Protolabs posts new speed record with System 3R

When it is seen how Protolabs uses a System 3R pallet system in the ever-tougher ‘lead time race’, it is easy to see why the company asserts that it is the world’s fastest supplier of both CNC milled and injection moulded components.

Regarding speed, operational reliability and repeatable precision, Protomold and Firstcut, the two elements in the company’s operations, both benefit greatly from System 3R’s Macro system. This applies equally to the manufacture of moulding tools and the milling of components.

All workpieces are mounted on Macro pallets. Thanks to the properties inherently offered by the patented 3Refix system’s guaranteed positioning, Protolabs can move the pallets from one machining process to another without jeopardising precision, no matter how many such moves the total process requires.

“Over the past four years, System 3R has undoubtedly helped us cut lead times considerably, if not to say dramatically,” reveals Lee Ball, production director.“Speed is the essence of our mission to supply customers with injection moulded or machined components. Protomold is really fast in supplying injection moulded parts to customers. We would not be able to produce moulding tools fast enough if we couldn’t first make the necessary graphite electrodes. Macro is with us all the way. Furthermore, the system is so easy to use.”

By combining the production processes in its Haas CNC milling machines and Agie-Charmilles die-sink EDM machines, Protolabs can rapidly supply parts made in the desired material. This is vital not only in each prototype project but also in the production of test pieces and the reproduction of unavailable, obsolete or faulty components.
For further information www.system3r.com

Smart adaptive machining with script programming

From ONA’s passion for EDM comes its obsession with incorporating constant improvements into the company’s machines that optimise production processes and improve finish quality.An example of this is ONA’s‘Script Programming’ tool. A high-grade programming language that allows for the creation of smart programs. It is possible to modify projects during the process to react to changing conditions, thereby guaranteeing piece quality.

All of the company’s models have the option of including an additional package with its Script Programming smart program creation tool. What advantages does this provide to customers’ production processes? Mainly improving production in terms of time and, above all, improving piece-part manufacturing quality.

ONA’s adaptive machining concept is based on the ability to react to changing conditions. Script Programming benefits from the application’s knowledge and experience, and translates that into dynamic programs capable of addressing changing conditions, rules and variables. The more knowledge it has about the manufacturing process, the more competitive it will be. The possibilities offered by Script Programming are infinite.None of this is possible with conventional programming, which is appropriate for pre-planned, static procedures where no changes are expected.

There are many advantages of Script Programming, including the ability to create personalised set-up cycles. Another benefit is the ability to execute actions conditioned by a series of premises.Without this option, the piece machining instructions are defined beforehand and cannot be changed. Thanks to Script Programming, it becomes possible to redefine the rules, adapting them to the process’s variable conditions during its execution.
For further information www.onaedm.co.uk

Hirschmann starts co-operative research project

Carl Hirschmann GmbH is supporting activities at Rheinisch-Westfälische Technische Hochschule (RWTH), auniversity in Aachen with a co-operative project together with machine tool manufacturer GF Machining Solution and the study group EAK (Erosiver Arbeitskreis). In mid-November, Dominik Gotthelf and Bernd Reiner, sales manager at Carl Hirschmann, visited the university in Aachen, where they handed over an FJR80NCYA30A rotating and indexing spindle.

This spindle is used in an AgieCharmilles CUT P 350wire EDM machine from GF Machining Solutions to profile grinding wheels.

“For us as initiator of the project, it was important to train the research project group in the use of our rotary spindle and the associated control system,” says Reiner.

Manufacturing on an EDM equipped with Hirschmann high-speed rotating and indexing spindles is an efficient alternative to hard turning or superfinishing for rotationally symmetric parts. Even smallest parts in stainless steel, hard metal or even conductive ceramics, which cannot be made by conventional processes like turning or grinding, can be manufactured efficiently, reports the company.

Besides high-speed rotation, the application of rotating and indexing spindles allows precise indexing and simultaneous machining (via the machine control). It is thus possible to machine the finest rotationally symmetric structures and precise surfaces and contours.

In addition to the training, the meeting focused on a transfer of knowledge between the students and the two companies on technology and parameter settings. This is the basis for a further common research project and further investigations. The students receive additional support from grinding wheel manufacturer Tyrolit.

Hirschmannis pleased regarding this project with university RWTH Aachen and is looking forward to the results.
For further information www.carlhirschmann.de

Makino unveils UPX600 high-precision wire EDM

At JIMTOF 2022 in November, Makino gave the public its first view of the company’s new UPX600 wire EDM for high-precision applications such as press dies,precision electronic parts and motor components. Features include a new machining power supply (EW200B), independent upper and lower machine drive control, and constant temperature control technology. The machine also contributes to the reduction of running costs by reducing the number of processing steps.

With the new EW200B machining power supply and machining conditions, it is possible to improve the optimum surface roughness, reduce the number of machining passes, and shorten the machining time by outputting electric discharge finely and efficiently during finish-machining.

Responsiveness is also a key feature of the machine thanks to a structure that allows independent movement of the upper head (Z/U/V axes) and lower head (X/Y axes).

By improving insulation, the rise time to the target voltage is shortened, enabling efficient micro-fabrication. Moreover, the three-sided elevating processing tank means operators can access the work area from three directions. As the machining tank descends below the top surface of the table, it is possible to work on the lower part of the workpiece. Even if the core is accidentally dropped, it can be easily retrieved.

The machine’s Hyper-i control offers intuitive operations with an efficient interface consisting of three categories: program, set-up and operation. The high-resolution 24-inch touchscreen feels like a tablet device.

Among the machine’s main specifications are: 650 x 500 x 320 mm travel in the X, Y and Z axes; ±350 x ±250 mm in the U and V axes; a maximum workpiece size of 1030 x 800 × 300 mm (width x depth x height); and a maximum payload of 1800 kg.
For further information www.ncmt.co.uk

How to optimise base-plate removal from 3D-printed parts

Stirling-based CA Models, a specialist in high-quality, fast-turnaround metal and plastic additive manufacturing, is using new investment in two wire-erosion machines from Sodi-Tech EDM to optimise the process of removing 3D-printed parts from their build platforms.

“We had two Sodick wire EDM machines that were still running well but getting on in years,” explains founder and managing director Clark Campbell. “I felt it was the right time to bring in some new technology for the next decade. The new Sodick machines are even more accurate and faster. At CA Models we are in the ‘quick’ business, where just about every client wants their parts yesterday. That’s why we need an in-house resource when it comes to wire erosion. Every time we have a really complex, accurate part to produce, the clock is ticking.”

He adds: “I think Sodick technology is brilliant and the reliability of the machines warrants some loyalty in my opinion,” says Mr Campbell. “I went to an open day at Sodi-Tech EDM’s Warwick facility and was really impressed with the latest machines, which will play their part in a big way over the coming years.”

Installed in September 2022, the new Sodick ALC600G and ALC800G wire EDM machines are already busy.

“For example, take a titanium build platform with 14 motorsport parts on the base,” says Mr Campbell. “When the printing process is complete, the entire platform goes into our furnace for heat treatment for 24 hours, after which we wire-off all the components from base plate using our Sodick technology. As the wire cuts so finely we do not lose any dimensional accuracy in the parts. Furthermore, the machines wire so quickly that we get a head start in finishing the components.”
For further information www.sodi-techedm.co.uk