Setting the course for high precision

Some 15 years ago, Ammann AG changed its strategic business orientation from a contract manufacturer for machined switch and track parts to Ammann Components, a system supplier specialising in complex, high-precision workpieces. Success and growth followed – thanks in part to the company’s high-quality machinery, which is dominated by several Heckert machining centres from Starrag. Now, the of Tägerwilen, Switzerland-based is expecting a further boost from its recently delivered Heckert H75.

The successor model to the successful Heckert HEC 500, the H75 comes with various improvements and promising options. The machine produces large aluminium gearbox housings for which the customer specifies centre distances with a tight tolerance.

Managing director Paul Ammann is especially enthusiastic about the machine’s spindle with its maximum torque of 950 Nm and speed up to 12,500 rpm. This capability makes the BAZ spindle equally suitable for aluminium and heavy machining. To maximise flexibility and keep set-up times to a minimum, the Heckert H75 features extensive tool storage: with its four coupled towers, the magazine has a capacity for almost 400 tools.

As the company plans long term for all its investments, the imminent move to a new location will have an impact on the Heckert H75, as Ammann explains: “At the moment, automation is neither necessary nor possible. At our new location, however, we’ll expand the Heckert H75 and our existing Heckert HEC 500 with a pallet system to create a low-manpower production system. It was therefore important to us that the H75 is fully compatible with the Heckert HEC 500 so that a second set-up station is not needed. As expected, our partner Starrag was extremely flexible and made the necessary adjustments to the Y-axis travel and pallet changer.”

More information www.starrag.com

LATHE FROM MILLS CNC PROVIDES FOCUS, DRIVE AND AMBITION AT MACROMANUFACTURING

Mills CNC, the UK’s exclusive distributor of DN Solutions and Zayer machine tools, has
recently supplied Macro Manufacturing, a progressive precision subcontract specialist start-
up based in Aberdeen, with a new high-performance multi-tasking lathe. The FANUC-
controlled DN Solutions Lynx 2600SY lathe with sub-spindle and Y axis was installed at the
company’s 89 m² facility in April 2024, where it machines a range of components for a
growing number of customers in the oil and gas, renewables, and agriculture industries, to
list but a few.
The parts, which Macro Manufacturing typically machines in medium batch sizes, are made
from a range of different materials. Prevalent among them are stainless steel grades 316,
316L and 17-4, duplex and super-duplex stainless steels, aluminium alloys, 4140 low-alloy
steel, exotic alloys such Inconel and Hastelloy, and certain engineering plastics that include
acetyl.
Components machined on site by Macro Manufacturing are also characterised by their
complexity, with tight geometric tolerances and exacting surface finish requirements
proving the norm rather than the exception. Although relatively small in size, these parts
frequently exhibit intricate and delicate features that can only be undergo efficient and
economic machining on a multi-tasking lathe.
Says Macro Manufacturing’s owner and director, Matthew Forbes: “The Lynx 2600SY is a
high-accuracy multi-tasking lathe that has significantly increased our in-house machining
capacity and capabilities. It enables us to machine complex parts quickly, in one set-up.
Since its arrival, we’ve been able to secure new machining contracts from both new and
existing customers, and have strengthened our position within several customer supply
chains.”
The Lynx 2600SY is the first machine tool Macro Manufacturing has acquired from DN
Solutions since the company’s incorporation in 2022. It is also the first new machine
acquired by the company in its two-year history. Like many new precision subcontract start-
ups, Macro Manufacturing had relatively humble beginnings, beginning life in what can only
be described a shed on a local farm. The company fulfilled its initial machining contracts
using little more than a couple of pre-owned CNC machine tools.
“The early days were a challenge,” recalls Forbes. “I was still employed full-time at my
previous company and was having to manage and run Macro Manufacturing in my spare
time – often during the night and through the weekends.”

This situation was always intended to be a stop-gap measure until the company was more
established. So, after a few months, Forbes decided to ‘bite the bullet’ and put all his time
and effort into making Macro Manufacturing a success.
As the driving force behind the company’s rise, Forbes is an apprentice-trained, time-served
engineer with significant machining (programming and operator) experience. He is
passionate about engineering and always had the desire and ambition to run his own
company. His vision, which he is now bringing to realisation, was (and is) to supply high-
quality, competitively-priced precision machined components to customers. The firm’s
ultimate ambition is to grow through the development of long-term partner relationships.
Part and parcel of these plans was to relocate the business to new premises and increase
the company’s in-house machining resources. Macro Manufacturing’s decision to invest in
the new Lynx 2600SY was made for a number of reasons.
“I knew that having access to a multi-tasking turning centre would enable us to expand our
customer base and take on more complex, and hopefully, more profitable work,” he
explains. “A lathe with integrated Y axis, sub-spindle and driven tooling capabilities would
allow us to machine precision parts to completion in one set-up and avoid the problem of
production bottlenecks that stem from transferring parts between machines. Furthermore,
the machine’s ability to run unattended, we believed, would make us more efficient and
productive.”
Having already experienced a Lynx 2100SY lathe in his previous employment, Forbes
approached Mills CNC to enquire about the availability of a larger capacity Lynx 2600SY.
“I liked Mills’ proactive approach from the outset,” he says. “They were interested in our
plans and made the investment process simple and straightforward.”
Mills CNC describes the 10” chuck/81 mm bar capacity Lynx 2600SY as a popular and proven
compact turning centre featuring a powerful, high-torque main spindle (18.5 kW/3500
rpm/403 Nm), a 6” chuck 4500 rpm sub-spindle and 6000 rpm driven tooling capabilities.
The lathe also features a ±52.5 mm Y axis, a 12-station/24-position servo-driven turret,
roller LM guideways and FANUC 0iTP control. In addition, the machine supplied to Macro
Manufacturing is equipped with an automatic tool setter, a Filtermist oil mist extraction unit
and 20 bar fixed coolant capability.
Says Forbes: “The Lynx 2600SY is a highly productive machine that’s ideal for fast and
accurate small parts processing. Since installation, our new lathe has been put through its
paces machining a range of complex parts and hasn’t missed a beat. The Lynx 2600SY has
made us more competitive. It’s proved more than instrumental in us acquiring new
customers and securing repeat business with many existing ones.”
Macro Manufacturing is not a company that rests on its laurels or leaves anything to chance.
In the not-too-distant future, the business will relocate again to larger premises, take on
additional staff and, as part of its commitment to continuous improvement, invest in more
advanced machine tools and ancillary technologies.

The company has ambitious growth plans for the future and, with Forbes at the helm, it is a
safe bet that Macro Manufacturing will bring these plans to fruition.
More information www.millscnc.co.uk

Vestas to repurpose Isle of Wight plant

Since 2002, the facilities of Vestas on the Isle of Wight have played an integral role in the
manufacture of turbine blades for wind projects across the world. At present, the
company’s factory focuses on manufacturing blades for the V174 offshore turbine. Demand
for this product is coming to an end, and constraints at the site mean it is not suitable for
the next generation of offshore blades. However, following an agreement in principle with
the UK Government, Vestas intends to repurpose the factory to build onshore blades,
mainly in support of the UK market.
More information www.vestas.com

Double power for machining large light parts

Schwäbische Werkzeugmaschinen (SW) is strengthening its portfolio of multi-spindle CNC
machining centres with the introduction of the BA space3-22 two-spindle machining centre.
This further development of the ‘space’ series is for machining particularly large, light metal
workpieces in sectors such as automotive and aerospace.
SW launched the single-spindle version of its BA space3 in 2020. Since then, the machine
has found use primarily in e-mobility applications. To achieve even greater efficiency, SW’s
R&D team subsequently began developing the two-spindle version for demanding
manufacturing processes such as giga-casting or machining other complex components in
the automotive and aerospace industries.
The BA space3-22 is currently the largest machine in the SW portfolio. Its independent
horizontal spindle arrangement enables two machining scenarios: simultaneous machining
of two parts by two spindles, or the use of both spindles on one large workpiece. This
flexibility is particularly valuable in series production, where maximum machine utilisation is
crucial. The benefits are clear: parallel machining significantly reduces production times and
increases output.
Markus Löhe, aerospace key account at SW, explains: “In a nutshell, two-spindle machines
double output. The BA space3-22 can be used as a conventional two-person machine or, for
very large components, can easily be configured as a one-person machine with an even
larger machining area.”
At the heart of the BA space3-22 are powerful linear and torque motors. In this
combination, the advantages of both motor types are exploited to the full: linear motors
guarantee fast and precise linear movements, while torque motors provide dynamic rotary
movements. This capability allows the machine to achieve maximum acceleration, not only

minimising machining time but also downtime during tool change and positioning. The rapid
feed rate of the BA space3-22 is 120 m/min.
More information www.sw-machines.com

Filtermist increases up time at Tooling 2000

One of the biggest challenges for any machine shop is workshop air quality and the impact
coolant mist has on staff wellbeing. To prevent coolant mist from impacting the air quality in
the workplace, Tooling 2000 installed on-machine mist extraction systems from Filtermist.
In addition to COSHH-compliant clean air, the Birmingham-based automotive subcontract
manufacturer is also benefitting in other less obvious ways, as senior business development
manager at Tooling 2000, Iain Bubb, explains: “Filtermist systems firstly protects our
workforce, which is of paramount importance. However, they also allow us to open our
machine doors sooner, providing more machining uptime.”
 
If the doors of the machines are opened immediately after a cutting cycle without Filtermist
system in place, oil mist enters the air. This results in a film on the machines, tools, floor and
anything else in the vicinity, causing a health and safety concern.

“With Filtermist, we’re removing all airborne particulates from the machine tool
atmosphere, which not only keeps the inside of the machine clean, but also also helps to
remove the swarf as it does not stick to any tacky coolant residue on the machine bed.”
 
With the Filtermist FX5002 mist extraction systems fitted to its range of Hurco machining
centres, Tooling 2000 finds maintenance of the technology easy to manage.
“We have a TPM [Total Productive Maintenance] system in place so, after a set number of
production hours, we change and clean the Filtermist filters. Productivity is also very
important to us as it cascades down to the bottom line. With the Filtermist technology we
get more uptime from our machines, giving us better productivity and profitability.”
More information www.filtermist.co.uk