Results Today - GF Machining Solutions
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
GF Machining Solutions Results Today The global customer magazine No13 Automation seals Yiben’s success Asia | 10–11 High speed, high tech, high quality Europe | 12–13 Staying ahead: a versatile solution Americas | 14–15 Printing the human body Medical | 18–21 Drones: into the great wide open Aerospace | 22–23
Contents
Results Today 13
In brief Ask our expert Complete solution
Mikron MILL P 500 advances mold makers’
From annual results to upcoming trade Industry 4.0 productivity, accuracy and autonomy.
fairs, get a look at GF Machining Solutions’ GF Machining Solutions’ software
activities around the world. engineering expert explains how 28–29
digital solutions put success at
4–7 customers’ fingertips. Precision airfoils
Premier aircraft engine providers
16–17 count on the new Liechti g-Mill 1000
airfoil machining center.
Regional
perspective 30–31
Expert insights
GF Machining Solutions Market Region Printing the human body Laser micromachining
Europe and South America provides University Hospital Basel’s 3D Print Lab Microlution’s MLTC
complete solutions for manufacturers is revolutionizing surgery and improving enables micromachining
in a complex region. patient outcomes. at the speed of light.
8–9 18–21 32–33
Into the great wide open Additive Manufacturing
Asia Once limited to military applications, New AgieCharmilles CUT AM 500
drones today tackle a host of civil and pushes the limits of EDM to advance
commercial applications. Additive Manufacturing.
Automation seals Yiben Mold’s success
as sealing solutions supplier to gold-star
automotive industry customers. 22–23 34–35
10–11 Customer Services
rConnect digital services platform
News links customers to success,
and the numbers prove it.
Europe Special die-sinking EDM for ASIA
FORM P 330 Dedicated connects users
36–37
High speed, high tech, high quality: performance in automotive and ICT.
Pankl Racing Systems leads with a fleet
of automated Mikron Mill solutions. 24–25 Academy
“Passion for Education” facilitates
12–13 Wire-cutting EDM
key knowledge transfer.
The future starts today with
the AgieCharmilles CUT P Pro’s
38–39
Americas
groundbreaking HMI and Spark Track.
Canadian thin-wall mold maker 26–27
Moulexpert counts on highly versatile
Mikron MILL P 800 U ST to stay ahead.
14–15
PRESIDENT’S EDITORIAL
A source of In these unprecedented times, we know
you are counting on us and that’s a
Dear readers,
strength in responsibility we take very seriously.
We are eager to prove our customer-centric
Welcome to GF Machining Solutions’
customer magazine, Results Today,
challenging orientation to you—and the success stories
and solutions detailed in this Results Today
your gateway to inspiration from our
successful customers around the world
times issue are a great place to start. and our complete solutions that help
enable their success!
Lastly, I will be retiring as president
of GF Machining Solutions at the end of I am proud, as president of GF Machining
June 2020 and I thank all of our customers Solutions, that our Division of GF has
for your loyalty. I will continue to support your confidence. Your success is our
the Division in an advisory capacity until success, and we are keenly focused
September and ask that you join me in on helping our customers bounce back
supporting my successor, Ivan Filisetti. from the current pandemic and flourish
in this “new normal.” This commitment
Pascal Boillat goes beyond simply selling machines. It
President, GF Machining Solutions means supporting you with best-in-class
service, application support, and expert
advice and training that only we, with our
broad technology portfolio and technology
leadership recognized across the globe,
can offer. Our complete solutions can
Dear readers, help your business recover—and help
customers grow in the future—whether
In the wake of the coronavirus disease you are looking to extend your capacity or
2019 (COVID-19) and its impact on the
global supply chain, it is clearly more
Committed to adopt a new technology.
important than ever for manufacturers
to have strong, integrity-based supplier
your success Last, I thank my predecessor, Pascal
Boillat, for his many years of leadership
relationships. That is exactly what
GF Machining Solutions delivers. Our broad
in the “new as president of GF Machining Solutions. He
will remain in the organization to support
portfolio—Milling, Spindles, Electrical
Discharge Machines (EDM), Laser texturing
normal” the Division by working on dedicated
special projects for the months to come.
and micromachining, Automation, Together with our teams around the world,
software, and Customer Services—as well we are passionate about your success and
as our application and process expertise we are eager to prove this to you.
make us a source of strength and a single
point of contact to customers worldwide. Ivan Filisetti
President, GF Machining Solutions
Whatever your market segment or
application challenge, you can work in
confidence that your success is at the
center of everything we do. As a Division of
the global GF group, we are in a uniquely
strong position to help your business
navigate a changing manufacturing
landscape and achieve the next level
of success.
3
In brief
Organizational
changes
New GF
Machining
Solutions’
president
named
Pascal Boillat, President of Ivan Filisetti will take reins as new
GF Machining Solutions, will retire GF Machining Solutions President,
With the retirement of GF Machining at the end of September 2020 effective July 1, 2020
Solutions President Pascal Boillat at the
end of September 2020, Ivan Filisetti will
take the reins as President, effective As part of GF Machining Solutions’
July 1, 2020. commitment to quality, innovation and
long-term growth, two key leadership
Boillat, who became president in January changes were implemented on
2013, led GF Machining Solutions to its
position as a world-leading machine tool
Commitment September 1, 2019.
manufacturer with a strong focus on
Digitalization and new technologies.
to quality, Scott Fosdick, former GF Machining
Solutions US President and Head of
He joined GF Machining Solutions as
Head of Operations in October 2010, after
innovation and Market Region North and Central America,
was promoted to the role of Head of
serving for seven years as President and
CEO of GE FANUC Automation Europe.
growth drive Sales, Marketing, Business Development
and Communications. Phil Hauser,
Filisetti, a mechanical engineer in
leadership formerly the Director of Sales and Head of
Turbine Group at GF Machining Solutions
automation and robotics, first joined GF
Machining Solutions in 1990, holding
changes USA, assumed Fosdick’s former position
with responsibility for sales, marketing
a number of management positions. and service operations in the region.
From 2000 to 2009, he held production,
logistics, operations and division manager
roles at two European machine tool
companies, rejoining GF Machining
Solutions in 2009. As GF Machining
Solutions Vice President for Operations,
he has had global responsibility for the
Division’s production and research and
development activities.
Scott Fosdick, Head of Sales, Phil Hauser, GF Machining Solutions US
Marketing, Business Development President and Head of Market Region
and Communications North and Central America
4 | Results Today 13
Smart, advanced technologies
showcased at EMO 2019
More than 3,200 guests representing the worldwide manufacturing industry experienced
firsthand how GF Machining Solutions is “connected to your needs,” at EMO Hannover 2019
last September in Hannover, Germany. On its 1,156-square-meter stand, the GF Division gave
visitors a peek into the future, with Industry 4.0-enabling solutions ranging from machine
tools to digital products and Customer Services, all developed to take manufacturers’
processes to the next level of productivity.
“Connected to your needs” was
the theme of GF Machining Solutions’
EMO showcase.
More than 3,000 guests from around GF Machining Solutions President In the aerospace corner of the
the world got a peek into the future Pascal Boillat speaks at the EMO GF Machining Solutions' booth, visitors
of manufacturing at GF Machining press conference. discovered dedicated solutions and
Solutions’ EMO 2019 booth. optimized manufacturing processes for
engine compressor and low-pressure
turbine applications.
5
In brief
Customers are at the heart of
expansions worldwide
In September 2019, the Division
Officials from GF Machining Solutions
inaugurated its new, CHF 100 million, and GF Piping Systems last November
44,000-square-meter innovation and commemorated the start of work on new
joint headquarters in Ontario, Canada.
production center in Biel/Bienne,
Switzerland. Situated on a 24,500-square-
meter site, the center unites former
GF Machining Solutions sites in Nidau,
Ipsach and Luterbach all under one
roof. The new building, which also is
the Division’s headquarters, boasts
13,000 square meters for production
and assembly, and allows room for a
research and development center as
well as a modern application center. At
this facility, customers can experience
GF Machining Solutions’ broad portfolio
firsthand and take part in on-site training.
Employees benefit from bright, spacious
project rooms fostering creativity and
interdisciplinary collaboration.
Additionally, in December 2019, GF
Machining Solutions moved to its new,
32,000-square-meter plant on 51,550
square meters of land in Changzhou,
China, with dedicated assembly lines for
its Mikron MILL P, MILL E U, HEM and HSM
products and a team of 200 employees.
GF Machining Solutions and GF Piping
The facility also includes application, office Systems officials last October broke
and storage areas. ground on a new joint headquarters in
Nuevo Leon, Mexico.
To further strengthen direct sales and
service to customers, GF Machining
Solutions and GF Piping Systems
GF Machining Solutions' new innovation
last year broke ground for new joint and production center in Biel/Bienne,
headquarters in Mexico and Canada. In Switzerland, unites former sites in
Nidau, Ipsach and Luterbach under
October, work began on a 7,000-square-
one roof, with 13,000 square meters
meter facility in Nuevo Leon, Mexico, of production and assembly space.
and in November, the two GF Divisions
officially began work on a 6,225-square-
meter facility in Ontario, Canada.
6 | Results Today 13
ROIC
Key figures 2019 EBIT
18.4%
GF Machining Solutions generated sales
of CHF 972 million, an organic decline
The reduction in sales and the lower
utilization of production capacities affected
57 MILLION
CHF
of 7.5% compared to the previous year. the operating result. It fell from CHF 88
Businesses in China and Western Europe
have been impacted the most, whereas
million to CHF 57 million, resulting in 5.9%
return on sales (ROS) compared to
EBITDA
the Division was even able to grow in the
United States, based on its strong position
a strong 8.3% in 2018.
71 MILLION
CHF
in aerospace and medical technologies. Innovations in the field of new technologies
Innovations and a strong focus on the
defined strategic market segments
such as Laser texturing and Additive
Manufacturing continued to see a high EBIT
Sales
margin
allowed the Division to clearly outperform demand from customers, growing 41%
the North American market. in 2019.
5.9%
972 MILLION
CHF
Successful launches Employees
in 2019 3,358
New AgieCharmilles LASER S series
sets new productivity milestone
Launched in Asia in February 2019,
GF Machining Solutions’ new high-
performance LASER S series of Laser
texturing solutions establishes a new
milestone in terms of productivity.
Revolutionary Spark Track
technology prevents wire breakage
GF Machining Solutions’ revolutionary new
Spark Track technology for wire-cutting
Electrical Discharge Machining (EDM)
represents a big breakthrough. Launched
in Switzerland in April 2019, Spark Track
prevents wire breakage, an age-old
dilemma that can arise from irregularly
shaped workpiece features. GF Machining Solutions’ and 3D
Systems’ new DMP Flex 350,
launched at EMO Hannover 2019,
improves print productivity,
The new high-performance drives time to market, and
LASER S series helps users slashes operating costs.
achieve unprecedented levels of
productivity and quality.
7
Market Region Europe and South America
Complete solutions for
a highly complex region
Encompassing more than 22 million square kilometers,
over 1.1 billion people, and a diverse cross-section of
manufacturing segments with often differing needs,
Market Region Europe and South America demonstrates
how GF Machining Solutions’ complete solutions help
manufacturers keep their customers coming back.
“We had the From large organizations with their
own supplier strategy and a need for
vision, we key account management to smaller
businesses seeking a competitive edge,
listened to the GF Division has plenty to offer.
the market, “The way we take care of customers is
shaped by the innovation, Swiss quality,
developed the and efficiency pillars of our business
strategy. Every new solution is evidence of
products, and the strength of these pillars,” Faccio says.
adapted our He cites a complete solution—including
Electrical Discharge Machining (EDM),
organization.” Milling, Automation and Software—GF
Machining Solutions conceived and
“This region is extremely complex, with installed for a global, Germany-based
countries and manufacturers of various pharmaceutical industry powerhouse.
Antonio Faccio, Head of Market Region Europe
and South America sizes and segments. The manufacturing “The customer wanted to achieve
industry across the entire region is highly targeted return on investment and reduce
competitive,” says Antonio Faccio, Head of production costs. They are very happy to
GF Machining Solutions Market Europe and have been able to achieve this—and even
South America. “Customers tell me that improve their results—with our multi-
our position as a single point of contact technology solution, project management,
for complete solutions to resolve their and after-sales support,” Faccio adds.
manufacturing challenges is a key point “They rely on us as a key supplier and we
in our favor.” are accountable for the project’s success.”
8 | Results Today 13
“Customers
tell me that
GF Machining
Solutions’
position as a
single point of
contact is a
key point in
our favor.”
Antonio Faccio, Head of Market Region Europe
and South America
“Our customers
worldwide
are more
The GF Division’s Renault Formula 1 On the advanced manufacturing side,
technical partnership in motorsports is GF Machining Solutions brings together
competitive
another example. Laser texturing, Additive Manufacturing
(AM) including both 3D metal printing and
and successful
“With a shop full of our machines, a unique EDM solution to separate AM
they appreciate the value we add: parts from the build plate, and Laser
because of
precision, speed, reliability, quality and micromachining.
performance,” he says. “Motorsports truly
their trust- and
puts our solutions to the test. The results “Ten years ago, we envisioned being
are confirmed by our partner’s extensive the reference for Laser texturing of
integrity-based
measuring to ensure that components big automotive dashboard molds, and
made with our machines fulfill the today it’s a fact,” Faccio says. “We had
partnerships
requirements.” the vision, we listened to the market,
developed the products, and adapted our
with us.”
Manufacturers in South America are also organization. Our customers worldwide
looking for trust-based partnership. are more competitive and successful
because of their trust- and integrity-based
“The level of entrepreneurship in South partnerships with us.”
Antonio Faccio, Head of Market Region Europe
America is very high. We see a lot of and South America
investment in advanced manufacturing
solutions to meet the needs of a variety of
segments, including automotive, medical,
aerospace, and consumer goods that
depend on mold making,” Faccio explains.
9
Market Region Asia
Yiben Mold’s success
in automotive industry
Founded in 2003 with ¥10 million (USD 1.4 million, €1.3 million)
in capital, Yiben today is an automotive industry success story:
Specializing in tooling and molds for post-processing sealing of
vehicles, Yiben’s gold-star list of customers includes Mercedes
Benz, BMW, GM, Volkswagen and Renault.
“The technology “The technology and solutions from GF
Machining Solutions help us achieve great
and solutions improvements in production efficiency,”
says Yiben owner Ni Liping. “We plan
from GF to integrate additional GF Machining
Solutions EDM machines into our
Machining production lines in the next half year.”
Solutions help Those are important considerations
at Yiben which, like other automotive
us achieve great industry suppliers, faces formidable
challenges, including the costs of raw
Yiben Mold owner Ni Liping says improvements materials, cutters and tool holders, labor,
and mold testing. At the same time, Yiben
in production
GF Machining Solutions helps drive the
company’s production efficiency with must deliver high-quality molds to its
both machine tools and Automation.
customers, reduce its five-axis machining
From its sprawling 12,000-square-meter
efficiency.” cycle times, and manage the costs of
training new employees. The automated
factory in near Shanghai, Yiben’s 350 Milling cells have proven themselves
employees produce up to 700 molds, 700 Yiben owner Ni Liping a real game-changer, reducing Yiben’s
sets of tooling, and 100 machines each manufacturing costs and lead time,
year. To make that happen, Yiben relies Changzhou. From concept to installation, optimizing its manufacturing process,
on a total of 36 GF Machining Solutions the collaboration between Yiben and and underscoring its leadership in its
Mikron Mill, AgieCharmilles Electrical Changzhou AgieCharmilles had the automotive subsegment.
Discharge Machining (EDM), and System solution up and running within a year.
3R Automation solutions—the results of Those achievements cement Yiben’s
ten years of trust-based collaboration. The results for Yiben are clear: Quality leading position among Tier 2 suppliers to
errors and labor costs have been the global automotive original equipment
Evidence of that solid relationship is found significantly reduced while production manufacturers and demonstrate GF
in Yiben’s two full Automation cells featuring efficiency and quality have increased Machining Solutions’ customer-centric
the Mikron MILL E 700 U manufactured dramatically. orientation—for ten years and counting.
at the GF Machining Solutions factory in
10 | Results Today 13Yiben Mold
No.58, Taizhong Road,
Taicang, Jiangsu Province, China
Contact
Phone: +86 512-33005800
Fax: +86 512-33005899
Website: http://www.yibenmold.com/
GF Machining Solutions machines
16x MILL E 700 U
1x HPM 1350U
1x HEM 700 U
6x UCP 800
2x FORM E 350
1x FORM 20
1x FO 23 UP
1x CUT 20 P
1x CUT 30 P
4x CUT 200 BP
2x CUT E 350 A perfectly machined mold for post-processing
vehicle sealing is made possible by GF Machining
Solutions’ five-axis Mikron Mill technology and
System 3R Automation.
Yiben Mold’s 12,000-square-meter One of the 700 flawlessly Yiben specializes in manufacturing
factory near Shanghai, China executed molds produced by molds and tooling for post-process
Yiben each year sealing for the automotive industry.
11Market Region Europe
Pankl Racing Systems leads
with high speed, high tech,
high quality
Pankl Racing Systems’ mission, “High speed, high tech, high
quality,” comes to life in Bruck an der Mur, Austria, where
a 380-member team develops and produces the bespoke
pistons, piston pins and connecting rods essential to both race
cars and high-performance road cars. Behind their success
is an impressive fleet of automated Mikron Mill high-speed
Milling machines.
“Our Mikron “Supplier relationships are always
important. Our suppliers are worldwide,
“A piston for an engine with rpm level
higher than 18,000 and ignition pressures
Mill machines since our products are quite special and
all of our materials and coatings are
up to 300 bar is highly stressed during its
use, so every surface must be perfect in
support our nonstandard and often designed and
evaluated just for Pankl,” says Peter
such a critical part in order to prevent the
risk of engine failure,” Rattinger says.
mission of high Rattinger, Head of Pankl’s Piston and
Piston Pin Department. “Our Mikron Mill Pankl bought its first Mikron Mill machine
speed, high machines support our mission of high
speed, high tech, and high quality.
for piston manufacturing 15 years ago
when the business was rethinking its
tech, and high They allow us to produce our parts very
quickly and efficiently with five-axis
manufacturing process due to changing
piston designs. When evaluating Milling
quality.” simultaneous Milling. The Workpiece
Changer (WPC) on the rear of each
machine suppliers, quality, geometric
accuracy and fast machining times were at
machine allows us to run our machines the top of the list. All these factors, plus a
Peter Rattinger, Head of the Piston and Piston Pin nights and weekends, even unattended.” high degree of automation, are necessary
Department, Pankl Racing Systems to guarantee the output of Pankl’s fastest-
That’s important, he says, because growing profit center manufacturing
Pankl pistons—machined primarily from approximately 30,000 pistons per year for
exclusively developed aluminum alloys the racing industry.
and high-strength steel—often have long
cycle times due to their complex shapes
and the requisite high surface quality.
12 | Results Today 13GF Machining Solutions machines*
2x Mikron XSM 400U
2x Mikron XSM 400U LP
1x Mikron HSM 400U LP
3x Mikron MILL S 400 U
2x Mikron MILL S 600 U
*All with Workpiece Changer
(WPC) Automation
Pankl Systems Austria GmbH,
Engine Systems
Kaltschmidstrasse 2-6
8600 Bruck an der Mur, Austria
Contact
Phone: +43 3862 33999 - 0
Website: www.pankl.com
Email: engine@pankl.com
At Pankl Racing Systems, a 380-member team develops and
produces the bespoke pistons, piston pins and connecting rods
essential to both race cars and high-performance road cars.
“With GF
Machining GF Machining Solutions' Mikron Mill
machines master Pankl pistons'
complex shapes and requisite high
Solutions, we surface quality.
have a strong
partner at
our side.”
Crankshaft components are highly
stressed during engine use, so every
Peter Rattinger, Head of the Piston and Piston Pin surface must be perfect in order to
Department, Pankl Racing Systems prevent the risk of engine failure.
“The Mikron XSM 400U was a natural fit
for us because it meets our requirements
and has compact Automation to increase
both efficiency and our productivity per
square meter,” says Rattinger, adding that
available smart modules also contribute to
The crankshaft rotates, in
his department’s success. conjunction with connecting rods,
to convert the reciprocating motion
of the pistons into rotational motion
“At the same time, GF Machining Solutions
essential to engines in race cars and
provides complete solutions. We don’t high-performance road cars.
have to talk with three or four different
companies to get solutions related to
Pankl Racing Systems Austria
our machining process,” he asserts,
noting that Pankl will soon add a new
Mikron MILL S 600 U to its fleet. “With GF
Machining Solutions, we have a strong
partner at our side, whether our question
© Images:
is related to hardware, software, or some
other technical issue.”
13Market Regions Americas
Thin-wall mold maker
Moulexpert finds “Swiss Army
knife” of solutions in Mikron
MILL P 800 U ST
Quebec, Canada-based multicavity injection mold designer
and manufacturer Moulexpert Inc. today machines high-
quality, thin-wall molds for round plastic food containers in
hours instead of days. GF Machining Solutions’ highly versatile
Mikron MILL P 800 U ST (simultaneous turn) machining center
plays a key role.
Moulexpert boasts a customer base Moulexpert also wanted to maintain the
spanning eastern Canada, Europe and agility to meet customer expectations
the United States. Focused primarily on for faster production without sacrificing
molds for food packing from the start, quality and reliability. It essentially
the business also took on mold making needed a “Swiss Army knife” of machines,
opportunities in different industry something small that could do a lot: high
segments and in 2011 decided to precision, high speed and high capacity.
concentrate on its strengths in designing
and manufacturing thin-wall molds for GF Machining Solutions’ Mikron MILL P
food packaging. 800 U ST (simultaneous turn), purchased
New molds are generally being
in 2018, checks all the boxes. With its produced by Moulexpert every two
Thin-wall molds present big challenges: high removal rates and precision on weeks, and the company plans to
expand its footprint in Canada and
It’s more difficult to inject plastic into round and other challenging mold cavity
expand further into the U.S. market.
the molds because the flow channels components, it meets Moulexpert’s need
are incredibly thin—just 0.015 inches for productivity, part table capacity, and
(0.381 cm). During plastic injection, these superior quality.
thin flow channels create tremendous
pressure inside the tool. Even with a good “With the Mikron MILL P 800 U ST,
mold design, any uneven wall thickness everything was there: roughing, finishing,
will have physical effects on the mold and five-axis, accuracy, and the ability to turn
prevent it from producing good containers. very big parts,” Project Manager Marc De
For that reason, it is essential to rely on a Grandmont says.
machine that can produce molds within a
tolerance of 5 microns.
The Mikron MILL P 800 U ST mills
and turns and features a powerful,
specifically designed 20,000 rpm spindle
with a hydraulic system that firmly locks
it in place for turning operations.
14 | Results Today 13Moulexpert Inc.
Moulexpert Project Manager Marc De Grandmont (left) and CEO
415, 3e Avenue
Steve Nadau (right) are convinced of the value the MILL P 800 U ST
Levis, Quebec, Canada
brings to the firm’s production of high-quality, thin-wall molds for
the food packaging sector.
Contact
Phone: +1 418 834-5544
Website: moulexpert.com
E-mail: https://www.moulexpert.com/contact-us
GF Machining Solutions machines
1x Mikron MILL P 800 U ST
“If we had This all-in-one solution enabled
Moulexpert to increase the overall capacity
purchased of the plant, reduce lead time to widen
profit margins, meet demand and quality
a turning specifications to strengthen the customer
experience, and make the business more
machine instead competitive by improving productivity for
those thin-wall molds for round-shaped
of the MILL P containers. It has also positioned the shop
to boost its capacity by 25%.
800 U ST, we Additional equipment and programming
Prior to acquiring the Mikron MILL P
800 U ST, Moulexpert’s 25 employees
would not have technology for automation integration are
likely on the horizon for Moulexpert as it
were making about 125 molds per year.
Today, the company produces about
270 molds, depending on size, with the
five-axis milling looks to manage growth-driven production
volume.
same number of employees—a 116%
improvement in productivity.
capabilities, and “GF Machining Solutions helps us with all
we would have of this,” CEO Steve Nadau confirms.
had to purchase
two machines.”
Marc De Grandmont, Project Manager,
Moulexpert Inc.
15Ask our expert: Jonas Ruesch
Driving manufacturing’s
digital transformation
GF Machining Solutions Head of Software Engineering Digital
Business Jonas Ruesch explains how the GF Division’s digital
solutions are making manufacturing more efficient, productive
and measurable—all at the touch of a finger.
“Capital cost What does all of this mean for
customers?
pressures Customers’ needs drive everything we do.
With our extended machine connectivity
and demand capabilities, they can tightly integrate our
machines into their digital environments.
for flexible Second, our web-based customer
portal, the Digital Hub—cocreated with
manufacturing customers—serves as a unique access
point for software measuring and
solutions are improving our machines’ performance. It
will also bring us closer to our customers.
accelerating a What can you tell us about
With this approach, we are responding
to demands for extended software
shift toward GF Machining Solutions’ Digital
Business?
services, which must run on top of
traditional human-machine interface (HMI)
service-oriented Around the globe, digitalization is rapidly
transforming how customers use and
functionality, can be installed at the click of
a button and are accessible from browsers
manufacturing integrate our equipment. In parallel,
capital cost pressures and demand for
and mobile devices, anytime, anywhere.
solutions.” flexible manufacturing solutions are
accelerating a shift toward service-
oriented manufacturing solutions. Our
Jonas Ruesch, Head of Software Engineering Digital Business establishes a services
Digital Business ecosystem, empowering customers to
leverage the true value of our machines
with less effort.
16 | Results Today 13“The Digital
Hub—
cocreated with
customers—
serves as
a unique
access point
for software
measuring
and improving
our machines’
performance, Tell us about GF Machining What’s on the horizon?
and will Solutions’ state-of-the-art
digital solutions.
The Digital Hub will allow for self-service
access to digital solutions like we are
also bring us Our OPC UA Interface v1.0 provides a
first unified connectivity layer across our
used to on our mobile phones. Being
connected, we can react to customer
closer to our technology portfolio, so all of our machines
can speak a common language. With this
needs faster and deliver updates with new
functionality within minutes. We foresee
customers.” option, relevant data is readily available
and can be can easily integrated into shop
commercial availability of Digital Hub-
based applications in 2021. One of the first
floor dashboards, so it becomes easy to will be the Part Inspector app. It leverages
Jonas Ruesch, Head of Software Engineering measure key performance indicators and recorded process data like EDM generator
Digital Business overall equipment effectiveness (OEE). signals to identify and tag problematic
OPC UA is available for all new patterns indicating production issues.
AgieCharmilles and Microlution machines We’re also working on an app with our
and our solutions developed with 3D Milling team to enable effortless tracking
Systems. For Mikron Mill and Liechti and control of machine equivalence for
machines, it will become available multiple machines.
later this year. We also offer software
applications supporting the data flow
around our machines. Our Multi-Process
Planning tool suite, MPP/eTRUE, brings the
right data to die-sinking EDM machines,
allowing customers to optimize electrode
geometry and process parameters based
on the true target mold shape.
Our eTracking software allows operators
and process engineers to “listen” to the
wire-cutting EDM process and track and
trace process data with respect to a
qualified reference.
17Expert insights: 3D Print Lab
A polymer (PLA) 3D skull model for surgery planning,
is produced on a fused deposition modeling/fused
filament fabrication (FDM/FFF) printer.
On the leading edge:
printing the human body
From 3D models of the human skull to 3D-printed patient
specific implants and biocompatible guides that tell surgeons
exactly where to cut during operations, the University Hospital
Basel’s state-of-the-art 3D Print Lab is revolutionizing surgery
and improving patient outcomes.
18 | Results Today 13“I feel that at the University of Basel’s Department
of Biomedical Engineering and a lecturer
recalls. “Today, you just need a mobile
phone or a laptop to visualize complex
patient-specific for cranio- and maxillofacial surgery, and
cofounder and codirector of USB’s 3D Print
anatomy.”
implants are Lab. And, as 3D printers become less expensive
and more accessible, they are more
the future of “Although my first computer, a
Commodore 64, had no internet
commonly used.
medicine and connection, I was really fascinated by
the possibilities and the opportunity
“Today, at our hospital it is routine for
doctors to order a 3D-printed model
that there to visualize solutions on a computer
screen,” Thieringer explains. “Today,
to support them in planning surgical
procedures for craniomaxillofacial defects,
will be a huge these visualization and manufacturing
technologies are everyday tools in
to work with patient-specific titanium
implants, or use biocompatible-certified
demand.” craniomaxillofacial (CMF) surgery. When
I began my career, computer-based
polymer surgical guides intraoperatively,”
Thieringer adds. “With surgical guides, you
planning, virtual surgical planning, and transfer information from the computer
Dr. Florian Thieringer, cofounder and codirector, patient-specific implants were reserved into the operating room: The guide shows
University Hospital Basel 3D Print Lab for very rare cases. Today, these are very you exactly where to cut the bone, drill a
powerful tools that we can use on a daily hole, or where a biopsy should be taken.”
basis to facilitate the treatment process—
At just 42 years old, Dr. Florian Thieringer not only in CMF but across a wide range of The benefits of medical additive
doesn’t consider himself a digital native: medical disciplines.” manufacturing are many and Thieringer is
His first personal computer didn’t even quick to add that additive manufacturing is
have an internet connection. Today, Thieringer recalls that early in his career, a complement to—rather than a threat to—
though, the tools his team is using to a single computer workstation used to conventional manufacturing technologies.
transform patient care extend far beyond analyze 3D images of the human skull was
an internet connection: 3D printing, the key a staggering investment.
medical additive manufacturing technology
Improving treatment processes
(MAM), plays a central role. Thieringer is “The workstations then were larger through virtual surgical planning
University Hospital Basel (USB) Assistant than the biggest refrigerator and cost and 3D printing also includes
postoperative quality control
Medical Director, head of a research group hundreds of thousands of dollars,” he
using radiological 3D data.
3D skull models such as this one help surgeons at
Basel University Hospital to plan and safely perform
complex operations.
19Expert insights: 3D Print Lab
“Compared to other workflows more While restoring the facial functions like shape not only self-image but how others
ideal for serial production—like milling chewing and speaking are important perceive the patient. Technologies like
of molds for plastic injection—additive considerations in CMF surgery, they MAM can make an enormous contribution
manufacturing can, with little effort, aren’t the only determinants of a to both functional and aesthetic
produce individualized models, implants, satisfactory patient outcome. Thieringer outcomes, and he’s looking forward to big
guides and instruments. If you have to says the aesthetic outcome is also of key breakthroughs in MAM technology in the
produce many parts of the same shape, importance, because the human face can coming decade.
a more traditional production method
would be more suitable.”
“We have
demonstrated
that MAM
can speed
up orbital
reconstruction
by 30%.”
Dr. Florian Thieringer, cofounder and codirector,
University Hospital Basel 3D Print Lab
The 3D Print Lab of the University Hospital of Basel prints models from a variety of
polymers and other materials and conducts research in new application areas such
On the patient-specific implants side, as intelligent implants and biomaterials for medical use, as well as in medical image
analysis and segmentation.
titanium and high-performance polyether
ether ketone (PEEK) are the materials of
choice, he says. 3D-printed patient-specific
implants can be adapted to the patient’s
specific anatomy so that function can be
restored in the best possible way.
“I feel that patient-specific implants
are the future of medicine and that
there will be a huge demand. I foresee
a real demand, for example, in CMF
surgery for patient-specific implants to
repair the cranial walls or for mandible
reconstruction after tumor surgery,
since the mandible should be perfectly
reconstructed to avoid impediments to
function,” Thieringer says enthusiastically.
“Complex orbital defects or dental
rehabilitation after severe trauma or
tumor treatment are other areas where
Binder jetting 3D printing allows Dr. Florian Thieringer, University
patient-specific implants can make a huge large-scale, full-color printing without Hospital Basel (USB) Assistant Medical
difference in the patient outcome.” support structures. This process is used Director, shows how 3D printing can be
in the 3D Print Lab mainly for complex used to bring 3D planning data from the
anatomical models such as skulls. computer to the operating room.
20 | Results Today 13Surgeons especially count on the With the help of a workflow The models produced with the binder
3D Print Lab for patient-specific developed at Basel University jetting process require infiltration
printed models and surgical guides Hospital, patients can be individually with liquid acrylate to achieve
to support them in planning surgical treated for complex cranial defects optimum strength.
procedures. based on 3D planning data.
Prof Florian Thieringer (right in A positive side effect of the use of The use of handheld 3D scanners
white jacket) observes a computed 3D models in the treatment process and 3D-printed models is now
tomography (CT) scan. Such scans is the possibility to improve the standard for many operations at
produce the digital radiological images training of residents. With the the University Hospital Basel.
on which individualized 3D-printed skull help of 3D printing, even complex
models, surgical guides, and patient- pathologies become "tangible."
specific implants are based.
“The technology is already quite Even with those challenges afoot,
sophisticated today, but I look forward Thieringer’s enthusiasm for MAM
to being able to print patient-specific is unbridled.
implants without the need for complex,
time-consuming post-processing,” he “I think patients realize the value of MAM,
says. “Medical device regulation is another too, because we can show a patient—on
big challenge as we enter an era in which a 3D-printed model of his or her own
hospitals can become manufacturers. For skull—exactly what we’re going to do in the
example, we have demonstrated that MAM operating room,” he says. “Postoperative
can speed up orbital reconstruction by patient compliance is better, too, because
30% at the same, or even superior, quality the patient becomes invested and part of
compared to a conventional operation the surgical planning process.”
using stock implants.”
Universität Basel, Christian Flierl
© Images:
21Expert insights: Drones
Into the great wide open—
with drones
With a history going back more than 180 years and once
limited to military applications, unmanned aerial vehicles
(UAVs), better known as drones, today tackle a host of civil and
commercial applications. It appears that the future is drone
enabled—and wide open.
Some authorities trace the history of “Over the past several years drone • During the coronavirus pandemic
drones to 1839, when Austrian soldiers technology has proven its value in serving (COVID-19), drones were used to enforce
used explosive-filled unmanned the greater good, from saving lives, lockdowns in China and France and were
balloons to attack the city of Venice—a mitigating risks to first responders, to employed to spray disinfectant in crowded
misadventure that resulted in balloons preventing diseases like malaria,” says DJI urban areas.
being blown back and bombing the Senior Director of Public Safety Integration
Austrians’ own lines. In 1898, Serbian- Romeo Durscher. DJI is the world leader
American inventor, electrical and in civilian drones and aerial imaging How might drones shape society in the
mechanical engineer, and futurist Nikola technology. future? Predictions run the gamut from
Tesla was granted a patent for a wireless, self-flying vehicles to construction aided
radio-controlled, unmanned boat, setting Indeed, the humanitarian applications of by drones equipped by 3D printers.
the course for modern wireless drones. drones are especially impressive: Flying cars, for example, have long
occupied the public’s collective vision
Since its earliest iterations, drone • Following the 2013 typhoon Haiyan, of how technology could transformation
technology has evolved to a staggering small and lightweight UAVs were used to mobility. Today, aerospace and automotive
degree. The global drone market, identify places where non-governmental manufacturers, world-class research
according to some estimates, is on organizations could set up camp and institutes, and governments are leading
target to grow by 15 percent through which roads were passable, to assess the charge to open the skies to drone-
the year 2025, propelled in large part by post-storm-surge damage and flooding, inspired self-flying vehicles.
commercial sectors, including oil and and to gauge which villages had been most
gas, construction, energy, entertainment, affected. If futurists are right, the horizons for
medical, and parcel delivery industries. drones are indeed wide open.
In fact, multinational professional services • As the famed Notre Dame Cathedral in
network PricewaterhouseCoopers (PwC) Paris, France, was burning in 2019, Paris
estimates the value of the total emerging firefighters sent in commercial drones
global drone market at US $127 billion with thermal cameras to track how the fire
through 2020. was spreading and where it originated.
Those images were used to determine the
most effective way to position fire hoses,
preventing even worse damage to the
850-year-old landmark.
22 | Results Today 13The global drone market, according
to some estimates, is on target to
grow by 15 percent through the year
2025, propelled in large part by
commercial sectors.
“Over the
past several
years drone
technology has
proven its value
in serving the
greater good,
from saving
lives, mitigating
risks to first
responders,
to preventing
diseases like
malaria.”
Romeo Durscher
DJI Senior Director of Public Safety Integration
Self-flying vehicles could be the next
frontier for drone technology—and
the mobility sector.
23News: Special die-sinking EDM
for ASIA
FORM P 330 Dedicated
connects you to performance
in automotive and ICT
Asia connector mold manufacturers for the automotive
and information and communications technology
(ICT) sectors are connected to success, thanks to the
AgieCharmilles FORM P 330 Dedicated.
Delivering high repeatability, output and
exceptional homogeneity, the tailored
and ready-to-use FORM P 330 Dedicated
die-sinking Electrical Discharge Machining
(EDM) solution positions mold makers for
performance in these highly demanding
market segments. Conceived especially
for these users, this machine ensures
perfect quality to reduce scrapped molds
and puts perfect results at the touch of
a finger. Its simple, effective Tooling and
competitiveness-driving Automation
solutions further advance users’ success.
The AgieCharmilles FORM P 330
Dedicated supports mold manufacturers
in the automotive and ICT sectors.
24 | Results Today 13Manufacturers • The production cost package with the
Rotary Tool Changer (RTC) or an external
can choose robot to fulfill the needs of manufacturers
confronting challenging labor costs
the package • The advanced package with a C axis,
aimed at middle- to large-size
that best suits manufacturers focusing on mold
quality and increased productivity.
their individual Customer-approved solution
Perfect homogeneity is essential in
the production of plastic injection
production The FORM P 330 Dedicated has already molds for automotive connectors.
The FORM P 330 Dedicated masters
impressed the chairman of a global this challenging mold requiring a
needs strategic mold supplier to top 500
companies. He said the improved HMI
homogenous surface (roughness of
VDI 18–22) andNews: Wire-cutting EDM
The future starts today
with the CUT P Pro series'
groundbreaking HMI and
Spark Track
As the future unfolds at high speed and reshapes the way
manufacturers work, GF Machining Solutions' AgieCharmilles
CUT P Pro wire-cutting Electrical Discharge Machining (EDM)
series break new ground.
Developed in collaboration with They also appreciate Uniqua’s enormous ensures that users experience the best
customers to meet their needs, the contribution to workshop productivity, as possible EDM performance—without the
CUT P Pro wire EDM series takes users' it helps them achieve increased efficiency risk of wire breakage. Spark Track, with
flexibility, productivity, speed and quality and a drastic reduction of the machine's its state-of-the-art ISPS, monitors and
to a new level. Featuring the new and non-productive time. measures sparks generated during the
easy-to-use Uniqua human-machine EDM process and uses that data to adjust
interface (HMI) and Intelligent Spark Whether the machine operator is used to machine parameters accordingly.
Protection System (ISPS) with working with the Vision interface or is a The result: greater EDM process security,
Spark Track technology, the CUT P Pro high-level job customer accustomed to ISO higher efficiency, and easier execution
series represents a new approach to programming, Uniqua's object-oriented of applications.
work management and planning. approach is an unprecedented alternative
that enables highest productivity. The completely automatic process enabled
Unleashing high flexibility Typically demanding tasks like stopping by the ISPS is highly effective, even
Specifically, Uniqua is easy for machine the machine, changing machining strategy, in the most difficult cutting conditions
operators to manage because its or changing a part are dramatically and for the most complex part shapes.
attractive, easy-to-understand graphics simplified by Uniqua. In fact, processes That means users can focus on cutting
guide the way to successful processing become logical with its intuitive onscreen without worrying about wire breakage:
and increased productivity. By simplifying icons, all available with a simple touch. Efficiency and the vision of zero-defect
the operator’s tasks, the HMI unleashes Moreover, its low learning curve makes manufacturing are built into the system.
high flexibility to increase production mastery easy, whether the user is new to
efficiency and reduce operating costs. machine programming, a seasoned Vision As the fourth industrial revolution—Industry
user, or a veteran ISO code programmer. 4.0—changes the way manufacturers
Customers currently using the Uniqua work, the CUT P Pro series with the new
HMI say it is easy to learn, has onboard Don’t worry, just cut Uniqua HMI and Spark Track technology
intelligence, and provides immediate, At the same time, the CUT P Pro solutions' underscores GF Machining Solutions’
visual operator-machine communication. groundbreaking Spark Track technology customer-centered innovation legacy.
26 | Results Today 13Screen display: The illustrated GF Machining Solutions’ Intelligent The AgieCharmilles CUT P Pro’s new
demonstration piece contains Spark Protection System (ISPS), and easy-to-use Uniqua HMI simplifies
very difficult geometries: bevels, available for the CUT P Pro wire- the machine operator’s job, increases
protrusions, and points. On the screen, cutting EDM series, resolves the issue production efficiency, and reduces
there is real-time control of the energy of wire breakage during machining of operating costs.
density on the wire. The ISPS detects complexly shaped parts.
when sparking becomes too intense.
Wire breakage is thus prevented even
with complex shapes.
Uniqua enables a high flexibility to
increase production efficiency and reduce
operating costs.
The AgieCharmilles CUT P Pro’s high flexibility
and ease of use are made possible by the new
Uniqua HMI and available Intelligent Spark
Protection System (ISPS) to prevent wire
breakage on irregularly shaped workpiece
features.
27News: Complete solution
Multicavity molds in certain
industries require high
positioning accuracy and
high surface finishes.
Mikron MILL P 500
The MILL P 500 meets
these demands, thanks to
its 42,000 rpm Step-Tec
Spindle and a stable
advances mold makers’
structural design that
ensures no cutting marks
on glossy finishes.
productivity, accuracy
and autonomy
30 m/min feed rate
42,000 rpm Step-Tec Spindle
The MILL P 500 delivers the highest
precision achievable on a standard three-
axis high-speed Milling machine. With its
high productivity and long-term stability
over long machining times, this solution is
a game-changer for mold and die makers.
The highest precision achievable on a standard three-axis
high-speed Milling machine is a hallmark of GF Machining
Solutions’ new Mikron MILL P 500—but its advantages
don’t stop there.
The MILL P 500 high-performance Milling MILL P 500 satisfies the needs of mold and reliability, availability and stability are
solution delivers long-term stability over die makers serving the automotive, home met by the MILL P 500’s mastery of
long machining periods as well as a appliance and packaging for consumer machine behavior related to temperature
competitive edge in terms of productivity. goods markets. fluctuations during machining as well
The MILL P 500 extends GF Machining as in the production area. Moreover,
Solutions’ three-axis performance Mold and die makers serving the ICT and manufacturers’ demands for best
portfolio with new solutions dedicated to EC segments require more consistent productivity per square meter, including
mold and die makers in the information precision and processes. The MILL P 500 optimal operator access to the machine, are
and communications technology (ICT) and delivers that crucial support with machine answered by the MILL P 500’s compactness
electronic components (EC) sectors. At the setup and tool management. In parallel, in comparison to competing machines.
same time, due to its large axis ratio, the these manufacturers’ needs for greater
28 | Results Today 13When using the CutterToolMonitoring (CTM) option, In the job list, the operator can also view
the user can see all the needed cutting tools to be the cutting tools and their status, as well
used in the job as well as their lifetime. as whether any tools are missing.
Building on a stable machine base, the Ra ≤ 0.1 μm CellManager software or JobTool Manager
MILL P 500 provides the high accuracy Manufacturers get their molds to their (JTM) to verify that all necessary cutting
and dynamics essential to the quality customers faster and at the expected tools are available before the Milling
production of mold cavities for plastic quality, thanks to the MILL P 500’s ability operation begins; Alarm Server that sends
injection as well as stamping die plates. to machine finishes finer than Ra 0.1 μm. messages from the machine to the user
Extending user's competitive edge is This solution reduces time-consuming, by e-mail or text message; CellMonitor to
the solution's excellent material removal labor-intensive manual polishing work display the status of all cells and individual
rate, made possible by the high-speed by days, so manufacturers can more machines and processes: and CellStatistic
Step-Tec Spindle. quickly meet their customers’ mold that retrieves and analyzes cell utilization
making demands. and order data.
±4 µm precision
The formidable manufacturing challenge of Excellent dynamic behavior Step-Tec HVC 140 Spindle
ensuring less than ±5 µm deviation on parts With its significantly high dynamics, The MILL P 500’s HVC 140 Spindle with
machined over long periods—often 24 hours the MILL P 500 significantly reduces HSK-E40 tool interface ranks best in class
or longer—is resolved by the MILL P 500. production costs. An additional competitive in terms of precision and thermostability.
Moreover, the solution’s good roughing edge in terms of productivity is ensured by At the same time, this Spindle delivers
behavior is enabled by the thermostabilized the MILL P 500’s 30 m/min feed rate and highest-ever static and dynamic stiffness
machine body. High quality is guaranteed— 42,000 rpm Step-Tec Spindle with 8.8 Nm with the least amount of runout. It has
regardless of the duration of the program— of torque and HSK-E40 tool interface. a dust-dry Spindle nose for medical or
by the process-supporting machine body. graphite machining.
On top of precision, users’ productivity is 24/7 automated process
advanced by state-of-the-art components, Around-the-clock productivity is In mold and die, the HVC 140 Spindle is
high technical machine availability, within easy reach, thanks to the the go-to solution for mold component
and an attractive array of Automation automated processes made possible manufacturing for information and
possibilities. Together, these characteristics by the MILL P 500’s well-integrated communications technology (ICT)
mean manufacturers can achieve both tool magazine and the affordable applications and other super-precision
precision and top surface finish without Mikron Work Pallet Changer WPC 10. moldmaking applications. On the parts
compromising on machining time. production side, it is particularly suitable
A variety of System 3R software options for high-precision machining and grinding
are available to even further boost the applications in medical, dental, watch and
MILL P 500’s autonomy. These include jewelry applications.
CutterToolMonitoring (CTM) when working
with System 3R's WorkShopManager
29Airfoils milling
New Liechti g-Mill 1000 takes
your airfoil manufacturing to
a new level
Premier aircraft engine providers count on Liechti’s
new g-Mill 1000 airfoil machining center for flawless,
economical production of bladed integrated disks
(BIDs) up to 1,000 mm in diameter.
The recently launched g-Mill 1000 has machine materials, including titanium
quickly earned big interest among some alloys. The Liechti g-Mill 1000 masters
of the world’s most demanding aerospace these challenges due to its unique ROLANT
players. That is because it delivers the (Rotations-Linear-Antrieb) kinematics.
high rigidity, high dynamics, and high
roughing rates essential to their five-axis ROLANT kinematics enable low machine
simultaneous machining of titanium and height and lower center of gravity which,
nickel BIDs (also called blisks or integrally along with superb rigidity, extend the
bladed rotors) up to 1,000 mm in diameter. service life of costly cutting tools and
4P: Solutions for
Advanced ergonomics allow easy, fast provide greater cutting tool access to the
lowest cost per part
loading and unloading of the workpiece workpiece. The part is loaded horizontally
Plan your profit
and secure operator safety. and then the table can be swung into
Solution engineering of
an overhead position which allows both your technical and economical
Developed in collaboration with aircraft optimal cutting tool access and chip flow. production requirements
engine manufacturers, the Liechti g-Mill Performance
Innovative technology for
1000 brings together g-performance In parallel, the four direct drives allow more
highest quality and quantity output
tuning, state-of-the-art TURBOSOFT accurate and highly dynamic machining. Partnership
plus software, and process development The continuous 3.5 m/min (140 inches per Support and performance updates over
leadership. This solution ensures best minute) feed rate guarantees the same tool entire machining solution life cycle
surface quality and tool life at the lowest tip velocity around the whole blade and its Profitability increase
More than 30 percent,
cost per part, due to direct drives on the edges. This is 40% faster compared with lowest cost/part
A, B, X and Y axes. Additional damping can other airfoil machining centers.
be added to the torque motor-driven axes.
Together, these characteristics establish a With its HSK 80 tool interface, adjustable
solid foundation for lowest cost per part. coolant nozzles, 1 g acceleration, and a
rigid monobloc base, the g-Mill 1000 is the
As aircraft engines become smaller and go-to solution for highest quality, lower
lighter weight to drive fuel efficiency, cycle time and ergonomics to support both
BIDs are subject to greater pressure part handling and operator safety.
and higher temperatures, requiring
more temperature-resistant, difficult-to-
30 | Results Today 13You can also read
