber, Urs Wespi (PB Swiss Tools), Klaus Rahnhöfer (Sumitomo (SHI) Demag), Peter Kirst and Urs Kocher (Mapag, from left to right)

Demag to deliver innovative multi-component, Mucell moulding cell, featuring index plate drive and automation — all from a single source: Sumitomo (SHI) Demag. Sour ce : S umit om o (SHI) Demag

Renowned Swiss hand tool manufacturer — PB Swiss Tools — recently installed one of the most innovativeinjectionmouldingsolutionsatitsproduction facility in Switzerland. Designed to boost productivity and maximise manufacturing precision, the fully-automated system validates Sumitomo (SHI) Demag’s expertise in engineering highly complex, multi-component moulding cells.

A fully collaborative effort, the cell comprises an efficient,energysavingIntelect350toninjectionmoulding machine. Equipped with the company’s latest multi-componentmouldingtechnology,itcanmouldthree different materials, including Mucell for the inner part ofthetoolhandle.Followingafour-stepprocess,thecell uses an ABB 6-axis robot coupled with an index plate drive to seamlessly rotate, present and remove the component after each overmoulding stage is complete. AcceptanceoftheplantinSchwaigtookplaceattheendof

May 2024, followed by delivery to Switzerland in July Commissioning is scheduled for the end of August.

Earlytechnologyadopters

PBSwissToolsisseenasa“lighthousecustomer”inSwitzerland reports Urs Kocher, Project Manager of Mapag, Bern, the company that represents Sumitomo (SHI) DemaginSwitzerland.“Weareimmenselyproudtohave supported such a prestigious customer This was only possible thanks to the hard work and diligent efforts of allpartiesinvolved-fromprojectplanningtoimplementation and delivery to the customer Sumitomo (SHI) Demag was able to provide its expertise as a prominent leaderinall-electricinjectionmouldingmachines,multi-component technology, special applications and automation,” adds Kocher

The production line epitomises flexibility As well as manufacturing new, ergonomically shaped handles for newproducts,thelineisalsoabletomanufactureawide variety of handle sizes from the existing PB Swiss Tools product portfolio For most products, the inner part of thehandleismouldedusingMucellfoamtechnologyto reduce weight and increase dimensional stability The handlecoreisthenovermouldedwitharigidmaterialto increasestabilityandstrength.Theprocessfinisheswith the application of a TPE overmoulding to give users a softer, more ergonomic grip. Using gripper recognition, each phase of the overmoulding process selects the correcttooldatainstructionsandmaterialshotweight.This alone was a complex challenge to navigate due to the mould tool set up and variety of polymers used.

Attheheartofthefully-enclosedproductioncellisan Intelect350/830-1100H-450L-450Ymachine.Delivering maximumprecisionwithparallel,dynamicmovements, the large mould space combined with high tie bar clearance,optimisestheworkingenvelop “Inprinciple,there arefourmouldingandovermouldingstations,”explains Klaus Rahnhöfer, Senior Business Development Engineer of Automation & Robotics at Sumitomo (SHI) Demag Mr Rahnhöfer is a proven expert in multi-component technology, with a wealth of experience in tool and mechanical engineering, plus integrated automationsolutions.BothKocherandRahnhöferdesignedand executed the project from start to finish.

PlasticsProcessing

Themulti-stepprocess

At station one on the operating side of the production cell,thecentrecoreofthetoolhandleismadeusingthe Mucell foaming technique. When the tool opens, the ejector moves forward and lifts the plate, rotating it 90 degrees counter clockwise. The ejector returns and the tool closes. “The parts are placed in the next station by retracting the index plate,” Rahnhöfer explains.

Station two is the L-injection unit. This is located in the lower part of the tool. Here, the inner handle grip cores are overmoulded with a harder material to increase stability and strength. After opening, the ejector advancesandliftstheplate,rotatesitanother90degrees counter clockwise, returns and closes the tool again.

Station three is the Y-injection unit. Here, a soft component made of TPE for high grip torques is applied to the product handle. Finally, at the fourth station, each partisstrippedbyahydrauliccorepullandscraper.This stageislocatedatthetopofthemouldtoolwherethere are no contoured inserts. This allows the mould to remainclosedsothethreeinjectionprocessescancontinue running uninterrupted. “The handles are mounted onbothsidesoftheirspinessotheycanbestrippedand removedbytherobot,”clarifiesRahnhöfer.Asaresultof the efficient design whereby product removal occurs at the same time as the overmoulding processes, the overall cycle time is reduced by approximately five seconds

Deliveringonprecision

PB Swiss Tools builds the grippers for the tool handles themselves, adjusting them to their different SKU sizes. “Each new grip size requires three pairs of new inserts. The toolmaker has done an excellent job here,” asserts Klaus Rahnhöfer, pointing out that combined with the moulding precision on all-electric machines helps to reduce material waste.

TheIntelectseriesisrenownedfordeliveringhighprecision and efficiency Much of this can be attributed to the company’s servo motors which are designed and built in-house. The dosing is fully electric to ensure the highest degree of accuracy The machine design also featuresauniqueautomatictie-barpullontheoperating side “The tie-bar hoists are normally only used in hydraulicmachines,however,wehaveadaptedthemtosuit our all-electric machines,” reports Rahnhöfer In addition, the servo motor of the index drive was integrated intothecontrolsystem.“Theprecisionoftheall-electric injection moulding machine was an important consideration,”confirmsMathiasGerber,PlasticsEngineering Manager at PB Swiss Tools. However, good service and innovative technologies that addressed all of the company’s requirements were decisive factors for choosing Sumitomo (SHI) Demag

The enthusiasm for this project was echoed throughout the plant. Urs Wespi, Production Manager at the PB Swiss Tools injection moulding plant reports: “Decades of experience working with technology installed by Sumitomo(SHI)DemagandtheMapagagencyfillsmewith confidence. The machines are not prone to failure. Yet, when you need support the service from the team is alwaysexcellent.Ifanyerrorcannotberesolvedwithtelephone support, a service technician comes within 24 hours. Few machinery manufacturers are this responsive.” (ast)

From additive manufacturing, robotics, machining to injection moulding, mould making and quality assurance – with toolcraft by your side, you can unleash the power of innovation.

As your technology partner, we bring together additive and subtractive manufacturing across the production process. This creates a unique consulting and manufacturing standard.

Schunkensuresprocess reliabilitywithNCsimulation

Schunk leverages advanced CAM programming and simulation software to enhance process reliability and efficiency in manufacturing. By simulating machining tasks, the company minimises downtime and ensures high-quality production.

Whenitcomestoprocessoptimisationinindustrial production, it's hard to overlook the gripping and clamping technology specialist Schunk The family-owned company stands out for its innovation, top quality, and solution expertise. This is also reflected in their own manufacturing, where the team works daily to produce the best possible components and products on high-quality machine tools, ensuring both process reliability and economic efficiency. AlongsideCAMprogrammingandautomation,thesimulation of manufacturing tasks before real machining, using Vericut, plays a crucial role.

When it comes to equipping robots and production machines,Schunkisago-topartnerformanyindustries worldwide Whether it's smartphones, airplanes, vehi-

cles, machines, knee joints, or nasal sprays: high-tech components from Schunk are often key players in their production. “Our components, applications, and services support our customers and partners globally in processoptimisation,”emphasisesFatihGülgönül,Headof Engineering He adds, “In addition to individual hightech components, we provide intelligent complete solutions for robotic systems as well as for various productionandautomationprocesses—allfromonesourcefor custom client applications.”

Highmanufacturingdepth,highquality

Due to its extensive product portfolio of over 13,000 standard components and 2,000 customer-specific

parts, Schunk’s main production sites in Lauffen and Hausen — north of Stuttgart — emphasise high manufacturing depth. “For us, each step of the process must deliver maximum efficiency with the highest quality That’swhywekeepallnecessarycompetenciesin-house and control every process step ourselves,” says Production Manager Steffen Gotzmann, highlighting the importance of in-house manufacturing at Schunk

At the Lauffen plant alone, about 250 skilled workers and over 150 CNC machines work in three shifts to efficiently produce various components, mainly for clampingtechnology,fromdifferentmaterials.Awalkthrough the production halls offers a great insight into Schunk's high-quality standards. In addition to well-organised production lines, the cleanliness and orderliness of workstationsstandout.Whetherturning,milling,grinding, or eroding, only top-tier machines from leading manufacturers are used.

“All core machines in our main production lines are CAM-programmed. This keeps downtime to a minimum,” says Gotzmann Schunk employs a total of 68 CAM programmers — nine of whom focus on custom clampingtechnologyforsmallerbatchesandorder-specific production. “In this department alone, we create around 3,000 NC programs annually for approximately 2,000custom-developed,designed,andproducedproducts,” Gülgönül explains.

Processreliabilityiskey

For both department heads, maximum process reliability is critical for a cost-effective production process, as waste is something Schunk cannot afford. Alongside CAM programming and automation, the simulation of productiontasksbeforeactualmachiningplaysasignificant role. “Machine simulation is a key element for a safemachiningprocess.Thesimulationintegratedinto theCAMsystemisnotenoughforus.It’scrucialthatthe simulation we run in the office perfectly matches the real processes on the machines, including the kinematicsoftheequipment.Onlythencanweensurethatwhat we’veprogrammedwillbeexecutedexactlyasintended,” GülgönülexplainswhySchunkusestheVericutsimulation and optimisation software.

“Vericut provided the complete package: the software delivers exactly what we need for efficient and safe production, and the Vericut team offers reliable support with their expertise,” explains Steffen Gotzmann. CAM administratorJuriBulingadds:“Whenmachinesareidle, it costs a lot of money, and we want to avoid that. That’s why investing in Vericut was the logical step.” With Vericut, the entire clamping situation — including the blank, clamping tools, machining tools, and the machine itself — can be simulated. According to Buling,

Vericut allows precise simulation of machining tasks, minimising downtime and improving process reliability

this virtual machining process has significantly increased process reliability in Schunk's production.

Currently, Schunk simulates 34 machine tools with VericutinLauffen:“Wecansimulateandoptimiseallour machines, including automated multi-channel turnmill centres — with 100 percent accurate kinematics. Wecanalsosimulatefeatureslikeengravingortransferringpartsfrommaintocounter-spindle—soVericutis anessentialpartofourprocesschain,”saysBuling Hans Erkelenz, Managing Director of CGTech Germany, adds: “Vericut simulates the real machine environment with precisemulti-axisandhigh-speedmovements,multiple setups,andcomplextoolshapes,providinginsightsinto potential collisions with holders or fixtures.”

Minimisedsetupanddowntime

ETMM-TIP

For more best practice cases visit www.vericut.com

Duetothewidevarietyofcustomer-specificsolutionsat Schunk,frequentsetupsarenecessary.“ThankstoCAM programming and Vericut simulation, we manage to keep these setup and downtime as low as possible. The NCprogramisalreadypreparedonthemachine,andwe know it works because we’ve verified it with Vericut,” Gotzmannexplains.ThisallowsSchunktouseavailable resources as efficiently as possible.

According to the production manager, having a verified NC program also gives machine operators more confidence, allowing them to run new parts faster and more effectively “Not to mention that we can optimise programs through Vericut without having to test them directly on the hardware — a significant advantage in times when continuous productivity increases are essentialtoremaincompetitive.”OptimisingNCprograms is especially crucial for series parts.

“Thesoftwaredeliversexactlywhatwe needforefficientandsafeproduction,and theVericutteamoffersreliablesupport withtheirexpertise.”

Steffen Gotzmann, Production Manager, Schunk

Since implementing Vericut, collisions have been eliminated at Schunk, and unnecessary costs due to downtimeareavoided.“Theprojectwaschallenging,so it's all the more remarkable that Vericut fully met the timeline,” emphasises Fatih Gülgönül. “Schunk is undoubtedlyaspecialclientforVericutduetoitsscaleand tight schedule,” notes Erkelenz. “Thanks to excellent supportfromSchunk,wewereabletointegratethefirst 30 machines into the simulation within a year — this waschallengingforourentireteam!I’mproudwewere able to meet all expectations 100 percent.”

ThenextstepsforSchunkarealreadyclear,asBuling concludes: “Our goal is to increasingly digitise all productionsitesandequipthemwithVericut—ultimately securing our competitiveness.” (ast)

DIE SINK MACHINES

NeptuneInjectionembraces EDMforunmatchedprecision

UK injection moulding and mould tooling company Neptune Injection has expanded its capabilities by adding two Sodick AD35L die sink EDM machines to its facility. The manufacturer relies on this high-precision technology for many advantages, including reduced lead times.

Aspartofitsongoinginvestmentinhigh-precision manufacturing technology, Neptune Injection hasexpandeditsmachiningcapabilitieswiththe addition of two new Sodick AD35L die sink EDM machines.BeingoneoftheUK’sleadinginjectionmoulding andmouldtoolingcompanies,NeptuneInjectionwhich ispartofNeptuneEngineeringhasgrownexponentially with the support of Sodick Europe and sole UK distributor Sodi-Tech EDM

The first Sodick machine was installed at Neptune Injection 12 years ago and now, the company has two AD35L die sink EDM machines, a compact high-performance Sodick VL400Q wire EDM, the market’s most precise entry-level machine — the VZ300L with linear

motor drives and linear scales and also the AD30L die sink EDM. This rapid uptake in Sodick EDM technology was set in motion in 2010 when Gary Statham acquired the business that has now been in operation for over 40 years.

Reflecting back at the start of the relationship with Sodick, Neptune Injection’s Managing Director, Gary Statham says: “The relationship with Sodick goes back to when I was an apprentice and we used Sodick machines. I then worked for another mould maker in the early 2000s and that company also had Sodick spark erosion machines. When I took over this business in 2010,thecompanyhadadifferentbrandofsparkerosion technology On the previous machines, the electrode

Neptune could reduce its lead times, reduce the time to spark and reduce the wear on electrodes with Sodick.

wearwasreallyhighwithverylongmachiningtimes.We knew from doing test cuts with Sodick that we could reduce our lead times, reduce the time to spark and reduce the wear on electrodes. This meant that we would needfewerelectrodestodoeachjobandtheresultwould be less machining time on our machining centres that produce the electrodes, creating additional savings in another department.”

Apartnershipbuiltonaccuracyandtrust

Now with more than 20 staff, ISO: 9001 accreditation andlights-outmanufacturingcapabilityattheHertfordshire business, Gary recalls: “When we started, there were just three of us at Neptune. I spoke to the sales engineer at Sodi-Tech as I wanted Sodick machines based onmyexperienceatpreviouscompanies.TheSodi-Tech engineer looked at the size of our company and helped usformulateapackagedealthatcamewithinourbudget and time constraints. They also provided additional training for our staff, helping us hugely along the way. When we needed backup, we would call Sodi-Tech and theywouldsendatrainingengineertous—theservice is exceptional. The machine and the service are great!”

It is this remarkable level of service for the industry-leading EDM machines that has seen the relationship flourish. Alluding to this, Sodi-Tech Director of Sales, Greg Capp says: “Over 12 years ago, Neptune approached us with the need for a machine for a specific job—wedeliveredthatmachine.Sincethen,theirbusiness has grown and Neptune Injection is not replacing machines but investing in new technology, which is growing their business even further Neptune Injection works in a range of different business areas and is after thesamethinginallofthesebusinesssegments—high accuracy, high surface finishes and repeatability With Sodick we can achieve all of those things.”

Underpinning this sentiment, Gary Statham from Neptune Injection adds: “We are a high precision toolmakingbusinessandthatiswhyweuseSodick.Theyare high-precision machine tools that give us the accuracy we require for the features that we are spark eroding.”

Reducingleadtimes,enhancing profitability

Spotlighting the longstanding relationship and its evolution, Greg Capp continues: “From a small business to where Neptune Injection is now, it demonstrates our great working relationship and that Gary trusts Sodick Thistrustisbuiltupontheknowledgethatthecustomer can get the same quality parts every single time when theyuseSodickmachines Thediesinkandwireerosion machinesworkhand-in-handandtheoperatingsystem is the same, so the staff using the machines can pick it upeasilyandinterchangefromonemachinetoanother.”

Recalling the transformation of the manufacturing sector and how Sodick’s advanced technologies and innovationshaveenabledNeptunetobeefficient,productive and competitive, Gary continues: “The lead times and prices on jobs can be so aggressive, so it’s very important to get it right. Around 15 to 20 years ago, you wouldbequoting16to20weeklead-timesforajob,now customers are expecting delivery in 6, 8 or 10 weeks. To achievethis,youneedtohaveamachinethatisextremelyefficientandcangiveyouexceptionalsurfacefinishes

andprecision—andquickly.TheSodickmachineshave linearmotors,sothepositionalaccuracyoftheelectrode is ‘spot on’ and within 2 µm. The surface finish goes downtoazeroVDI,whichmeansforalotoftheworkwe do,wedon’thavetohandpolishafterwards.Thisenables ustofinishtheentirejobonthesparkeroder—reducing our lead times, our internal costs and reducing our external costs for polishing, thereby increasing our profitability.”

Summarising how the Sodick EDM technology has enhanced manufacturing operations at Neptune, Gary says: “The footprint of the machine is small in comparison to the work envelope and this is great for us, as we don’t have the biggest facility. Furthermore, the manufacturing time is much faster than it is with other machine tool suppliers. What sets the Sodick machines apart from the competition is the repeatability, you can also achieve great surface finishes with a very fast cuttingtime.Onmachinetoolsfromotherbrands,youneed more electrodes to spark the jobs, which adds time and cost. On the wire machines, you often need to make additional cuts around the metalwork. So, rather than doingajobin3cuts,youmayneedtodofourorfivecutsto getthefinishedpart—thisextendstheproductiontime on other machines. On the Sodick EDM’s, we know that in three cuts we can achieve the impeccable precision and surface finishes that we need.” (ast)

“Weareahighprecision toolmakingbusinessandthat iswhyweuseSodick.”

Gary Statham, Managing Director, Neptune Injection

ETMM-TIP

Discover the latest advancements, expert insights, and cutting-edge EDM technologies at www.etmm-online.com/edm

A row of Sodick machines at Neptune Injection

Sour ce : Sodick

REDUCING FRICTION

Nanocoolinglubricant boostsdeep-holedrilling

Koller Formenbau has successfully increased the performance and process reliability of its Cheto IXN 3000 travelling column deep-hole drilling and milling centre with the Nano Coolant cooling lubricant — with impressive results.

The Cheto IXN 3000 travelling column deep-hole drilling and milling centre is a multifunctional machine that enables the complete machining of even large injection moulding tools.

When it comes to really large moulds and tools, Koller Formenbau in Hebersdorf is one of the top addresses. The experts specialise in really large moulds. The company is part of the Koller Group, which can map the entire value chain for its clients, primarily from the automotive industry, from the initial idea to component development and industrial series production — worldwide. In addition to large injection mouldingtools,largecompositetoolsarealsoproduced in Hebersdorf, Germany. Among other things, the expertsbuildlargetoolsforinstrumentpanelsorbumpers forexternalcustomersworldwideandprocuresmalland medium-sized tools

Koller Formenbau has responded to the growing dimensions of tools and moulds by consistently developing its machine pool. For example, the factory now has an OPS Ingersoll Gantry Eagle 2000, the world’s largest die-sinking EDM machine with a lowerable work tank, on which the mould makers also offer contract EDM in XXL.Inthemillingarea,too,thecompanyhasexpanded its capacities in recent years with high-quality largescale machining centres The latest and quite spectacularadditionistheChetoIXN3000deep-holedrillingand millingcentrewithatravellingcolumn—thefirstsuch machine in the German-speaking area.

Large injection moulds require suitably designed, effective cooling systems Until now, the necessary deephole drilling for this has been carried out by the mould makersonarangeofequipmentincludinganAuerbach AX6TLF deep-hole drilling centre. “We used to have a largeproportionofthedrillingdonebyexternalcontractors,” reports Production Manager Markus Ferstl. “Originally, we planned to continue outsourcing the drilling as before. But in order to achieve more flexibility here, wedecidedtobringtheseordersbackin-house.Inaddition, however, we also wanted to further develop our manufacturing processes technologically. And for that, we approached the market positively and openly and looked for the right machine for us. ”

Thinkingoutsidethebox

At the suggestion of Dremo boss Gasteier, the mould makersventuredtolookbeyondthefamiliarrangeofthe well-known relevant manufacturers At the Portuguese specialist Cheto, the IXN series impressed with perfor-

mance and technical refinements. In several meetings withthemanufacturerandwithusersinPortugal,those responsible were able to see for themselves the performanceandtechnicalpossibilitiesofthemachineseries.

Ultimately,thedecisionwasmadeinfavourofCheto’s IXN3000travellingcolumndeep-holedrillingandmillingcentre.Themodelispartofafamilyofmachinesthat enables multifunctional machining with up to seven axes.Thefocushereisonthecompletemachiningofthe workpieces on a single machine. The very stable and inherentlyrigidoveralldesignofthemachineenablesnot only deep-hole drilling but also qualified milling operations in the five-sided machining of even very complex workpieces

“This is exactly what we need — we are continuously working on streamlining our process chains, strategies andprocesses,andonmakingourproductionmoreproductive, efficient and reliable,” explains Ferstl. “One of our goals in introducing the new machine was to reorganise the machining of workpieces with many large coolantholesandalsotooptimiseourworkflowswitha view to complete machining The new concept also includes separating the machining process from the presence of the operator.”

The machine is controlled by a Heidenhain TNC 640, with the option of a Siemens 840D or Fagor-CNC 8065. Three of the seven axes are located in the moving column — in X, Y and Z (3000 x 1500 x 800 mm), two ball screwseachensurehighlyprecisemovements Afurther movementintheZdirection(Z1axis)isimplementedas a clampable displacement axis of the machine table, which is designed as a rotary table (700 mm) Its rotary axis is the B-axis (360° continuous). The table offers a machiningareaof1,800x1,800mmandcanholdworkpieces up to 30 tonnes in weight. The A-axis is the swivelling axis in the machining head (+35°/-25°)

“The highlight is the W-axis integrated into the machining head, which carries the spindle — a linear feed axis that really comes into its own in deep hole drilling,” explainsFerstl.“Itallowsthedrillingtooltomoveinthe feed direction by up to 1700 mm. In combination with theZ-axistravel,wecandrillholesofupto2,500mmin one go with the appropriate drilling tools — fully automatically up to a drill length of 1,700 mm.”

Automatictoolchange

Cheto allows for this with up to five special cassettes in which the gun drills are pre-set and which are automatically exchanged from a separate magazine To do this, the spindle moves the holder on the W-axis to the rearmost position. The desired cassette, which, in addition to the drill, also contains a sophisticated system of supportsteadiesforthetool,isinsertedinfrontofit.When

the tool holder is inserted into the holder, the system is ready for deep-hole drilling

Oliver

for more than a decade. This allows the company to develop competitively.

WRITTEN BY RichardPergler Journalist Pergler Media

“Wearecontinuouslyworkingon streamliningourprocesschains,strategies andprocessestomakeourproduction moreproductive,efficientandreliable.”

Markus Ferstl, Production Manager, Koller Formenbau

Aftermachining,thedrillingcassettecanbereplaced with a conventional tool from a magazine with 60 ISO 50spacesorwithanotherdeep-holedrillingcassette—a drillbitwithadifferentdiameterorevenasistertool.All of this is done very reliably and without operator intervention. For milling, the spindle is securely clamped in the foremost position of the W-axis — this also allows forrobustroughingoperations,conventionaldrillingor demanding threading operations

For programming, the mould makers use the current version 4.1 of the Tebis CAD/CAM software package throughout the company. “Only for deep-hole drilling did our manager use software that is considered the technology leader for this niche area,” Ferstl recalls. “At thebeginning,hehadsomeconcernsaboutthechangeover — after all, Tebis does not specialise in deep-hole drilling, but covers a wide range of very different machiningoperations.ButTebisquicklyprovedconvincing — especially the very good Tebis postprocessor for the Cheto Andwiththechangeover,ourCAD/CAMchainis now a unified whole.”

Addedtothisarefunctionsthatsignificantlyimprove process reliability “As far as I know, the Cheto machine istheonlyonethatcanmeasureasingle-flutedgundrill using a Blum laser,” explains Ferstl. “In addition, the Cheto IXN 3000 works with the Wise active control system, a software that gives the machine a kind of lookahead capability during deep-hole drilling The control system recognises the actual machining state from various performance parameters, vibration sensors on the spindleandreal-timemeasurementofcoolantpressure andflow,andcanautomaticallyadjustthefeedrateand spindletorque.Thismeansthatwecanoperateourtools very reliably even at their limits and get the most out of a machining process.”

Convincingcompletepackage

Before the Cheto, deep drilling at Koller was characterised by manned machining — three shifts, three operatorspermachine.“Today,ofthethreeshiftsinwhichthe Cheto is operated, only one shift is complete with an operator,”explainsFerstl.“Thetoolchanges—including thoseofthedeep-holedrills—runautomaticallyduring the machining process. All of this is done very safely

Sustainable partnership: Markus Ferstl (left) has been relying on the expertise of machine specialist

Gasteier

The machine is designed to be very user-friendly. The Cheto IXN 3000 is controlled by a Heidenhain TNC 640, but the machine is also optionally available with a Siemens 840D or a Fagor-CNC 8065.

Since we’ve had the Cheto, we haven’t had to outsource any drilling to external service providers.”

The values are convincing, the processes are right. WhenOliverGasteier,whohasbeenadvisingandactivelysupportingthemouldmakersfordecades,introduced the new Nano Coolant lubricoolant this spring, Ferstl was open to trying it out. “We have found that his suggestions are well-founded. He said that the new Nano Coolantwouldbringsignificantimprovements,particularly in the area of feed rates and tool life.”

ly higher,” confirms Ferstl. “This has also attracted the attention of our partner for our deep-hole drilling tools. Wehadbeenmachininga2316steelwithahighchromiumcontentforthemthatisnoteasytodrill.Inthetrials for the toolmaker, we were able to achieve very good results with the new coolant, which also completely convinced the toolmaker.”

What’smore,thecarbonbeadsinthecoolinglubricant have an antibacterial effect. The liquid has no smell, is non-stickyandisverypleasanttotouch.Anditdoesnot attack seals or rotary feedthroughs, for example, thus reducing wear on the machine.

“The discharge via the workpieces is also very low becausethecoolinglubricantrunsoffwell,”explainsFerstl. “Andthecomponentthatevaporatesispurewater—the nano-beads remain in the cycle. So we only have to add

“Wecandrillholesofupto 2,500mminonego—upto adrilllengthof1,700mm fullyautomatically.”

Markus Ferstl

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Looking for state-of-theart deep hole drilling and milling solutions? Visit www.cheto.eu

Thenewcoolinglubricantisbasedonanunusualprinciple. While conventional cooling lubricants are designed to reduce sliding friction, for example between the cutting edge and the material, the Nano Coolant reliesonrollingfriction:inphysicalterms,thenewcooling lubricant is a (molecular) dispersion. In normal tap water, billions of nanometre-sized carbon spheres are distributed here. These act like rollers between the cutting edge and the material — rolling friction is significantly easier to overcome than sliding friction.

“With the Nano Coolant, we have achieved improvements of 30 to 40 percent in the feed rates, the tool life has doubled, the heat development is much lower and thus the quality and surface of the holes are significant-

tap water And it doesn’t even need to be specially treated. The only special thing is that the cooling lubricant mustalwaysremaininmotionsothatthenanobeadsdo not settle.”

Inthemeantime,theNanoCoolanthasalsobeenused on the Auerbach — with similar success. The next step will be to test the nano-coolant in grinding and milling “Based on the principle of rolling friction, we expect, for example, that the formation of built-up edges will be greatly reduced in milling,” explains the production manager “Wehavealreadyreorderedinordertotestthe nano-coolant on other machines and, if successful, to use it permanently.” (ast)

Koller’s mould-making division specialises in the really big moulds. These are becoming ever more complex, and the requirements are also constantly growing

Sour ce Maschinenmarkt

INDUSTRIAL ROBOT

Versatilerobotfortoughjobs

The M-950iA/500 serial-link robot from Fanuc brings versatility to heavyliftingtasks.Serial-linkmeansthereisnointerferenceofthe mainJ3armwith porting mechan

Thearmofthe above and rotat provides a much tion and more ing and handling Also, the rotation theJ3axisonthe is impressive, payloadof500 2,830 mm.

StandardIP67 andIP54forthe idealchoicefor Severe dust a motor covers, moreoptionsallo on customer needs, equipment of strong robot company’s exist serial-link robot kg payload and reach.

www.fanuc.eu

AUTOMATION Robotsfordigitaltransformation

Mitsubishi Electric has launched its Melfa RH10CRH and RH20CRH Scara robots, providing manufacturers with greater flexibility in adopting digital manufacturing while addressing skilled workforce shortages. These new robots enhance industrial automation through high-speed operation,easyinstallationandefficiency.Compactandlightweight,they are ideal for manufacturers aiming to boost productivity while navigating space and weight constraints.

Engineeredwithversatilityinmind,theMelfaRH-CRHserieshas been designed for a wide range of applications, including assembly, coating,andprecisionconveyance.Withmaximumreachradiirangingfrom600mmto1,000mmandpayloadcapacitiesofupto10kg and 20 kg, respectively, the RH-10CRH and RH-20CRH offer performance and adaptability to meet various production needs

TheMelfaRH-CRHseriesalsooffersadvancedfunctionality,trackingoperations,supportfor3Dand2Dvisionsensors,andforcesensing, ensuring precise performance for high-speed tasks emea.mitsubishielectric.com

HIGH-PERFORMANCE MATERIALS

Newgenerationofstainlesssteels

Swiss Steel Group has launched Ugima-X, the third generation of high-performance stainless steels that offer significant advances in terms of machiningefficiency,tool life and process reproducibility

The new generation introduces three specifically optimised materials designed to meet diverse industrialneeds.Ugima-X4021isamartensiticstainlesssteeltailored for demanding mechanical applications requiring high strength. Ugima-X 4028, another martensitic stainless steel, offers enhanced corrosion resistance and improved dimensional stability, making it ideal for precision components Meanwhile, Ugima-X 4460 is a duplexstainlesssteelthatcombinesexceptionalmechanicalproperties with outstanding resistance to corrosive environments, ensuring durability and reliability in challenging conditions.

According to Swiss Steel Group, these new high performance materialshaveanaverageproductivityincreaseof20percent,increased tool life of 25 percent to 50 percent, optimised chip formation and exceptional reproducibility swisssteel-group.com

MACHINING AND GRINDING Lubricantsandfluidmanagement

With the Zubora and Multicut product lines, Zeller+Gmelin is demonstrating how modern water-miscible cooling lubricants and cutting oils further increase efficiency and sustainability in metalworking One example is the fully synthetic cooling lubricant Zubora TTS PF, which is completely pictogram-free. This not only brings advantages in the area of occupational safety and storage, but also meets health and environmental protection requirements.

Inthefieldofcuttingoils,Zeller+GmelinoffersMulticutproducts thathavebeenspeciallydevelopedforthedemandingprocessingof non-ferrous metals. The products include, among others, Multicut GrindHP15NFandMulticutPlus10NF,whichofferidealconditions for a long tool life and precise results. The special formulations of the cutting oils, including modern base oils designed for low consumption, such as hydrocrack and ester oils, emphasise their sustainable orientation. Multicut Grind HP 15 NF was specially developedforcircularandprofilegrindingandisidealforuseingrinding machines in which parts made of copper or brass are installed. zeller-gmelin.de

MULTI-PURPOSE MACHINING

Turningcentresdriveinnovation atDiamondPrecision

Diamond Precision Engineering, a specialist in subcontract manufacturing, recently invested in two Nakamura-Tome turning centres. These machines have improved their production efficiency, reduced cycle times and enabled unattended overnight automation.

Located across three sites on the Wirral, Diamond Precision Engineering has evolved from a small toolmaking business to a subcontract manufacturing specialist. From a company producing press tools andfixturesinitsinfancy,DiamondPrecisionnowoffers 3D printing, laser cutting and CNC folding, fabrication and CNC machining As a business that always invests inhigh-endtechnology,DiamondPrecisionhasrecently installedtwoNakamura-Tometurningcentresfromthe Engineering Technology Group (ETG), a WT150 and an AS200

Discussingthehistoryofthebusinessfoundedin1986, Company Director Harry Pitt says: “The business was startedbymyfatherandithasbeenbuiltupfromthere. ItwasatoolmakingbusinessanditevolvedtoaCNCmachineshopandlaterlasercuttingandfabrication,taking the business across three sites My brother and I have always been very much involved and inspired into a ca-

reer in manufacturing where my brother now runs the laser cutting and fabrication site and I manage the machining division. It is here that we have just installed Nakamura machines from ETG.”

Harry recalls that his father has always enjoyed auctions,leadingtovariouspurchasesovertheyears,some successful and others less so He notes that new machinescansometimesbemorecost-effectivethanolder ones due to the maintenance expenses associated with aging equipment. For instance, when they recently bought a new laser machine, the payments were actually lower than the maintenance costs of an older model. The Company Director explains that their machine shophadbeendealingwithreliabilityissuesfromsome aging lathes, which made job planning difficult. There were also challenges in finding support and repair servicesforthesemachines.Giventheseissues,theydecided to invest in a new, reliable machine to improve effi-

Small prismatic parts machined in one-hit from square section bar on the AS200 instead of undergoing multiple set-ups on a machining centre

ciency and speed up production. He emphasises that staying competitive requires continuously producing parts faster and with better quality

Discussing the advantages of the Nakamura WT150II from ETG, Harry mentions that they had previously quoted a job at three times the price the customer was willingtopay,andhewasdeterminedtowinthecontract WiththenewWT150IImachine,theywereabletoundercut the client's price point and secure an order for 4,000 parts. This,hesuggests,demonstrates howthespeedandproductivity of Nakamura technology can not only make them competitive but also position them as leaders in the industry

at Diamond Precision.

“Wehavedrastically reducedthecycletime andwedon’tneedan operatorpresent.”

Since investing in the Nakamura WT150II and AS200, Diamond Precision has adopted newmachiningmethodologies to manufacture existing parts differently, utilising the full capability of the machines fromETG AsHarrycontinues:“Formydad,mybrother andI—investinginourbusinesstoinnovateisourpassion. Finding faster ways to make parts and be more efficientisareallyrewardingandsatisfyingpastime.What wearetryingtodoiseliminatepartscomingoffturning centresandthengoingforsecondarymillingoperations. We will always look for the most efficient way to manufacture parts.”

Harry Pitt, Company Director, Diamond Precision Engineering

viouslymanufacturedonamachiningcentreanditwas ahorriblytrickyjobtohandle.The316stainlesssteelpart had three operations until one of our teams suggested barfeeding the job on a Nakamura. Now, the AS200 is producingabetter-qualitypartandasitisbar-fed,itcan runautomatedallday.Equallyimportant,itisproducing a better quality part and more consistent surface finish as it is even deburred in-cycle. Now, we have drastically reduced the cycle time and we don’t need an operator present.Asasmallbusiness,wehavetoinnovateorour competitors will overtake us Fortunately, we are really lucky that we have some great guys with fantastic and creative manufacturing ideas in our business.”

Harry shared his thoughts on the Nakamura AS200, noting that although their AS200 is not a twin-spindle andtwin-turretmodel,ithasgreatlyimpressedthem.He highlighted that the single-spindle and single-turret configuration can handle many jobs in just one operation. For instance, they have a job involving a family of two components, where their programming expertise allows them to profile both parts in a single operation andthensimplypartthemoff,resultingintwofinished parts from one process.

Achievingunattendedovernightproduction

The Company Director also mentioned another job wheretheNakamuratechnologysignificantlyimproved theirprocess.Previously,thisjobinvolvedlasercutting, preparingitonaturningcentre,performingafinalturning operation, and then using a special machine to cut teethintothepart.Now,theycanplacethepartdirectly on the AS200, where all turning operations and teeth machining are completed in a single operation. He pointed out that while the AS200 isn’t used for conventional turning or milling, it functions effectively as a form-cutting machine.

Fromcomplexoperationstoefficient automation

Alludingtooneexample,Harrysays:“Weareparting-off withslittingdiskstominimisematerialusage-wewant to try every little thing to improve our processes. As a company that is always trying new ideas, we have previously been limited by the capabilities of the machine — theNakamura’sneverletusdown.Whateverwewantto try,wecando Previously,wewouldseeothercompanies trying new innovations and our machines would let us down — this is not the case with Nakamura.”

Looking specifically at the Nakamura AS200 where Diamond Precision is machining a small job from a squarebarthatwouldhaveoriginallybeenprocessedon a machining centre, Harry says: “The small job was pre-

With both the larger Nakamura WT150II and the smallerNakamuraAS200machinesequippedwithpart catchers, live tooling, and barfeeders, Harry noted that the combination already provides a high level of automation. He added that automation itself is a learning process, describing it as an art form. While running the machines during the day is one challenge, Nakamura's technology has taught them how to leave the machines running unattended overnight. However, this also presentschallenges,suchasefficientlyremovingpartsfrom the machine. For example, with a batch of 700 parts being produced overnight, removing them from the machine can be complex. While the WT150II has a conveyorthatsimplifiesthisprocess,itcanbemorechallenging withsmallermachines.Herecountedanincidentwhere swarfbecametoolongandstringy,jammingtheconveyor and stopping the machine, which led to a valuable learning experience. They have since implemented strategiestobreaktheswarf,addingonlythreeseconds to the cycle, but allowing the machine to run continuously from Friday morning through to Saturday night.

In conclusion, Harry says: “The one thing that really impressedmeishowwelltheNakamuramachineshold workpiece dimensions, tolerances and the surface finishes.Leavingyourmachinestorununmannedallofthe time is like a ‘mythical artform’. We are still very much learning the intricacies of tool, swarf and material management—butwithNakamura,weknowthatwhatwas onceimpossibleforourbusinessisnowachievable.”(ast)

The Nakamura WT150II

MULTI-TASKING MACHINE

Onesetup,endlesspossibilities

British manufacturing company Advanced Precision CNC has expanded its machining capabilities with the addition of a new Yamazaki Mazak Integrex Multi-Tasking machine. This latest investment marks the company’s 10th Mazak machine.

Advanced Precision CNC has recently added to its stableofYamazakiMazakmachinetoolswiththe purchase of a new Integrex Multi-Tasking machine. The Bromsgrove manufacturer, set up in 2013 by Managing Director Paul Grace, has developed a strong customer base across a wide variety of industries since openingitsdoors,includingcoatings,wireformtooling, medical, aerospace, fabrication and bespoke machine component build.

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Visit www.mazakeu.com for further information about advanced technology solutions.

Thecompany’ssuccessisbuiltoninvestinginbest-inclass machines that can manufacture the highest-quality components “We don’t compromise on the quality of the machines we buy and that is why we’ve invested inthenewIntegrex,”saysPaulGrace,adding:“Thebusiness was set up with Mazak machines and we have never deviated from that first commitment to investing in the best machines.”

10thMazakmachine

The new machine is already Advanced Precision CNC’s 10th Mazak machine to be brought into its 6,000 sq ft Stoke Prior premises that employs 15 staff and one ap-

Bromsgrove-based Advanced Precision CNC has recently invested in an Integrex i-250H S Multi-Tasking machine.

prentice ThemachineshopnowincludestwoUK-made VTC-760Cverticaltravellingcolumnmachiningcentres aswellasaVTC-300CII;twoVCN-530Chigh-productivity vertical machining centres and four Quick Turn lathes.

As part of its latest machining investment, Advanced PrecisionhasspecifiedanIntegrexi-250HSMulti-Taskingmachine—thehigh-speed,high-torqueoptionfrom Mazak’s flagship range that is capable of machining a wide range of components at exceptional speeds to deliveroutstandingproductivity Thankstotheflatdesign of the front, the Integrex i-H series considerably improves peripheral equipment accessibility such as a robot and raw material stocker

Paulsays:“TheIntegrexaddsadifferentdimensionto ourmachiningcapability;itallowsustoperformmultiple machining tasks in one setup with one program. Specifically, I wanted to reduce the number of tool changes and do things quicker Now, we’re completing jobstothesame,ifnotanevenhighstandard,andmuch faster Also, because we’re getting more work done, we cangoafteradditionalopportunities.Injustsixmonths its already helping us to grow the business.”

Collaborationinfocus

Advanced Precision CNC has been a Mazak customer sincethebeginningandtheirreputationinthelocalarea has grown with local customers. However, that proximity to Mazak was also a huge help “I recently needed a new spindle on one of our VTC machines. Mazak helped strip the old spindle and install a new one in a matter of days, meaning the machine downtime was kepttoaminimumandwecouldkeepourowncustomershappy ThatiswhatIhavecometoexpectfromMazak and is why I keep going back,” Paul Grace says.

Jason Butler, Sales Director at Yamazaki Mazak UK, adds:“PaulandtheteamatAdvancedPrecisionCNCare the blueprint for starting and growing a modern machine shop We have taken great pleasure in seeing the businessdevelopanditisparticularlyexcitingtoseethe company take delivery of its first Multi-Tasking machine. One of our core values at Mazak is to foster close relationships with our customers so we feel we are part of the same team. Ultimately, closer collaboration can deliver more productivity and profitability, to help our customers continue to grow. This is exactly the type of relationshipwehavewithPaulandweareexcitedtosee where the journey takes us.” (ast)

HUMAN TOUCH MEETS AI PRECISION

FuturetrendsforAIinthe usedmachinerymarket

Artificial Intelligence (AI) is already part of everyday life for many people. Whether in medicine, IT or customer service — the areas of application for AI are diverse. The first areas of application are also already emerging in the used machinery market.

ArtificialIntelligence(AI)isplayinganincreasingly important role in many industries. This advanced technology is not only valued for its ability to analyse complex data and make decisions. It also offersthepotentialtooptimiseprocessesandautomate routinetasks Thetradeinusedmachineryinparticular shows how AI opens up new possibilities and can revolutionise existing processes.

Fromanideatoauniversaltool

The origins of artificial intelligence date back to the 1950s,whenscientistsbegantoexploretheideaofthinking and learning machines. Today, AI encompasses a wide range of advanced technologies such as machine learning,neuralnetworksandautonomoussystemsthat canmakedecisionsontheirown.Thesetechniqueshave enabled the use of AI in a wide range of applications, fromoptimisingcomplexproductionlinestoimproving customerinteractionandsupportingdiagnosisinmedicine.TheadvantageofAIsystemsliesintheirabilityto learnfromlargeamountsofdataandrecognisepatterns, makingthemanindispensableanalysisandforecasting tool.Inmanyindustries,AIisthereforenotonlyusedto increase efficiency, but also to develop new business models and transform existing markets.

5Trendsintheusedmachinerymarket

The used machinery market is also beginning to recogniseandexploitthebenefitsofartificialintelligence.The following five AI trends are emerging that could have a significant impact on the trade:

ƒ Pricingandvalueassessment: AI models use extensive data analyses to determine the current market value of used machinery and provide realistic price recommendations. For example, age, manufacturer, machine type and maintenance periods are compared.

ƒ Maintenanceprediction: By analysing operating data, AI systems can predict when maintenance work is required. This minimises downtime and maximises the service life of the machines.

ƒ Demandforecasting: AI can analyse sales trends and past transaction data to predict future fluctuations in demand and determine the optimal time to sell.

ƒ Supplychainoptimisation: AI can anticipate supply chain disruptions and plan more efficient transport routes, resulting in faster delivery times

ƒ AdaptationandretrofittingthroughAI: AI can analyse existing production processes and show where used machines can be used effectively to modernise, expand areas of application or increase efficiency. By analysing an AI, opportunities for modernising and adapting used machines can be identified in order to expand their areas of application and increase efficiency.

Although AI offers support in many areas and enables significantefficiencygains,itcannotreplacethepersonalandexpertserviceofspecialisedusedmachinerydealers.Thefutureoftheusedmachinerymarketliesinthe combinationofhumanexpertiseandtheanalyticalprecision of AI. (ast)

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Surplex offers an efficient platform that simplifies the process of selling used machinery at www.surplex.com

How much is my used machine worth? When is the perfect time to sell? AI can help sellers with such questions.

CUTTING TOOLS

HornUSAexpandswith owncoatingsystems

Horn USA seamlessly integrates two advanced coating systems from Cemecon into its U.S. production facilities, paving the way for greater flexibility and faster turnaround times. In this way, Horn can now tailor solutions to exact customer requirements.

In 70 countries, the top players in automotive, chemical, aerospace, medical technology and tool and mould making industries trust Horn’s precision tools to drive their success. The USA is one of the most significantmarketsforthecuttingtoolindustryandisbecoming increasingly so

Initsquestforperfectionandenhancedservice,Horn USA has now integrated a state-of-the-art coating line withtwoCC800Hipimssystemsintoitsproductionprocess.ThisallowsHorntosupplyUScustomerswithcustomised solutions for their individual requirements rapidly. The trust built over years of collaboration betweenHornandCemeconinEuropeandNorthAmerica has paved the way for a seamless transition to in-house coating for Horn USA.

Horn’strademarkisdeliveringhigh-qualityprecision tools for demanding machining operations with short deliverytimes,whichiswhereothersstruggle.Tomake this guarantee worldwide, you need high-performance production facilities with cutting-edge technology

around the globe — especially in key markets such as the USA

At the main plant in Tübingen, Germany the unique HipimstechnologyfromCemeconhaslongbeenoneof the cornerstones of Horn’s success. Since 2004, Horn USA has had its precision tools coated by the experts at Cemecon, Inc. Now the production in Franklin, TN has been expanded and enhanced with in-house coating expertisetobeabletosupporttheUSmarketquicklyand efficiently with fully optimised products.

Theperfectcombination

“It was clear to us that if we were to switch to our own coating production, we had to produce the same coatingsourselves,fromdayone.Weneededtoproducethe same quality as before using Cemecon’s coating service and we needed the new products from Tübingen to be easily duplicated in the US In other words, we needed thesametechnologicalcapabilitiesasinGermany.And

The transition to in-house coating production went smoothly at Horn USA – thanks to Cemecon training

thetrainingtonotonlyintegratethecoatingtechnology intoUSproduction,butalsotofullytakeadvantageofits potential,”saysChadKing,GeneralManager,HornUSA.

Horn looked for and found a solution with its long-standing partner Cemecon. Horn invested in a turnkeycoatingline—consistingoftwoHipimscoating systems, substrate pre- and post-treatment equipment, andallothernecessaryperipheralsystems—withtechnology “made in Germany” and training “made in the USA” ChadKingcomments:“WithCemeconasourtechnology partner, we have received the all-inclusive turnkeypackage:First,thetechnicalequipmentandsecond, thefullcustomerservicepackagecompletewithknowledgetransfer,trainingforour employees,andsupportfrom the coating experts from Horseheads in collaboration with our German colleagues This combination is perfect and allows us to do an outstanding job!”

Smoothstart

Whenintegratinganin-house coating line into the production, Cemecon has a decisive advantage: The experts use the same technology in their coating service every day — in all coating centers around the globe. As a result, the teamatCemecon,Inc.knows the coating and peripheral systems, processes and workflows down to the smallest detail and provides its customers with optimum support. “Horn and Cemecon have a decades-long partnership — both here in the USA and in Germany This means weknowHorn’srequirements and high-end quality level inside out,” says Ryan Lake, Sales Manager at Cemecon.

The operation of the Hipims coating system is self-explanatory; the key to the success of in-house coating productionliesinunderstanding the workflows and the entire process from start to finish Over the years, Cemecon has optimised the processes so thattheyareeasytolearnand understand. “We pass on our knowledge and experience duringtrainingatourcoating centerinHorseheads,NYorat the customer’s site. The training is identical for customers and our own employees We know from our own experiencethatourtrainingquickly and reliably imparts the

know-how needed to master the coating process successfully.Andiftherearestillquestions,wecontinuouslysupportourcustomerswheneveritisneeded,”saysEli Roberts, Technical Manager at Cemecon.

ChadKingconcludes:“Forjustoverayear,we’vebeen revolutionising our coating production in Franklin, thanks to our dynamic partnership with Cemecon. By blending cutting-edge technology with unparalleled process expertise and synchronised training, we’ve achievedaflawlesstransitiontoin-housecoating From dayone,we’vedeliveredexceptionalqualityandgained the power to innovate our coatings and tailor them to our exact needs.” (ast)

DLC-ALESSeries

Chip BreakerEffect

CUTTING TOOL DESIGN

Thedecisiveroleof efficientchipremoval

Laser-cut chip shape geometries are a revolution for the production of tools for metal cutting. What previously seemed impossible has now been proven in numerous projects. An interview with the Simtek board member and experienced tool developer Norbert Seifermann.

With the 3D laser, defined geometries can be individually designed for each application.

Precision tool manufacturer Simtek is pushing the boundariesofmetalcuttingwithlasertechnology.

Byintegratinglaser-cutchipgeometriesintotheir tools, they have overcome the limitations of traditional grindingandsinteringmethods,achievinggreaterchip control, process reliability, and tool efficiency Norbert Seifermann, an experienced tool developer, discusses thechallengesandbreakthroughsoflasermachiningin carbide tools.

Mr Seifermann, since when has chip removal playedsuchanimportantroleinmetalcutting?

Eversincemetalmachiningbegan,thefocushasbeen on optimal chip removal. This is certainly not yet so relevant in our training workshop, where our apprentices are first taught to get a feel for the chip using a file and tap wrench. They then sweep or blow away their few chips with a broom or compressed air. This changes as soonastheCNCmachineisused.Inmachining,thepersonwhobreaksthechipbestandbringsitundercontrol achieves better production results. In the end, this pays

offfortheuserinmanywaysthroughincreasedprocess reliability, higher cycle rates, longer tool life and, ultimately, lower costs.

Why are short chips so important for metal cutting?

Users of our precision tools like short chips that they can remove from the cutting process in a controlled manner Automated machining with long chips, for example, is hardly feasible — we can hardly guarantee process reliability in this case. The key to high process reliability and long tool life is therefore optimum chip control.

Inyourexperience,whendoyoureachanimpasse withgrindingthechipformgeometries?

Grinding is often no longer practical for milling cutters or boring tools for small diameters. Experience has shown that we reach our limits with certain geometric details.Forexample,facetgrindingorfreegrindingdoes not always lead to the desired result with small tool diameters. We mainly use our tools for machining small parts;oursmallesttoolsaresuitablefordiametersof0.3 mm. Here, limits are already set for grinding, especially when the chip geometry is complex.

Canyougiveusanexampleofthis?

Yes, of course. If, for example, we want a short chip whengroovingintheX-axisdirectionduringagrooving operation,butacurledchipthatisguidedoutofthemachining process in a controlled manner when turning along the Z-axis, grinding reaches its limits. It was not possibletoapplythischipgeometrytoagroundtool,so two tools had to be used for this

Whynotusesinteringasaproventechnology?

Sinteringhasprovedeffectivemainlyinthemassmarket.Producingpressingtoolsforsinteringisonlyworthwhileinthemassmarketofreversiblecuttinginserts,for example, and for larger tool quantities. In our tool segmentwithaveryhighvariance,sinteringisonlypartiallyanoption.Afterall,wecannotproduceapressingtool foreachtool;thatwouldbefartoocostlyanduneconomical.

Andhowdidyouplantosolvethisproblem?

We had been toying with the idea of using lasers for this purpose for quite some time. We knew that it wouldn't be easy with hard metal, because other manufacturershadalreadytrieditandhadimplementeditto someextentforlargertools Buttheideaofflexiblecom-

bination tools with individual chip geometries was an enticing one and I couldn't get it out of my head.

Howdidyoufinallymanagetoovercomethischallenge?

After several years of testing and many unsuccessful attempts, as well as some setbacks, we finally found a way. We are now able to laser the required chip breaker geometryintothecarbideforbothstandardandspecial tools. With the 3D laser, defined geometries can be individually designed for each application

Whatmakesthelasingofcarbidesochallenging?

It'snoteasytolaserhardmetal,asothershavealready discovered. Hard metal essentially consists of tungsten carbide and a cobalt component. The two components havedifferentevaporationand melting points, which makes laserprocessingtricky Wehad to find a method of applying thelaserdirectlytothecutting geometry

What are the advantages of laser machining over otherprocesses?

AsImentionedearlier,laser machining allows the cutting geometries to be optimally applied to the tool for the respective machining task. Lasers allow us to apply optimum rake angles to the cutting edges, with a cutting edge rounding of just 5 µm. We can also producecombinationtools,as it were, and thus support the trend towards complete machining of a component. Particularly with special tools, someadditionaltoolsarethen no longer needed, and the variety of tools at the customer’s site is also reduced.

How has laser technology provedinpractice?

In numerous applications over four years, we have optimisedlasertechnologytosuch an extent that we can now enter the broad market with process reliability Our goal is to control the chip even under the most challenging conditions and to maintain and increase process reliability

What do your customers think of this new technology?

Our customers have accepted lasering well. For example, we have a customer who repeatedly had problems with chipbreaking Afterswitching to a lasered tool, the problem was completely solved. This customerhasbeenreordering the tool for four years now.

How do you see the future of laser engraving in toolmanufacturing?

Initially, we only laser-engraved customised special tools. Now, standard tools are also being added successively I am convinced that lasers will develop into a key technology Even if we can’t find a solution for every application, it is definitely realistic for 80 to 90 percent of cases. Other tool manufacturers will adapt this technologytoreplacemorecost-intensivesintering Lasertechnology will revolutionise the production of clasp geometriesinmetalworkinganditwillbehardtoimaginethe future without it.

Thankyoufortheinterview,MrSeifermann! (ast)

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COORDINATE MEASURING MACHINE

Rapidinspectionoflarge, tight-tolerancecomponents

CMS Cepcor has significantly upgraded its quality control by acquiring an Altera M

Coordinate Measuring Machine from LK Metrology. This investment improves measurement accuracy, streamlines inspection processes, and supports the company’s commitment to precision manufacturing.

FLK Altera M

ounded in 1989 and headquartered in Coalville, Leicestershire, England, CMS Cepcor is a leading supplier of aftermarket crusher spares, manganese-steel wear liners and other equipment to the mining, aggregate production and associated industries worldwide. Last year, in February 2024, the company took delivery of its first coordinate measuring machine (CMM), greatly enhancing quality control of the products it manufactures or refurbishes to tight tolerances. Having a nominal inspection volume of 3,000 x 1,500 x 1,000 mm, the CMM is an Altera M built by UK firm LK MetrologyatitsfactoryinCastleDonington,Derbyshire Previously, CMS Cepcor had been using a pair of manually-operated, portable, 6-axis arms with a 2.5-metre anda3-metrereachrespectivelytocheckcast-iron,cast or forged steel, and bronze components by touch-probing them. This was a lengthy process, as well as being

insufficiently precise to measure some parts without difficulty

Afurtherdifficultywasthatsometimesanarmwould besetuponametrologyfixturetableandintheprocess of measuring multiple items, such as head nuts or locking bolts produced in batches of up to 50, an urgent request would be made by the shop floor staff for the arm tobetransferredtoamachinetooltoevaluatethedimensions of a part in situ before it is removed from the machine. That meant immediately relocating the arm, performing the new measurements, returning the arm to the table and most probably starting the original cycle again.

With the coordinate measuring machine in place and the arms now more or less dedicated to in-process metrology, as well as less stringent inspection tasks, such wasted time is a thing of the past

The

30.15.10 on the shop floor at CMS Cepcor’s manufacturing facility in Coalville.

“TheLKCMMhasamaximumpermissible firsttermerroroflessthantwomicrons, soisabletomeasureevenverylargeparts exactlyandrepeatably.”

Les Hickens, Quality Manager, CMS Cepcor

The high level of accuracy is particularly useful when the company and a customer are discussing the dimensions of a lead-bronze bushing, for example, a material that has a high coefficient of expansion.

Seamlessintegration

“Our Altera M has thermal compensation, with a sensor builtintoeachaxisandatemperatureprobesuppliedfor attaching to the component under investigation It would not be practical to wait 24 hours while a large, heavycastingnormalisesitstemperaturewiththatofthe CMM,”saysLesHickens,QualityManageratCMSCepcor Hickens revealed that before investing in the CMM, machinesfromtwoothersupplierswereconsidered.LK was chosen on the basis of the good build quality of the Altera M, the stable ceramic bridge and spindle and the competitive price, as well as the proximity of the manufacturer's factory for providing back-up and service

Many parts undergoing quality control are rotational, initially turned on a Doosan lathe and then milled and drilled in a second operation on an Honor Seiki vertical boringmilloraNormamachiningcentre.Consequently it was considered expedient for LK to supply the Altera M 30.15.10 with a Renishaw PH10MQ Plus motorised indexing head and an SP25M probe for analogue contact scanning, capable of measuring up to 1,000 points per second. The system is able to verify any out-of-roundnessmuchfasterthanifatouchprobeisusedtocapture asuccessionofdiscretepoints,andtheresultingreports are more robust due to the large amount of data

Innovmetric's Polyworks Inspector software was also suppliedwiththeCMM.IthasdelightedtheCMSCepcor metrology team, as it is simple to learn and use and makes training new operators easy. The same software is being retrofitted to the portable measuring arms, as well as a handheld optical scanner on site employed for checking very large castings, so only one seat of Polyworks is needed, saving expense.

Hickensconcluded:“AtCMSCepcor,wearecommitted toexcellenceandourinvestmentintheAlteraMreflects that.Alreadyafterafewmonths,ithasresultedinastepchangeinourmetrologycapabilityandthebenefitswere already tangible. Like a CNC machine tool, once set up and programmed the CMM executes inspection programsautomatically,allowingoperatorstofocusonothertasksaroundthefactory,whichtranslatesintooverall productivity improvement. The heightened precision ensures that the components we supply are controlled carefully to the relevant specifications, making sure we consistently meet our rigorous quality standards. Moreoverbystrengtheningourinspectioncapabilities,weare able to foster greater confidence in our customers and suppliers, thereby improving our partnerships and reputation.” (ast)

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ISTMAWorldNews&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

EVENT REVIEW

ISTMAGeneralAssembly2025held inBrazil

São Paulo, Brazil, recently hostedtheISTMAGeneralAssembly 2025, a noteworthy event in the tooling and manufacturing industry HeldfromMarch25to27, 2025, the assembly gathered industryprofessionalsandorganizations to facilitate innovation and strengthen international partnerships.

OrganizedbyABINFER,theBrazilianNationalAssociation,alongside SENAI/SP, the event addressed industry challenges and explored emerging opportunities on a global scale

TheassemblybeganonMarch25withtheISTMAGeneralAssembly at 09:00, followed by a networking lunch and two workshops: “Looking to the Future” and “Education as a Success Key.” The day concluded with a formal dinner from 18:00 to 21:00, providing additional opportunities for dialogue.

OnMarch26,participantsvisitedSENAIschoolsandVolkswagen do Brasil, gaining insights into the educational and industrial practices influencing the tooling and manufacturing sectors

The event's agenda on March 27 offered an optional visit to the PlasticoBrasilexhibition,showcasingthelatesttechnologiesinthe plastics and rubber industries. 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

Szerszámgyártók Magyarorsazági Szövetsége (SZMSZ) www.szmsz.hu

Unione Costruttori Italiani Stampi e Attrezzature di Precisione (UCISAP) www.ucisap.it

Stowarzyszenie Techniczne –Tworzywa Sztuczne www.stts.com.pl

Associação Nacional da Indústria de Moldes (CEFAMOL) www.cefamol.pt

NEW ISTMA MEMBER AachenerWerkzeugbauAkademie joinsISTMA

ISTMA World has announced the addition of the WBA Aachener Werkzeugbau Akademie to its ISTMA Global Partners Program. This new partnership aims to enhance innovation and collaboration within the tooling and manufacturing sector, highlighting ISTMA’s commitment to fostering significant relationships across the industry

WBA, known for its leadership in consulting, education and researchwithinthetoolanddieindustry,bringsvaluableexpertiseand resources to ISTMA’s expansive global network. This collaboration isexpectedtofacilitatethesharingofknowledge,promotebestpracticesandacceleratetechnologicaladvancementsintoolingandmachining

TheISTMAGlobalPartnersProgramisdesignedtocreatestrategic connections among major industry players, thereby enhancing the competitivenessandcapabilitiesofISTMA’smemberorganizations worldwide. WBA’s participation reinforces ISTMA’s role as a central hub for innovation and cooperation in the special tooling and machining sectors.

Through this alliance, ISTMA and WBA aim to drive collective progressandsustainindustrygrowthbyleveragingtheircombined strengthstoaddresscurrentchallengesandseizenewopportunities within the global marketplace. www.werkzeugbau-akademie.de

Slovenian Tool and Die Development Center www.tecos.si

Toolmaking Association of South Africa (TASA) www.tasaweb.co.za

Swedish Moulding and Press Tools Association www.sinf.se

Swissmem www.swissmem.ch

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