Ultimate reliability: 35-year-old wire EDM still in use

When Kress Funkenerosion was founded in 1990 in Mühlhausen, near Nuremberg, its future rested on a single machine: a FANUC Tape Cut W2. As a young tool- and mould-making subcontractor serving demanding sectors such as automotive, aerospace and medical, uptime was critical. The brief for that first investment was straightforward: deliver high-quality wire-cut components with absolute reliability.

More than three decades later, that same machine remains in daily operation, a testament to the durability and engineering philosophy of FANUC.

The machine’s longevity set the tone for the company’s future direction. Impressed by consistent performance and minimal maintenance requirements, Kress Funkenerosion standardised on FANUC wire EDM technology, investing in a further 12 machines over the years.

The most recent additions are two FANUC ROBOCUT α-C400iC models, which provide both precision and versatility. Managing director Michael Schander reports that tolerances of ±3 µm are achieved with ease, supported by reliable automatic wire threading in under 10 seconds. Yet, for Schander, performance figures tell only part of the story.

“What really sets FANUC apart is the build quality,” he says. “The last service call I remember was over six years ago. That level of reliability is exceptional.”

Today, all wire EDM machines on site are FANUC models, forming the backbone of the company’s ISO 9001-accredited operation. For founder Gerhard Kress, the decision remains clear: “The first machine I bought in 1990 is still running. After more than 30 years of experience, I see no reason to change.”

More information www.fanuc.eu

Sodick wire EDM powers automotive excellence

Set against the backdrop of Northern Italy’s industrial heartland, Meclostampi Group has specialised in progressive toolmaking since 1971. Founded by Cavaliere Antonio Canobbio and now led by Valter Canobbio, the company serves demanding automotive customers with a clear philosophy: quality first. That mindset has driven its continued investment in EDM technology from Sodick since 1988.

“Our parts are only as good as the machine that produces them,” says Canobbio. “Choosing the cheapest option is short-sighted, and the same applies to service.”

Operating from a 7000 m² facility in Lomazzo, Lombardy, and employing more than 80 skilled staff, Meclostampi partners with RF Celada SpA to deploy advanced Sodick wire EDM technology. The close collaboration ensures high levels of machine performance are matched by responsive technical support.

A key advantage has been Sodick’s ability to overcome the long-standing challenges of machining carbide.

“In the past, carbide created surface issues on other machines,” explains Canobbio. “Sodick solved this issue years ahead of its competitors.”

The result is superior surface integrity, greater tool life and enhanced process reliability.

Meclostampi’s Sodick fleet includes ALC 600G, SLC 600G and AG60L models equipped with linear motor drives, advanced generators and intelligent control systems. These technologies deliver micron-level accuracy, smooth surface finishes and consistent positioning performance – critical factors in the production of progressive, transfer and deep-drawing tools for automotive applications.

Reliability is equally important, as Canobbio confirms: “I don’t remember a stoppage for maintenance.”

With in-house stamping presses ranging from 250 to 6000 kN, Meclostampi can validate tool accuracy and longevity under real production conditions.

“Speed, accuracy, reliability and flexibility define quality tooling,” he concludes. “Investing in the right technology ensures we remain the best partner for our customers, today and in the future.”

More information www.sodick.eu

MACHINE TOOLS BUILT BY DN SOLUTIONS MEASURE UP TO ABERLINK’S HIGH STANDARDS

Mills CNC has recently supplied Aberlink – the largest UK-owned manufacturer of co-ordinate measuring machines (CMMs), vision systems and 3D measurement software – with two DN Solutions machine tools as part of a strategic investment in its in-house manufacturing capability.

The machines, a large-capacity DN Solutions DNM 6700XL three-axis vertical machining centre and a compact DN Solutions Lynx 2100LSYB multi-tasking lathe, arrived simultaneously in March 2025 at Aberlink’s recently revamped machine shop in Stroud, Gloucestershire. Their arrival marks a significant milestone in the company’s ongoing drive to improve productivity, eliminate bottlenecks and futureproof its production operations.

Since commissioning, both machines have been put through their paces machining a wide range of high-precision components that are integral to every Aberlink CMM. These include bridge beams and rails of varying lengths and widths, air bearings, racks, plates, pinions and housings. Typically produced in relatively small batches of up to 50-off, these components are machined from extruded aluminium alloys, aluminium billet and bar stock, as well as steel, brass and selected engineering plastics.

Despite modest batch sizes, the technical demands are high. Tight geometric tolerances and excellent surface finishes are essential to ensure the positional accuracy and repeatability that define Aberlink’s CMM performance. Consistency from part to part is critical, as even minor deviations can influence overall machine accuracy.

Aberlink’s CMM portfolio is both broad and continually evolving. The range includes compact shop-floor systems such as the Fulcrum and Extol, designed to sit alongside CNC machine tools in production environments, as well as larger bridge-type machines like the Axiom, Halo, Horizon and Azimuth, typically installed in dedicated, temperature-controlled inspection rooms. Across the board – whether manual or CNC-controlled, Cartesian or non-Cartesian – Aberlink says its CMMs are recognised globally for their rigidity, speed, reliability and ease of use.

In 2024, the company received a King’s Award for Enterprise for the design innovation and error mapping capabilities incorporated into its Extol CNC CMM. This accolade further cemented Aberlink’s reputation as a technology-led manufacturer committed to continuous improvement.

Affordability is another important differentiator. In addition to robust build quality and proprietary 3D measurement software, Aberlink provides free software upgrades and does not charge annual maintenance fees – a policy that resonates strongly with customers wary of hidden lifecycle costs. As a result, the company’s CMMs are widely specified by precision component and mould tool manufacturers serving the aerospace, automotive, motorsport, medical, oil and gas, and energy sectors, both in the UK and internationally.

All design and assembly operations are centred at Aberlink’s Eastcombe manufacturing facility. The site incorporates a visitor showroom, expanded assembly areas and dedicated software development, applications and customer service departments. At the heart of the operation, however, lies the machine shop – divided into discrete milling and turning sections and equipped with a mix of CNC and manual machines, including several long-serving legacy platforms installed in the late 1990s and early 2000s.

“In the early days, before our first Windows-based CMM was launched, we actually operated as a precision subcontract machining business,” explains Marcus Eales, owner and director. “As demand for our CMMs increased, the machine shop expanded in tandem. It has always been, and remains, a vital cog in our growth and success.”

With demand continuing to rise, particularly from overseas markets such as China, Aberlink undertook a comprehensive machine shop audit in 2024 as part of a company-wide continuous improvement initiative. The objective was to benchmark performance, identify pinch points and ensure that production capacity aligned with sales growth.

“Our machine shop produces a high volume of precision components,” says Eales. “There can be up to 150 different parts in our best-selling Axiom CMM alone. Meeting tight delivery schedules means our machining processes must be efficient, reliable and capable.”

The audit highlighted inefficiencies in the milling of extruded aluminium beams and rails on an ageing Cincinnati FTV-640 machining centre. Although the machine remained accurate, slower spindle speeds and feed rates were extending cycle times and constraining throughput. Replacing it with a modern, faster and more powerful vertical machining centre was identified as a priority.

At the same time, the review exposed limitations in the turning department. Existing two-axis, single-spindle lathes were capable of basic turning, facing, drilling and boring operations, but lacked Y-axis capability, driven tooling and sub-spindles. Complex components requiring off-centre features or secondary milling operations demanded multiple set-ups and manual intervention, creating bottlenecks and placing additional pressure on milling resources.

“Single-spindle, single-turret lathes have inherent limitations,” explains director Ian Rhodes. “Without Y-axis or sub-spindle capability, you’re forced into multiple operations. That affects cycle times, labour input and overall efficiency.”

Aberlink therefore developed a detailed ‘needs and wants’ specification covering both milling and turning requirements before approaching the market. Although the company had not previously invested in equipment from Mills CNC, its reputation for supplying high-performance, competitively priced DN Solutions machines – backed by strong aftersales support – quickly brought it into contention.

“Mills CNC has a good standing in the marketplace, and many of our customers are familiar with DN Solutions machines,” says managing director Rachel Cook. “Their cutting performance, long-term precision and reliability, combined with Mills’ service support, made them a compelling choice.”

The DN Solutions DNM 6700XL selected offers generous axis travels, rapid traverse rates and an 18.5 kW, 15,000 rpm spindle, supported by a 40-tool automatic toolchanger. Equipped with a FANUC 0iM control and Renishaw probing, the machine delivers improved cycle times and productivity compared with its predecessor, particularly during the heavy-duty roughing of aluminium extrusions.

“The DNM 6700XL is faster, more powerful and more flexible,” says Rhodes. “It comfortably handles everything we throw at it, from roughing long beams to finishing precision components.”

Complementing this machine, the DN Solutions Lynx 2100LSYB multi-tasking lathe features an 8” chuck, 65 mm bar capacity, sub-spindle, Y-axis travel and driven tooling up to 6000 rpm. Supplied with a FANUC 0iT control, quick-change collet chucks and a Hydrafeed short magazine bar loader, the machine enables complete machining of complex, high-precision parts in a single set-up and can operate unattended for extended periods.

“Being able to machine parts in one hit has transformed our turning operations,” says Eales. “The addition of the bar loader has released capacity, reduced labour input and improved consistency. We’ve seen tangible gains in productivity and cost control.”

For Aberlink, whose CMMs depend on uncompromising mechanical accuracy, strengthening in-house manufacturing capability is fundamental. The twin investment in advanced milling and multi-tasking turning technology not only eliminates previous bottlenecks but also provides headroom for future growth.

“We’re delighted with the two DN Solutions machines acquired from Mills CNC,” concludes Cook. “They were proactive and easy to work with, and installation was handled smoothly with minimal disruption. This investment reinforces our commitment to quality, efficiency and continued innovation.”

More information www.millscnc.co.uk

SMW Autoblok unveils APS zero-point clamping modules

SMW Autoblok says its next-generation APS 138‑E and APS 138‑I zero-point clamping modules are engineered to deliver <0.005 mm repeatability, maximum rigidity and universal interface compatibility across nearly all zero-point systems currently in the market. The APS 138 series enables high-speed part changeover, full automation support and high machining accuracy across turning, milling and grinding operations, reports the company.

With the APS 138-E for external mounting and APS 138-I for integrated, built-in applications, both modules provide the same mechanical performance characteristics: a three-jaw clamping design, spring-actuated locking and pull-down forces up to 26 kN assisted by SMW Autoblock’s ‘Turbo’ function. Holding force reaches 75 kN using standard ISO 4762-12.9 screws, and modules can be unlocked pneumatically at 6 bar via side or bottom actuation.

“This platform is designed as a direct-fit alternative to other zero-point systems on the market,” says Larry Robbins, president and CEO at SMW Autoblok USA. “Shops don’t have to reconfigure their work-holding systems to gain a boost in precision and speed.”

The APS system serves as a universal interface between the machine tool, clamping device and workpiece. It requires no traditional fixturing methods and is suitable for pallet automation and modular set up.

All APS modules are Proofline-sealed for full protection against coolant, corrosion and swarf. An integrated air purge system for cleaning and locating surfaces is standard, helping maintain chip-free mating surfaces, essential for automation and high-tolerance part handling. Select models support pneumatic stroke control for real-time monitoring and feedback during robotic load/unload cycles.

The three-jaw system includes three clamping slides, providing higher pull-down forces and eliminating the need for special set-ups during multi-directional milling operations.

More information www.smwautoblok.com

Kurt launches pneumatic vice for five-axis machining

In the fast-paced world of precision machining, factors such as speed, accuracy and repeatability are everything, which is why Kurt Workholding has developed its PFA620 five-axis pneumatic vice.

The Kurt PFA620 is an air-actuated self-centring vice designed for modern five-axis machining centres. Compact, powerful and automation-ready, it is suitable for shops looking to shorten set-up times without sacrificing precision.

The new air vice was recently featured as part of a fully automated, lights-out work cell at the Yamazen open house in Elk Grove, Illinois. At the event, the air vice could be seen mounted on a custom base directly to the platter of a Brother Speedio U500Xd2 machining centre with an integrated robot. 

“The automated access door allows the robot to move parts in and out of machine without an operator present,” explains Andrew Justin, Kurt Workholding sales engineer. “You can load stock into the drawer system and let the machine run for hours unattended until stock is depleted. At this point, you replenish the raw stock and start the cycle over again. The PFA620 mounts to any five-axis platter both through the body and with a custom adapter plate if necessary.”

The PFA620 can be integrated into a rotary union with pneumatics so there are no external air lines: all pneumatics are captured within the base plate and vice. This design allows for maximum access on five sides while not potentially damaging external air lines. New Kurt air vice models will feature porting on the bottom of the vice to eliminate exposed air lines.

Unlike typical pneumatic vices, the Kurt PFA620 offers manual full-stroke adjustment via a hex screw and handle, giving machinists the freedom to quickly adapt to parts of varying sizes.

More information www.kurtworkholding.com