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2/2011
Volume XIII | Issue 2 | March 2011 | €11 www.etmm-online.com
Machining Equipment
Special Section EDM Europe Quarterly Interview
Collaboration in medical The Spring 2011 issue Prof. Reimund Neugebauer
technology production 14 of our supplement 43 from Fraunhofer IWU 18
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EDM Technology
and Mould Making
E
lectrical discharge
machining (EDM) is an
important technology for
tool and mould making.
Over the past decade, there
have been some significant
developments in the EDM
field—advancing what is
sometimes call the “black
magic” technology.
From my perspective, the
EDM machine manufacturers and the providers of
EDM accessories have been more active recently in
terms of developmental activities. I am looking for-
ward to seeing more new EDM-related products this
year at EMO Hannover, where the biggest display
of EDM technology anywhere in the world will be
exhibited. When I put out a call for editorial for the
EDM Europe supplement you’ll find in this issue of
ETMM, the response was stronger than usual. I can
tell that the EDM suppliers are asserting themselves
as the industry sees a business upswing.
EDM has always meant high-precision machin-
ing, even when working with very small-scale cutting
requirements. But today’s EDM machines are faster
and more efficient than ever. For a long time, EDM
has been at the leading edge of lights-out operation,
where machines work around the clock unattend-
ed. However, erosion machines now are even more
advanced, offering excellent off-site monitoring and
servicing capabilities.
You can read about some of these EDM advances
starting on page 43 of this magazine, where the
Spring EDM Europe supplement appears.
Because EDM is so important to the mould mak-
ing industry, ETMM has been committed to reporting
on this technology since 2001, with we introduced
the bound-in EDM Europe supplement. The annual
EDM Europe Buyer’s Guide debuted in 2006. Look for
further 2011 quarterly EDM Europe supplements in
the June, September and November (EDME Buyer’s
Guide) issues of ETMM.
Douglas Sellers
MANAGING DIRECTOR/EDITOR-IN-CHIEF
Table of Contents
COVER STORY
Special
Report ............. 22
VDW Foresees 30% Growth
in German Machine Tool
Production Output for 2011
Product
Focus ............... 24
Recently introduced products
from suppliers of machining
equipment for the tool and
mould making industry
Quick Sourcing Grid:
Machining Equipment ......................28
A handy table of companies that supply machining equipment
to the tool and mould making industry
Cover photo courtesy of Yamazaki Mazak U.K. Ltd.
Editor’s Message ................................3
EDM Europe Spring 2011 Electrical discharge machining technology is improving all the
time, and ETMM continues to report on this four times a year
Special Report ..... 44
The trade magazine for electrical discharge machining The Electrode Materials Industry News ....................................7
Corporate, professional and educational events that define the
Volume X | Number 1 | Spring 2011 www.edm-europe.com
to Use for CNC-Controlled
Die-Sinking EDM direction of the industry
Special Report ..... 46 Special Section
Page 50 EDM Wire: Where Spool Tangles Medical Technology .........................14
SPECIAL SUPPLEMENT Come From Partners Show That Working Together Is Working Smarter
Special Report Case Study Products & Services
Electrode materials for CAM to take wire The top innovations
CNC die-sinking EDM ........ 44 erosion to a new level ...... 48 of industry suppliers .......... 52
Special Section
Case Study ................................ 48
Using CAM to Perform EDM Machining at a New Level
Medical Technology .........................16
3D Printer Helps Accelerate Quest for Diabetes Cure
Technology................................ 50
Competitive Standing Can Hinge on a Company’s Choice Interview..........................................18
of Dielectric-Fluid Filters Genuine Sustainability Is Attainable Only in a Network
Products & Services................... 52 Special Report ..................................32
Recently introduced equipment and services from all over Calculating Part Behaviour via Process Chain Simulation
4 European Tool & Mould Making | March 2011 | www.etmm-online.com
wide product range
large repertory of stock types
customer-specific executions
modern, rational manufacturing methods
Volume XIII | Issue 2 | March 2011
over 30.000 heating elements daily
Case Study ....................36 certified according to DIN ISO 9001:2000
Software Helps Supplier to Achieve Shorter
Lead Times high life span
Case Study ....................37 500 qualified employees
Quick Dry-Ice Cleaning System Keeps Foam
Moulds Working over 240 patent applications
Case Study ....................38 made in Germany
Loyal Customer Evolves with Reliable,
Versatile CAM System
Technology............................................................ 40
Electrification of Hot Runner Systems
Technology............................................................ 41
we are your
Pluggable Nozzle Tips to Prevent Flow Marks best choice for
Products & Services............................................... 58 heating elements
Recently introduced equipment and services from all over
ISTMA.................................................................... 65
Directory of ISTMA Europe Member Associations
Company Index......................................................66
A listing of the industry suppliers who supported this issue with articles and
advertisements
NEXT ISSUE
April 2011
The focus of the Cover Story in the next issue of ETMM is
Quality Control. This section will include an overview article, Türk+Hillinger GmbH
short Product Focus articles and a Quick Sourcing Grid of 78532 Tuttlingen Germany
Tel. +49 74 61 70 14 0
QC-equipment suppliers serving the tool and mould making Fax +49 74 61 70 1410
industry. info@tuerk-hillinger.de
The April issue also offers:
www.tuerk-hillinger.de
• A Special Report on the mould making market in China
• A Technology section focus on computer software available
to help tool and mould makers maintain competitiveness
• A preview report on the quality assurance exhibition Control,
taking place in Stuttgart May 3–6
www.etmm-online.com | March 2011 | European Tool & Mould Making
since 1963
VOLUME XIII NUMBER 2 MARCH 2011
EUROPEAN TOOL & MOULD MAKING
Published by SellersMedia
PUBLISHER/EDITOR-IN-CHIEF
Douglas Sellers
d.sellers@sellersmedia.com
SELLERSMEDIA
Otto-von-Guericke-Ring 3A, 65205 Wiesbaden, Germany
Tel: +49 6122 95590 • Fax: +49 6122 51090
info@etmm-online.com
www.etmm-online.com
P R O D U C T I O N , C I R C U L AT I O N & I N F O R M AT I O N S E R V I C E S
Briggette Jaya
b.jaya@sellersmedia.com
Melanie Rossel
m.rossel@sellersmedia.com
GRAPHIC DESIGNERS
Jason Sellers
j.sellers@sellersmedia.com
Law Wai Man
lwm@sellersmedia.com
I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T
Markus Müller
m.mueller@sellersmedia.com
SALES MANAGER
Britta Solloway
b.solloway@sellersmedia.com
ADVERTISING SALES FRANCE
Evelyne Gisselbrecht
33 Rue du Puy-de-Dôme, 63370 Lempdes, France
Tel: +33 473 619557 • Fax: +33 473 619661
e.gisselbrecht@sellersmedia.com
R E P R E S E N TAT I V E A G E N T F O R TA I W A N , C H I N A & H O N G K O N G
Robert Yu, Worldwide Services Co. Ltd.
11F-B, No. 540 Wen Hsin Road, Section 1, Taichung 408, Taiwan
Tel: +886 4 23251784 • Fax: +886 4 23252967
sales@wwstaiwan.com
NORTH AMERICAN OFFICE
30765 Pacific Coast Highway, PMB 351
Malibu, CA 90265-3643 USA
Tel: +1 805 744-7924 • Fax: +1 310 507-2032
usoffice@tool-moldmaking.com
BUSINESS MANAGER
MiSook Musselman
mmusselman@tool-moldmaking.com
Official
Media Partner of
ISTMA Europe
EDITORIAL CONTRIBUTIONS: Product/service information bulletins and press releases
should be submitted in English and should be accompanied by a colour photograph or
transparency. The publishers assume no responsibility for return of artwork, photographs
or manuscripts. NOTICE: Every precaution is taken to ensure accuracy of contents; however,
the publishers cannot accept responsibility for the correctness of the information supplied
or advertised or for any opinion expressed herein.
SUBSCRIPTIONS: European Tool & Mould Making is published 10 times per year.
Annual subscription in Europe: € 79.00 incl. VAT (1 year), € 150.00 incl. VAT (2 years)
Readers outside Europe: € 99.00 incl. VAT (1 year), € 185.00 incl. VAT (2 years)
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Subscription inquiries, back issues, address changes: send your request to European Tool & Mould Making
by e-mail to etmm@tool-moldmaking.com or by fax to +49 6122 51090.
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zur Feststellung der Verbreitung von Werbeträgern e.V. (IVW), Berlin
Printed at: Kössinger AG, www.koessinger.de
Copyright © 2011 ACCESS COMMUNICATIONS INC. ALL RIGHTS RESERVED
Industry News
At EMO Hannover 2011 in September, Service
Will Be Sold Along with Tools and Machines
Tools and services under the microscope:
MAPAL PRÄZISIONSWERKZEUGE DR. KRESS KG
Germany’s former reputation as
a “service desert” is long gone. today, vendors work with customers to
analyze and optimize processes.
Machine tool manufacturers in
particular now see that mak- The trade fair is a platform not just
ing good service support avail- for premiering tools but for showcas-
able strengthens the incen- ing service as a “product” in its own
tive to buy. Customer demand right.
for additional services leads
to companies differentiating
themselves by the type of cus-
» EMO Hannover 2011
Hannover, Germany
tomer-responsive service they www.emo-hannover.de
provide, around the clock and
around the globe. Acknowledging
this current reality, EMO Hannover
2011, the world-leading trade fair
for machine tools and high-precision
tools, will be running under the mot-
to “More than machine tools” when it
opens its doors September 19–24.
Mapal Präzisionswerkzeuge Dr.
Kress KG exemplifies the increasing
focus on holistic approaches to cus-
tomer service, where product provi-
sion is supplemented by the added
value of services based on the ven-
dor’s process expertise. The compa-
ny offers a portfolio of customized
services, called Complete Process
Management, that comprises pro-
cess design, process introduction
and logistical services, tool manage-
ment and optimization, and complete
retooling of existing production lines.
Says Frank Stäbler, Mapal’s head of
tool management and tool logistics:
“Intelligent tool services come into
play precisely when, in addition to
the direct tool costs, indirect costs—
Watch Mastercam circle the globe at
for tool management or storage for www.tinyurl.com/mcglobe.
instance—have to be rendered trans-
parent and meaningfully reduced.”
Demand for services is increasing
substantially, and especially in Asia
and Eastern Europe, where manufac-
turers use staff from the tool service
provider for logistical support, preset-
ting and plant retooling. Representa-
tives of such companies will certainly
be present when EMO returns to Han-
nover for the first time since 2007.
www.etmm-online.com | March 2011 | European Tool & Mould Making 7
Industry News
Berthold Hermle AG to Hold Annual In-House
Exhibition of All of Its Machines in April
Maschinenfabrik Berthold Hermle
AG will mount its traditional in-house
machine tool exhibition again this
year at the innovative production
facility located in Gosheim. From
April 13 through 16, interested pro-
fessionals can tour the plant and
examine machines in action. All of
the new products Hermle introduced
in 2010 will be available for viewing
in one place. In fact, more than 20
Hermle machines will be on exhibit
in the technology and training cen-
tre, processing interesting workpiec-
es representing a variety of customer
industries.
A key innovation area for Hermle is
automation. The company will there-
fore present several automation sys-
tems under production conditions tion about the latest trends in tools, area and training and presentation
at the open house, including pal- CAD/CAM and control technology will rooms also will be on show.
let changers, handling systems and be more than 30 exhibitors. Hermle
robot systems. has augmented its exhibition with
Also, clamping technology is the such special-focus presentations for » Maschinenfabrik Berthold
Hermle AG
subject of a special show within the many years. Gosheim, Germany
event. Providing visitors with informa- Hermle’s newly designed reception www.hermle.de
DEMAT/Messe Brasil Joint Venture Results in
Creation of EuroMold Brasil, Debuting in 2012
With its latest trade fair, EuroMold its trademark fair concept to oth- Market analysis conducted by
Brasil, which is set to premiere er attractive international markets. DEMAT, along with identification of
August 20–24, 2012, in Joinville, Bra- The fifth Asiamold, co-organized the current needs of international
zil (south of São Paulo), DEMAT GmbH with Messe Frankfurt, will be held in exhibitors, led to the creation of the
extends its range of exhibitions to Guangzhou, China, this year. After Brazilian event, which will be co-locat-
five continents. DEMAT set up a joint 2010’s auspicious premiere, Ameri- ed with Interplast 2012, the Fair and
venture with Messe Brasil to realize mold returns in 2011, this time taking Congress of the Integration of Plastic
this newest version of the EuroMold place in Chicago, USA. Afrimold will Technology. EuroMold Brasil provides
idea of a fair for mould manufactur- be reprised in Johannesburg, South another way for visitors and exhibi-
ing, tooling and design. EuroMold Africa, this year, as well. In addition, tors alike to expand business possibili-
Brasil brings DEMAT’s successful trade through EuroMold group pavilions, ties in the mould, tooling and design
show concept “From Idea to Series European exhibitors can discover supply chain.
Production” to South America. the potential of the Indian market at
DEMAT GmbH, one of the most DieMould India and get to know the
renowned exhibition organizers in Russian market better at RosMould in
» DEMAT GmbH
Frankfurt/Main, Germany
Germany, had already transferred Moscow. www.demat.com
8 European Tool & Mould Making | March 2011 | www.etmm-online.com
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Industry News
UK Machine Tool Rapid.Tech 2011
Builders Will Share in Erfurt Features
Consolidated Facilities Expert Forums
Hardinge Machine
Tools Ltd. (along with Generative (or additive) manufacturing processes are
Bridgeport) and Jones the focus of Rapid.Tech 2011, the 8th rapid technol-
and Shipman plan to ogy trade fair, scheduled for May 24–25 in Erfurt, Ger-
consolidate their tech- many. The fair programme comprises a users confer-
nical, distribution and ence, a design engineers day, the 3rd CAD/CAM and
administrative facili- Rapid Prototyping in Dental Technology expert forum,
ties in Leicestershire, the 2nd Medical Technology expert forum, and an avi-
UK. The machine tool ation expert forum, premiering this year.
manufacturers will The two-day users conference introduces beginners
continue to operate to the additive manufacturing of end products and
as two independent also supplies advanced users with an update on state-
companies while shar- of-the-art technology. The special expert forums give
ing a single facility in the city of Leicester. Most Hardinge users and prospective users practical, industry-specif-
and Bridgeport business operations will be moved from ic information about generative manufacturing pro-
premises in Whetstone into the current Jones and Shipman cesses. The design engineers day focuses specifically
building in Leicester. In addition, a second facility close to on these target groups’ processing requirements.
the Leicester site is planned, to which some 50 Whetstone Since 2004, Rapid.Tech has used intensive interdis-
personnel will be relocating. ciplinary dialogues to examine the development of
All three of the flagship brands are enjoying healthy additive manufacturing from the production of pro-
sales as manufacturing output increases. However, says totypes to the direct manufacturing of end products
John McTernan (photo), the Hardinge Group’s European and their components. The focus in 2011 is on direct
sales and marketing director, “we continue to look to opti- generative manufacturing, a process that experts
mize the business.” The pooling of resources should result regard as having the greatest application potential.
in productivity gains for the group.
» Rapid.Tech 2011
» Hardinge Machine Tools Ltd. Erfurt, Germany
Whetstone, Leics, UK www.rapidtech.de
www.hardinge.co.uk
Get on board and catch the NEW release!
CAD/CAM Software with world class precision and control...
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For more information, please call (800) 787-3827 or find your reseller at surfcam.com • Visit us on Facebook, Twitter and YouTubetechnical mouldings
Stratasys Gets ISO 9001:2008 engineering resins
Certification for TQM System smart hot runner solutions
Stratasys, which makes additive man- Stratasys says that its drive to
ufacturing machines for prototyping improve quality was rooted in les-
and producing plastic parts and owns sons learned early on. An additive
the patented FDM® (fused-deposition manufacturing system released to
modelling) process, has received ISO the market prematurely disappointed
9001:2008 certification for its total customers, and the company spent a
quality management (TQM) system. lot of money rectifying the problem.
ISO 9001:2008 provides a structure “The experience set us on a course of
for a quality management system continuous improvement that contin-
that strives to ensure customer sat- ues today,” says Stenoien.
isfaction, consistent high quality and The manufacturer, which markets
efficiency. Fortus-brand 3D production systems
“Our new quality management sys- and the Dimension line of 3D print-
tem gives us a foundation to grow ers, is headquartered in Minneapolis,
capabilities and sales in direct digital Minnesota, USA. Enterprise Minne-
manufacturing,” declares COO Tom sota was the primary consultant for
Stenoien, who adds that the certifica- Stratasys’ ISO 9001:2008 certification
tion sends the message that the com- effort.
pany is serious about supporting such
production market segments as the
aerospace, defense and medical tech-
» Stratasys GmbH
Frankfurt/Main, Germany
nology industries. www.stratasys.com
Integrated Imaging/Analysis
Software Supports Microscopy
face metrology reports with full trace-
ability. It is available as entry-level
software, in a version dedicated to
Leica’s dual-core 3D microscope, and
as a top-of-the-line universal solution,
with optional modules for advanced
applications.
“Leica Map software is based upon
According to a signed agreement the latest generation of Mountains
between Digital Surf and Leica Micro- Technology, which was released in
systems, Leica Map surface imaging the second half of 2010,” explains
and metrology software based on François Blateyron, chief operating
Digital Surf’s Mountains Technology® officer at Digital Surf. Mountains
Proudly supported in Europe by:
imaging and analysis software for sur- Technology–based software has been Mastip HRS
face metrology instruments will be integrated into many makes of indus- Strack Norma GmbH
used with the Leica Application Suite trial and laboratory measurement Tekis Teknik A.S.
for Leica industrial microscopes. New instrumentation. Hales Tool & Die Ltd
Sverital S.p.A.
Leica Map can visualize and quan-
tify features of measured surfaces,
characterize 3D surface texture and
» Digital Surf SARL
your partner in technical moulding
Besançon, France
geometry, and generate visual sur- www.digitalsurf.fr
www.etmm-online.com | March 2011 | European Tool & Mould MakingIndustry News
New SolidCAM GmbH
CGTech Sets Up May
Marketing Manager
Vericut Users Meeting
Has Background in
CAD/CAM and CNC
CGTech Ltd., provider of Vericut® CNC machine simu-
lation, verification and optimization software, will
hold VUE 2011, the next UK Vericut Users Exchange,
on May 18, at the Williams F1 Conference Centre in Since its founding in
Grove, Oxfordshire. VUE 2011 is an opportunity for 1984, SolidCAM has
Vericut users to learn about current and future ver- grown to be a world-
sions of the software and to meet the CGTech team wide leader in inte-
and other Vericut users for exchanges of ideas and grated CAM technolo-
techniques. Users will be able to give the developers gy. The SolidCAM suite
feedback and make suggestions for future product of machining-software
enhancements. modules offers seam-
This year’s VUE will focus on the new features less integration and
and performance improvements offered in the just- full associativity with
released Vericut Version 7.1, many of which were sug- the CAD systems Solid-
gested by users at previous VUE events. Works and Autodesk
Inventor. SolidCAM
GmbH was established
» CGTech Ltd.
in 1994 in Germany
Hove, E Sussex, UK
www.cgtech.co.uk and today consists of six branches plus qualified resell-
ers, all supporting the more than 2,000 SolidCAM cus-
tomers working in the country. And
now, Stephan Terhorst (photo) has
taken over as marketing manager for
SolidCAM in Germany.
Terhorst had worked in sales and
marketing for a SolidCAM subsidiary
Easily configure your Quick Ship Euro molds in northwestern Germany since 2009,
before which time he acquired con-
via our download center & order them siderable experience as a user of, and
in 1 click! production manager for, CAD/CAM
and CNC control technology. Gerhard
www.dmeeu.com
Lägeler, the manager of SolidCAM
GmbH, observes that, because
“Stephan has his roots in CNC produc-
tion” and has experience “on both
sides of the table, he knows what
CAD/CAM users expect.”
Terhorst sees his task as serving as
an interface between customers, busi-
ness partners and employees, as well
as the market and the public. “My pri-
mary challenge,” he remarks, “is to
guarantee open communication so
Yourr contact: that the interests of all members of
DME Europe
E
dme_europe@dmeeu.com CZ: dme_cz@dmeeu.com PL: dme_polska@dmeeu.com
the SolidCAM family are best served.”
UK: dme_uk@dmeeu.com DE: dme_normalien@dmeeu.com PT: expulsores_girona@dmeeu.com
CH: dme_schweiz@dmeeu.com ES: expulsores_girona@dmeeu.com Export: dme_export@dmeeu.com
» SolidCAM GmbH
www.dmeeu.com Schramberg, Germany
www.solidcam.de
12 European Tool & Mould Making | March 2011 | www.etmm-online.comSINUMERIK MDynamics
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VLHPHQVFRPVLQXPHULNSpecial Section | Medical Technology
Partners Show That Working
Together Is Working Smarter
Collaborators in a medical component–moulding project share their expertise in
order to improve a manufacturer’s productivity and reduce scrap generation.
The three partners colla-
T he medical device manufac-
turer ICU Medical needed to
improve productivity in making
The moulded
Breather Cap is an
extremely small
borated to increase pro-
ductivity, reduce costs
and maintain very high
its Breather Cap IV-connector yet vital part of the quality in moulding the
component while maintaining CLAVE connector, Breather Cap connector
quality and streamlining costs. which is a one- component.
The company achieved this goal piece needlefree
by collaborating with partners IV-set connection times shorter and
who understood its needs. Those device. The func- allow the employ-
partners were the mould maker tion of the plastic ment of moulds
Tech Mold Inc. and Husky Injec- cap is to prevent designed to have
tion Molding Systems, the injec- contamination. more cavities.
tion moulding equipment and To produce the
services provider. Husky’s contri- component, ICU
butions to the project included a Medical had been
The Best
hot runner system with Ultra- using a 32-cavity Partners
Sync electric plate actuation. mould with a 12-year-old injec- To achieve its goals, ICU Medical
tion moulding machine, but it looked for suppliers that not only
was seeking to upgrade the tech- could help it produce a high-qual-
nology after quality issues such ity part, but also would provide
as flash and gate remnant (caused open communication and support
by tool wear) arose. The company its long-term needs. The company
sought a solution to these prob- ended up selecting Husky and
lems that could also make cycle Tech Mold, with both of which
it had previously worked in
designing a complete pro-
ductivity-enhancing, scrap-
reducing system solution for
the CLAVE. ICU hoped to
replicate this success with
the Breather Cap.
The project had an
aggressive lead time,
explains ICU tooling
engineer Jeffrey Mil-
ler, so the manufac-
turer wanted reliable
partners of proven
The Husky Altanium Matrix
temperature controller (left),
Tech Mold 32-drop mould
core and cavity (centre) and
UltraSync-E hot runner.
14 European Tool & Mould Making | March 2011 | www.etmm-online.comtrustworthiness. “Because we had For the Long Term
ongoing relationships with both SUCCESS THROUGH QUALITY
Husky and Tech Mold,” he says,
“we knew we could ensure that
everyone would be on the same
page and understand our goals
from the start.”
Reducing setup time and mini-
mizing downtime are important
factors for medical device manu-
facturers, explains Jeffrey Miller,
because doctors can lose patients
2011
ICU was familiar with Husky’s when products are not delivered
high level of service and its main- on time. For this reason, ICU
tenance-friendly turnkey systems Medical needs supply partners
that allow for quick mould chang- that can provide fast, responsive
es, and knew that Tech Mold spe- service should production issues
cialized in high-cavitation moulds arise. “With other machine build-
&ORUM
and provided outstanding after- ers, we sometimes had to wait
sales support. two weeks before we could be
visited by a service technician,”
notes Miller. “After we first start-
A System Solution ed working with Husky, they
The three project partners worked assigned a local service technician
together to design a turnkey sys- to our area. We now have five
tem comprising machine, mould, Husky machines, and the average
hot runner and temperature con- response time when we have an
troller. Communicating freely and issue is less than 24 hours.”
sharing knowledge in their respec- Husky’s area manager Gaetano
tive areas of expertise, they were Santospirito, who was involved in
able to develop an advanced sys- the project from the beginning,
tem very quickly. says simply that “Husky’s ongo-
To produce the Breather Cap ing goal is to develop solutions
with future requirements in mind, for our customers that will enable
ICU switched to a Husky machine them to be more competitive, sus-
that includes a 32-drop Ultra 350 tainable and profitable.”
hot runner with UltraSync electric The three-part collaboration
plate actuation and an Altanium was successful because each part-
Matrix temperature controller. To ner fulfilled a particular project
accompany the hot runners, Tech role. ICU shared its expertise
Mold built a 32-cavity mould in medical device manufactur-
designed for fast heat removal ing, the Husky team contributed
and rapid cooling. knowledge of plastics processing
Husky’s UltraSync technology and complete turnkey systems,
supports fast cycling by ensuring and Tech Mold employed its engi-
precise simultaneous gate closing, neering skill to produce the appro-
which results in consistent part
filling and excellent gate qual-
priate high-quality mould tool.
“We are off to a great start
3. – 6. May
ity. The mould’s ability to accel-
erate cooling, along with the
repeatability of UltraSync valve
on this project,” concludes Miller.
“Our relationship with Husky and
Tech Mold has definitely helped
STUTTGART
$IRECTLY ADJACENT TO THE AIRPORT
A8
gate technology, improved cycle us to achieve some ambitious AND THE MOTORWAY
time by some 30%. Running a goals, and we are confident they
sub-5-second cycle on a 32-cav- will be there to support our long-
ity mould, ICU can match the term needs.”
production capacity of a 64-cavity
mould operating on cycles of 6 to
7 seconds. Also, Husky’s system is » Husky Injection Molding 0% 3CHALL 'MB( #O +'
Tel. +49(0)7025.9206 - 0 · CONTROL SCHALL MESSENDE
Systems S.A.
ideal for the Breather Cap because Dudelange, Luxembourg
it is cleanroom compatible. www.husky.ca www.schall-virtuell.de
www.control-messe.de
www.etmm-online.com | March 2011 | European Tool & Mould MakingSpecial Section | Medical Technology
3D Printer Helps Accelerate
Quest for Diabetes Cure
An OEM’s ability to produce rapid prototypes in-house improves design flexibility
and cuts medical equipment development time in half.
T he US medical OEM Biorep
Technologies focuses primar-
ily on developing devices that
a dozen parts that
were prototyped
individually using
contribute to finding a cure for the Eden250 and
diabetes. Its design team is led then assembled. As
by Felipe Echeverri, engineering Echeverri recalls:
director, and Andres Bernal, R&D “We produced five
engineer. A few years ago, as Bio- complete proto-
rep found itself outsourcing the types in all, plus
rapid prototyping (RP) of small dozens of individ-
parts more frequently, the head ual parts along the
designers thought RP technology way. We would set
needed to be brought in-house. up parts to print
They evaluated 3D overnight, and when we came
printing systems back in the morning, we could
and decided on test the new concept right away.”
the Eden250 3D Another recent Biorep project
printer from Objet enabled by the Eden250 was a sil-
Geometries. This icone-membrane petri dish devel-
small, high-quality oped in response to a hypothesis
machine met Bio- of the Diabetes Research Institute
rep’s selection cri- (DRI) in Miami that cells in a dish
teria for accuracy, would be more viable if oxygen
ease of use, main- could reach them from both the
tenance, surface top and the bottom.
finish and price. Using the Eden250, Biorep pro-
Accuracy is important, because reliable valves to control medical totyped the initial design of the
Biorep uses rapid prototypes to laboratory fluids flowing through “oxygen sandwich,” tried various
prove concepts and check fit, silicone tubing and prevent them approaches to ensure manufactur-
form, and function before com- from contacting equipment parts, ability and proper assembly, and
mitting to tooling for injection provides an example. All experi- finally created prototypes to con-
moulding. The compact Eden250 mental designs for the manifold firm that the design could be mass
quickly and accurately builds pro- were prototyped on the Eden250, produced (bottom photo).
totypes of any geometry clean- and an Objet prototype (top photo) The innovative petri dish
ly and cost-effectively. Models helped sell the project concept to went from the drawing board to
produced on it are smooth and Biorep management. field testing in six months—half
durable, with fine details and out- “Our ability to produce rapid the normal development time—
standing surface finish. prototypes in-house was crucial thanks to Biorep’s in-house RP
Echeverri reports that the to the success of this project,” says capability and, specifically, the 3D
Eden250 has helped his team pro- Bernal. “Because we were able to printer supplied by Objet.
duce better designs and has accel- produce a lot of prototypes very
erated time-to-market for new quickly at very low cost, we did a
products. The patent-pending lot of testing.”
» Objet Geometries GmbH
Rheinmünster, Germany
Pinch Manifold, a device with 32 The Pinch Manifold has about www.objet.com
16 European Tool & Mould Making | March 2011 | www.etmm-online.comArtistic As a leading manufacturer of 5-axis machining centres, Hermle are expanding their portfolio: Perfect precision, dependable service and automation competence are now available for workpieces weighing up to 2500 Kgs. Annual Open House in Gosheim, Germany April 13th – 16th, 2011 www.hermle.de Maschinenfabrik Berthold Hermle AG, Gosheim · Phone: +49 7426/95-0 · info@hermle.de
Interview
Genuine Sustainability Is
Attainable Only in a Network
In an interview, Prof. Reimund Neugebauer, the longtime director of the
Fraunhofer IWU, discusses the ‘greening’ of production operations.
T he Fraunhofer Institute for
Machine Tools and Forming
Technology (IWU) in Chemnitz,
ing colleagues from the USA and
Switzerland, who support interna-
tional scientists in their work on
Germany, spotlighted the sustain- energy-efficient solutions.
ability and energy-efficiency of
production lines at a colloquium In newly industrializing countries,
held in Autumn 2010. Prof. Dr.- are there efforts to provide govern-
Ing. Reimund Neugebauer, direc- ment support for the introduction of
tor of the Fraunhofer IWU, talks sustainable production technology?
about his major focuses in this In India, due not least to its
forward-looking area. The inter- soaring economic growth, there
view was conducted by Nikolaus is keen interest in solutions for
Fecht, a freelance journalist from energy- and material-efficient
Gelsenkirchen, Germany. production. During an Octo-
ber 2010 visit to us by Anand
What were the keynote issues at the Sharma, the Indian minister of
International Chemnitz Manufac- commerce and industry, a mem-
turing Colloquium organized by the Third, a new trend respect- orandum of understanding was
Fraunhofer IWU? ing the machining of very large signed, through which a coopera-
There were three main topics. components is observable: it’s tion between the Confederation
First, dry machining: its introduc- called “machine goes to compo- of Indian Industry, the Central
tion has been largely completed nent.” Mobile machining units Manufacturing Technology Insti-
when it comes to cutting with a have been developed that move tute and the Fraunhofer Society
particular blade cutter. Dry fine- along such components as marine would be set up. This initiative
machining, by contrast, is only crankshafts, turbine rotors and focuses on collaboration in devel-
beginning—in grinding applica- rollers. Ultraefficient mechatron- oping and implementing green,
tions, for example, where ener- ics guarantee reproducible high- clean and energy-efficient produc-
gy consumption due to coolants precision machining. tion technology.
is much more than 50% of the
total. There are some excellent In terms of the green production How is the auto industry balancing
approaches here. line, how are high-tech countries like economics and eco-compatibility?
Second, automakers and air- the USA, Switzerland and Germany During our colloquium, Volkswa-
craft manufacturers are increas- alike, and how do they differ? gen director Jochem Heizmann
ingly using lightweight and eco- Common to all is a heightened described the competitive advan-
compatible materials that are not sense of awareness. These coun- tages that can be gained from
easy to machine. Dependable tries are tackling the issue with a purposeful utilization of the
processability and productiv- real sense of responsibility, which potential in resource-efficient pro-
ity constitute challenges for pro- has led to their leading role in duction techniques. For example,
cess design and the machinery developing and using sustainable 40% of the materials used in the
involved. What looks promising technologies in production opera- Golf 6 are recyclates. Volkswagen
here is alternative cooling strate- tions. At Chemnitz, by the way, has already shown that parts can
gies, such as high-pressure cool- we have a high-technology cluster consist of 100% recycled materi-
ing and the use of cryogens. with 75 young researchers, includ- als. Energy analyses of the car
18 European Tool & Mould Making | March 2011 | www.etmm-online.comCatch new dimensions
in worldwide customer focus
ASK Chemicals is one of the world’s largest providers of comprehensive total
solutions and customised consulting services for the casting industry.
Through our local presence in 24 countries, with 30 locations in the most important
casting markets around the world, we help you keep pace with global developments
in the worldwide casting industry. Together, we will find innovative solutions and
make progress faster.
ASK Chemicals – We advance your casting
Meet us at GIFA
Dusseldorf/Germany
June 28 – July 02, 2011
Hall 12, Booth A24
Learn more about ASK Chemicals at www.ask-chemicals.com
Foundry Chemicals | Feeding Solutions & Filters
Foundry Services | Metallurgy Products $1$6+/$1' 6²'&+(0,(-2,179(1785(Exhibition for Rapid Technology and Manufacturing
BZhhZHijii\Vgi!The World‘s Top Trade Fair
for Injection Moulders
nowadays begin with the design manufacturer still needs the end
phase and cover the lifetime of user to optimize its own process. Made by Fakuma!
2011
the finished product, all the way Ultimately, automakers will be
through to recycling and reuse of the innovation drivers, with the
its individual parts. machine tool producer being the
cooperation partner.
How can machine tool manufactur-
ers support committed users such as How can makers and users quantify
the automotive industry in their eco- machine tool energy consumption?
campaigns? Our 75 young researchers are
German machine tool manufac- focusing on how to analyze and
turers particularly are focusing record energy consumption in the
on sustainability nowadays. This design and operation of machine
relates to the development of tools, using virtual reality for visu-
resource-efficient machine tools, alization. In the future, a machine
energy monitoring and energy tool user will be able to see how
management. But the machine much energy a machine tool
design consumes in what areas
during a session of virtual produc-
Following a time of service as a tion. In my estimation, the first
senior executive in the industri- EDP solutions for this will appear
al sector, Reimund Neugebauer in two or three years.
entered academia in 1989. Direc-
tor of the Fraunhofer IWU since How do you assess the shared activi-
1992, he became a professor of ties of the German machine tool
machine tool design and forming industry, like “Blue Competence”?
technology at Chemnitz Univer- I think this is the right approach
sity of Applied Science in 1993. for the sector, because comprehen-
Prof. Neugebauer has been exec- sive solutions demand a sustain-
utive director of the University able development outlay. Under
Institute for Machine Tools and the aegis of Blue Competence,
Production Processes since 2000. manufacturers can exchange news
In addition, for the past year, he and views in a pre-competitive
has served as president of the environment.
German Scientific Society for Pro-
duction Engineering (WGP). What role will EMO 2011 in Han-
The Fraunhofer Institute for nover play?
Machine Tools and Forming Tech- The Fraunhofer IWU will be an
nology is an application-driven exhibitor and is working with
R&D institution working in the the VDW [German Machine Tool
field of production scieince Builders’ Association] to organize
for automobile and machinery a Blue Competence conference on
manufacturers. Some 400 staff resource-efficient production.
members in Chemnitz, Dresden
and Augsburg are engaged in
I expect the fair to empha-
size resource-efficiency through
18 – 22 Oct.
researches into machine tools, reducing energy consumption in FRIEDRICHSHAFEN
forming technology, joining and stand-alone processes, expanding
assembly technology, adaptronics/ the use of dry machining and
mechatronics and virtual reality. alternative cooling strategies, and
On September 20 and 21, 2011, further consolidating processing.
the Fraunhofer IWU and the VDW
will jointly present a congress on
sustainable production at EMO » VDW Verein Deutscher
P.E. Schall GmbH & Co. KG
Werkzeugmaschinenfabriken Tel +49 (0) 7025.9206-0 · fakuma@schall-messen.de
Hannover. Frankfurt/Main, Germany
www.vdw.de www.schall-virtuell.de
www.fakuma-messe.de
www.etmm-online.com | March 2011 | European Tool & Mould MakingCover Story | Special Report
VDW Foresees 30% Growth
in German Machine Tool
Production Output for 2011
The global machine tool industry is being reshuffled, but German
manufacturers approach the future with confidence.
Martin Kapp, VDW chairman: “We now
T he German machine
tool industry forecasts a
30% increase in production
have to get back on course following
what was a very severe crisis.”
output for 2011. “With the
return to an anticipated vol- 2010, it employed 63,800
ume of almost €13 billion, people, 13% less than the
we would have caught up peak figure in October 2008.
on almost all the deleteri- But things have been slowly
ous effects of the crisis,” said improving in this area since
Martin Kapp, chairman of July. Kapp says that flexibility
the VDW (German Machine in human resources deploy-
Tool Builders’ Association), ment has been very benefi-
at the group’s annual press cial for the industry.
conference in Frankfurt am
Main in February.
Asians Surge
“Internationally, the crisis
Industry Status has meant a major reshuf-
Since the end of 2009, the fling of the machine tool
sector has seen two-figure industry,” Kapp noted at the
growth in order bookings press conference. Machine
quarter by quarter, driven tool output in Taiwan, Korea,
initially by China, South Japan and China grew sub-
Korea and India, which stantially in 2010, while the
quickly shook off the crisis, production output in Europe
and continuing as demand was –1% relative to 2009. The
from abroad picked up across a Exports were down just 1% USA too, at –9%, fell significantly
wider front. “Our industry’s world- from 2009 to 2010. For years, short of growth in output.
wide presence, its high proportion China has been Germany’s big- China, for the first time, was
of exports at two-thirds, and its gest—and a growing—market ahead of Japan, Germany, Italy
superlative technological position for machine tools. With a cur- and Korea at the top of the
on the international stage are rent export share of around 28%, machine tool production rank-
paying off here,” explained Kapp. China buys almost four times as ings last year. The USA placed
Eventually, the upturn spread to much as the second-place USA. eighth, and Switzerland, Austria
domestic demand as well. The machine tool sector was and Spain ranked seventh, ninth
In August 2010, sales revenues able to respond quickly to the and tenth, respectively.
showed a plus for the first time in incipient upturn because, during Martin Kapp sees no immedi-
two years. However, German pro- the crisis, it had held onto its ate threat to the German machine
duction output for 2010 was still highly qualified specialist staff in tool industry from Asia, since 90%
3% below that of 2009. the core workforce. In December of China’s production involves
22 European Tool & Mould Making | March 2011 | www.etmm-online.comwww.thebrightworldofmetals.com
www.gmtn.de
relatively simple machines for the domestic market.
And, according to a recent VDW study, hardly any
autonomous technological innovation work is now
being done there.
The Bright
The second major Eastern competitor, Japan, World
focuses predominantly on the production of stan-
dard machines with short lead times. Changes in
of Metals.
order bookings are reflected swiftly in the company’s Düsseldorf, Germany
production output, in both the upturn and down- 28 June – 02 July 2011
turn phases of the business cycle. Germany, with
its high proportion of customized machines and
lengthy projects, will be catching up this year, pre-
dicts the sanguine VDW chairman.
Confidence in the Future
“We now have to get back on course following what
was a very severe crisis.” Thus concluded Martin
Kapp at the press conference. The focus will be
on consolidating balance sheets, earnings, capital
resources and financing options, and on minimizing
costs. The sector must do this while cognizant that
a good three-fifths of global machine tools produced
today are sold in Asia. It is essential for machine
builders to keep advancing their international pres-
ence in terms of both sales and service support, and
to continually upgrade production capabilities.
Kapp is certain that the German machine tool
industry will profit from the rising global demand
for production technology. These manufacturers are
technological leaders, and they will continue to press
the competitive advantage that comes from this. It’s
an obvious step, for example, to transfer production
expertise developed for one client sector to other
sectors as well. Medical technology and aviation are
markets with high potential. These sectors’ stringent,
specialized product requirements can be met only
with ultrasophisticated production technology.
“That’s the Germans’ specialty,” declares Kapp, One date – one place – four events
“offering state-of-the-art solutional competence so Make the most of four high-calibre trade
that their customers in turn remain internationally fairs – for foundry technology, metallurgy,
thermo process technology and precision
competitive.” castings – in one place and with one entrance
Finally, requirements for the machine tools them- ticket.
selves are evolving. The need to reduce greenhouse- The industries’ Number 1 worldwide, multiple
gas emissions in the face of climate change is inten- synergies, connections and networks all in
just one show visit.
sifying the focus on sustainability in production
Welcome to Düsseldorf!
operations. The machine tool is crucial here. Many
companies are working intensively with their ven-
dors to develop new solutions for sustainable, effi-
cient production systems.
» VDW Verein Deutscher
Werkzeugmaschinenfabriken
Frankfurt/Main, Germany
www.vdw.de
www.etmm-online.com | March 2011 | European Tool & Mould MakingCover Story | Product Focus
Gantry-Style Machining Centres for High-Speed
Machining and Milling of Large Workpieces
Compact, easy-to-access Matrix- minium, resin or composite. The
series machining centres feature machine’s working area is equal
a gantry structure and mobile to its overall size.
crossbeam designed by Breton Other key Matrix features
S.p.A. to satisfy the demanding include a thermosymmetrical
high-speed-machining (HSM) and machine structure, specially
milling requirements of the aero- designed structural elements
space industry, but they are also and a thermal stabilizing system
suitable for machining complex to ensure HSM accuracy, and a
large workpieces such as dies customizable working area that
and moulds. Rigidity and high allows easy loading and unload-
dynamics are distinctive features ing of very large workpiec-
of the range. Thanks to linear axes with 40-kW continuous power and es. The machining centre can oper-
that offer traverses to 40 m/min, a 28,000-rpm capability. Thus, the ate stand-alone for processing large
direct-drive twist head that rotates Matrix can machine light alloys and workpieces or can be configured with
at speeds to 100 rpm, and the con- other special-alloy aeronautic materi- two workstations for shuttle and
tinuous rotation of the c-axis, these als. Centres can be variously config- batch machining operations. Its struc-
machines offer continuous high- ured with x-axis travels of 2,000 to ture and consolidated 5-axis heads
precision 5-axis machining capacity 3,900 mm, y-axis distances of 1,600 enable all five faces of a workpiece to
for complex profiling. to 8,000 mm, and a z-axis between be machined without repositioning.
The twist head, which can be posi- 800 and 1,600 mm in extent. These
tioned at any angle within the work- parameters meet HSM requirements
ing range and locked in place by for medium-sized and large workpiec-
» Breton S.p.A.
Castello di Godego (TV), Italy
hydraulic brakes, accepts spindles es made of special alloy, steel, alu- www.breton.it
Standard 5-Axis Trunnion HMC for Machining
Hard Metals Has Custom Precursors
The new HU100A-5XLL 5-axis trun- several custom-engineered centres for a high-torque HSK-100 or HSK-125
nion horizontal machining centre with similar configurations and attri- spindle. Flexible-manufacturing-sys-
(HMC) is designed to machine large, butes for customers in mould and tem ready, the machine has a 1,700
complex and heavy (up to 3,000-kg) die manufacturing and other sectors x 1,000-mm pallet, and its automat-
hard-metal parts. requiring machine rigidity and stiff- ic tool changer accommodates 360
Mitsui Seiki add- ness for high accuracy. tools up to 500 mm long, as wide as
ed this HMC to its The HU100A-5XLL offers an x-y-z 305 mm in diameter and weighing as
line of standard working envelope of 2,500 x 1,750 much as 30 kg each.
machines after x 1,400 mm plus tilting and rotat- A 3D finite-element-designed struc-
having produced ing trunnion-table axes. A ture, hand-scraped castings, and
50-taper spindle is sup- hardened and ground-steel box ways
plied as standard, but are behind this HMC’s high accuracy
manufacturers per- and ultrarigidity. Critical components
forming extra- are all designed and built in-house.
heavy rough-
ing in titani-
um or tough
» Mitsui Seiki USA Inc.
Franklin Lakes, NJ, USA
steels can opt www.mitsuiseiki.com
24 European Tool & Mould Making | March 2011 | www.etmm-online.comCover Story | Product Focus
Automation-Ready 5-Axis Horizontal Machining
Centre Offers Large Processing Capacity
traverses are 60 m/min in the x- and
y-axes and 50 m/min in the z-axis. A
direct-drive motor turns the tilting
table at a maximum feed rate of 50
rpm and feeds the b-axis at 75 rpm,
ensuring simultaneous high speed
and high precision.
» Matsuura Europe GmbH
Wiesbaden-Delkenheim, Germany
www.matsuura.de
The latest and largest 5-axis produc-
tion machine from Matsuura is the
MAM72-100H horizontal machining
centre, which is able to process bil-
lets and components measuring up Shaping
to 1,000 mm in diameter, 770 mm
in height and 780 kg in weight. Like
all of Matsuura’s 5-axis machines, the
MAM72-100H functions best with
steel.
flexible multiple setups. It is designed
to process a wide array of materials
Sliding core
for diverse applications and to offer moulds
Discover th
extensive benefits derived from its e advantag
an interact es with
ive 3D anim
proven advanced capabilities in unat- www.meu at ion.
sburger.com
/slidingcor
tended operation. Process integration emoulds
and high-precision one-hit processing
of complex workpieces are standard
with this machine. » in total 9 different sizes –
Matsuura developed the MAM72- all of them 100% compatible
100H in response to requests from with the existing F range
users of the existing MAM72 for a – available from stock
machine with a larger working enve- » tried and tested design with
lope and greater processing capac- optimum power transmission
through reinforced closing
ity. The new machine features x-y-z
bolster plate and completely
travels of 1,050 x 920 x 960 mm, an adjusted guide system
a-axis table that tilts between –120°
and +30°, and full 360° c-axis rota-
tion. Its working surface has dimen-
sions of 630 x 630 mm.
Designed for maximum rigidity, the
MAM72-100H offers an especially sta-
ble machining platform for a machine
Precise, stress relieved standard parts for mould and tool construction
in its capacity class. Equipped with a
12,000-rpm high-torque horizontally High stock availability
aligned spindle—torque of 451 Nm
is standard; 700 Nm is optional—the
Parma (I)
machine is a dynamic and robust tool 24.–26.03.2011
Hall 6, Stand B36 Meusburger Georg GmbH & Co KG | Standard moulds | Kesselstr. 42 | A-6960 Wolfurt
for machining hard-to-cut materials T 00 43 (0) 55 74 / 67 06-0 | F -11 | sales@meusburger.com | www.meusburger.com
such as titanium and Inconel. Rapid
www.etmm-online.com | March 2011 | European Tool & Mould Making 25Specialist trade fair
and user‘s conference High-Precision Universal
for rapid technology
Cylindrical Grinding Machine
Offers Fast Metal Removal
The new S41 CNC universal cylin- tem resolution of 10 nm. The result-
drical grinding machine from Fritz ing grinding precision and efficiency
Studer AG is designed to grind with contribute greatly to minimizing aux-
very high precision while removing iliary times. Swivel movement of the
metal at an enhanced rate. Its lon- turret wheelhead (b-axis) is also by
gitudinal (z-axis) and cross (x-axis) direct drive. New grinding wheels can
slides and the wheelhead’s swivel be positioned quickly within a place-
24 + 25 May 2011 axis are equipped with electric direct ment range of less than 1 arc-second.
drives that move
The annual venue for them to the work-
practitioner, developers ing position quick-
ly and precisely.
and visionaries including:
Developed from
scratch, the S41
· User‘s Conference
uses technology
· Design Engineers Day suited to today’s
· Trade Forum „CAD/CAM higher production
requirements but
and Rapid Prototyping in
based on know-
Dental Technology“ how gained from
· Trade Forum „Medical Tech- an earlier machine.
The new grind-
nology“
er handles more
· Trade Forum „Aviation“ applications and
provides short-
er grinding cycles
than the previous
model.
One of the out-
standing features
of the S41 univer-
sal machine is the
rigid, thermally
stable machine bed of mineral-cast The height of the centres on the
Granitan® S103 that absorbs the high standard S41 is 225 mm, with 275
forces occurring during grinding at mm being optionally available. The
high metal-removal rates. It is solidly maximum distance between cen-
constructed, with the guideways of tres is either 1,000 mm (standard) or
http://uk.rapidtech.de both slides moulded directly into it. 1,600 mm (special variant). Also help-
These StuderGuide® guideways exhib- ing extend the application range, up
it straightness of better than 0.003 to four external grinding wheels and
mm over a 950-mm measured length. three internal grinding spindles can
The machine bed helps ensure con- be combined into more than 30 pos-
stant high levels of grinding precision sible grinding head configurations.
and workpiece surface quality.
The machine slides are moved
by the linear direct drives at travel
» Fritz Studer AG
Steffisburg, Switzerland
speeds up to 20 m/sec with axis sys- www.studer.com
European Tool & Mould Making | March 2011 | www.etmm-online.comYou can also read
