Additive Manufacturing and 3D printing feature

DN SOLUTIONS DNM 6700XL BOOSTS LARGE-COMPONENT MACHINING AT COMPLETE ENGINEERING SERVICES 

Complete Engineering Services’ recent investment in a DN Solutions DNM 6700XL vertical machining centre from Mills CNC is helping the Carlisle-based precision subcontract specialist meet growing demand for large, complex and high-precision components. 

Mills CNC, the exclusive distributor of DN Solutions and Zayer machine tools in the UK and Ireland, supplied the extra-long-bed DNM 6700XL equipped with a Detron fourth-axis rotary table and Siemens 828D control with ShopMill conversational programming software. 

Installed at Complete Engineering Services’ 12,000 sq ft machine shop in June 2026, the machine is already being put through its paces machining components for customers in motorsport, timber processing, power generation, renewables, fluid sealing systems, packaging and rail. These include prototypes and one-offs through to pre-production parts and small-to-medium batches, manufactured from materials including stainless steel, aluminium, mild steel, titanium and exotic alloys. Components are machined to tight geometric tolerances and high surface finishes. 

Complete Engineering Services provides customers with three- and four-axis milling and multi-axis turning, complemented by two simultaneous five-axis machining centres and two advanced wire EDM machines. The company also has 3D printing and light fabrication capabilities, in-house inspection and access to secondary services including heat treatment, anodising and plating. 

This broad capability supports the company’s aim of providing an integrated design, machining, finishing and assembly service from a single source. 

“We provide customers with a one-stop engineering service that, through a range of integrated advanced technologies and the skill and experience of our staff, can deliver high-quality prototypes, pre-production and production parts from concept through to completion,” says managing director Andrew Monkhouse. 

Continuous improvement is central to the company’s approach, with regular investment in people, plant, equipment, systems and processes. Its machining capacity is routinely upgraded by replacing older machine tools with newer, more efficient multi-axis and multi-tasking models. 

The DNM 6700XL is the second CNC machine tool Complete Engineering Services has acquired from Mills CNC in its 28-year history. The first was a Lynx 2600Y multi-tasking lathe, installed in June 2024. 

The Siemens 828D-controlled Lynx 2600Y features an 18.5 kW/3500 rpm high-torque spindle, a servo-driven 12-station BMT-65 turret with 24-position indexing, a ±52.5 mm Y axis and 5000 rpm driven tooling. These capabilities allow turning, milling, drilling and tapping operations to be completed in a single set up. 

To increase productivity and overcome floorspace limitations that prevented the installation of a bar feeder, Complete Engineering Services equipped the lathe with a bar puller.  

Mounted on the turret, the mechanical gripper automatically draws bar stock forward through the spindle to predetermined lengths, allowing front- and back-end operations to be completed in one setup and enabling unattended running. 

“Our Lynx 2600Y is inherently flexible and delivers excellent cutting performance. The machine has been a great addition to our machine shop,” says Monkhouse. “Prior to acquiring the lathe, we were on numerous jobs having to perform first operations on an older lathe and then transfer parts to a machining centre for milling, drilling and tapping. Such labour-intensive processes were inefficient, created production bottlenecks and affected our productivity.” 

He adds: “We needed to change things, and with the arrival of the Lynx 2600Y, with its integrated Y axis, C axis and driven tooling, we were able to transform our small-parts processing operations.” 

The company’s positive experience with both the Lynx 2600Y and Mills CNC subsequently influenced its decision to turn to Mills again when the need arose to replace an older large-capacity machining centre. In late 2025, Complete Engineering Services decided to replace the 15-year-old machine, which was used to process large, complex components, with a faster and more powerful model. 

“The older machine was getting a bit long in the tooth, was more prone to breakdown and the operator dedicated to run it was about to retire,” he recalls. “This set of circumstances provided the ideal opportunity to improve and increase our large-machining capacity and capabilities by investing in a new machine.” 

Rather than conducting a wider search, the company made Mills CNC its first, and ultimately only, point of contact for its requirements. 

A key requirement was Siemens control, as most machines in the company’s machine shop use Siemens controls and ShopMill or ShopTurn conversational software. This provides operator familiarity and makes it easier to transfer work between machines. 

The new machine also needed a larger worktable and greater X-, Y- and Z-axis travels than its predecessor, together with a powerful, fast spindle with through-spindle coolant to reduce cycle times and increase material removal rates during roughing. 

A generous-capacity automatic tool changer was another priority, particularly for long machining runs and jobs requiring numerous tools or sister tooling. Finally, a fourth-axis rotary table was required to increase flexibility, reduce the number of setups and improve overall process efficiency. 

“The DN Solutions DNM 6700XL is an impressive machine and its technical specifications fitted the bill,” says Monkhouse. 

The DNM 6700XL is a rigidly designed vertical machining centre from DN Solutions’ DNM range. The machine supplied to Complete Engineering Services features an 18.5 kW/12,000 rpm spindle delivering 117.8 Nm, with 20 bar coolant capability. 

Its 2100 x 670 x 625 mm X/Y/Z-axis travels and 2200 x 670 mm worktable, with a maximum table load of 1300 kg, provide the capacity required for larger components. Linear-axis rapid rates of 30 m/min and a 40-tool automatic tool changer further support productivity. 

The machine is equipped with the Siemens 828D control, a Detron GXA-255H rotary table with a 10-inch chuck, Renishaw tool and workpiece probing systems and a Filtermist extraction unit. 

Since installation, the DNM 6700XL has been used to machine a variety of long, shaft-type components. It is currently machining 30 stainless steel dead-plates – flat, stable transfer plates used in industrial, food and beverage processing and packaging lines. 

Approximately 1.5 m long, the dead-plates are secured using bespoke fixturing and machined incrementally using multi-pass cuts to produce a mirror finish across their surfaces. Other operations include high-accuracy chamfers, holes and counterbores. 

The investments in the Lynx 2600Y and DNM 6700XL are already helping Complete Engineering Services improve productivity and process efficiency while expanding its capacity for demanding work. 

For a company committed to continuous improvement, the machines also demonstrate the value of maintaining a close relationship with a technology partner able to support its changing requirements. 

With the DNM 6700XL now established in its machine shop, Complete Engineering Services looks well placed to build further on the capabilities that have helped drive its growth – with Mills CNC playing an important role in that ongoing development. 

More information www.millscnc.co.uk 

LEUZE SENSOR TECHNOLOGY ENABLES SAFE AUTOMATION AT SEW-EURODRIVE

Anyone entering the world of drive technology and automation will know SEW-Eurodrive. Products from the Baden-Württemberg, Germany-based family business drive almost everything that moves, from airport baggage-handling systems and e-commerce parcel sorters to conveyor technology in networked production environments.

This global operation is supported by around 22,700 employees across 92 assembly plants and 18 manufacturing plants in 57 countries. The company continually invests in its facilities, most recently at Graben-Neudorf near its headquarters in Bruchsal, where a smart factory for shaft and gear-part production opened at the end of 2024.

A key element of the expansion is a fully automated production buffer warehouse, or logistics module, in the North Hall. For its implementation, SEW- Eurodrive turned to SIVAplan for intralogistics expertise and Leuze for sensor technology.

The fully automated, single-aisle high-bay warehouse acts as a production buffer between gear and shaft production and the hardening shop.

“The automated warehouse decouples the soft machining, hardening and hard machining processes,” explains Michael Schütz, head of the hardening shop at SEW- Eurodrive. “In the hardening shop, the gear parts and shafts are made more resistant, wear-resistant and durable in special furnaces.”

The scale of the installation is impressive. Constructed from 70 tonnes of steel, its two 9-m high racks extend for more than 76 m and provide 2300 storage locations using double-deep storage. Two fully automated stacker cranes operate between the racks on a common traversing axis.

“The stacker cranes transport the special hardening racks with products from production to the furnace system,” says Christian Langsdorf, head of sales at SIVAplan. “After hardening, the racks containing the shafts and gear parts are returned to storage and retrieved as required for further processing.”

The total conveying distance is 152 m, with each rack and its contents weighing up to 510 kg.

As the general contractor, SIVAplan implemented the logistics module and higher-level control system in collaboration with PROCAM Steuerungstechnik. The control system coordinates the subordinate machines, systems and vehicles while also communicating with SEW- Eurodrive’s SAP ERP system.

Leuze sensor technology is central to the automated process. Mobile robots transport finished components to the warehouse, guided by the master controller. At each of the four material transfer stations, two RSL 400 safety laser scanners protect access to the system.

“The RSL 400s generate a vertical protective field and grant access once the mobile robot has successfully registered,” explains Frank Wüster, sales manager at Leuze. “The mobile robot can then use this access to deliver the goods. Access remains secured on the side of the vehicle.”

Once the robot has passed through the protective field, the area automatically returns to its safe state. The RSL 400’s integrated PROFIsafe/PROFINET interface also simplifies integration with the safety control system.

Following transfer, each loaded rack passes through a contour checking station. Leuze HT25C diffuse sensors detect the racks and control the conveyor technology, while CML 720i measuring light curtains capture their outer contours. Additional sensors monitor rack presence and control the light curtains, with the inspection results transmitted via PROFINET.

A particularly practical feature is the ability of the diffuse sensors to ignore high-visibility clothing.

“This prevents incorrect detections caused by people wearing high-vis vests who are standing in front of or walking past the transfer station,” states Wüster.

Industrial IP cameras provide additional images of the racks from above and the side.

Although the system is highly automated, each material transfer station incorporates a manual workstation where employees can unload and inspect racks. MLC 530-SPG safety light curtains protect operators during these activities.

The system uses Leuze’s patented Smart Process Gating (SPG), eliminating the need for additional muting sensors immediately upstream or downstream. Instead, a PLC switching signal combined with interruption of the protective field by the transported goods activates the gating function.

The Type 4 MLC 530-SPG light curtains meet the highest safety requirements of EN IEC 61496, achieving Performance Level e and SIL 3.

Manual inspection is particularly important because the racks themselves are exposed to extreme conditions.

Says Schütz: “The racks are loaded into the furnaces along with the workpieces to be hardened. They are therefore subjected to extreme thermal conditions, which can deform them in the long term. That’s why the racks are automatically discharged to this station to be remeasured after a certain number of furnace cycles.”

Once inspected, the racks are returned to storage by the stacker cranes. Precise positioning is essential, particularly because both cranes operate on the same rail and pedestrian walkways must also be safeguarded.

Leuze FBPS 600i safety barcode positioning systems provide safe position detection and safeguarded velocity monitoring in combination with SEW-Eurodrive’s latest-generation MOVI-C inverters. Each stacker crane has two FBPS 600i systems, one for the lifting axis and one for the travel axis.

The system continuously monitors crane position and velocity and can switch safety envelopes to restrict crane movement if a pedestrian enters an aisle.

Only one sensor is required for safe position detection, simplifying installation. With a reading distance of 50 to 170 mm from the barcode tape, the FBPS 600i reads multiple codes during each scan, processing them redundantly before delivering millimetre-precise information to the SEW inverter.

“The scanning beam is intentionally positioned at an angle,” explains Oliver Gortner, key account manager intralogistics at Leuze. “The device’s movement along this angled path ensures each code is scanned at different points. This prevents reading errors caused by local dirt or damage.”

The system’s short error response time of just 10 ms also supports short braking distances and higher travel speeds.

Finally, once a crane reaches the correct storage location, a Leuze IPS 200i camera-based sensor performs fine positioning. Mounted on each stacker crane, it detects a reflector on the shelf support and provides absolute position values to the SEW controller. This capability allows the rack to be transferred precisely into its designated compartment without the need for multiple diffuse sensors.

The result is a highly integrated logistics system that fits seamlessly into SEW-Eurodrive’s production operation. From safeguarding material transfers and inspecting racks to positioning the stacker cranes with millimetre precision, Leuze sensor technology supports virtually every critical stage.

For SEW-Eurodrive, the automated high-bay warehouse provides more than a production buffer. It helps absorb peak loads, decouples key manufacturing processes and provides the flexibility to accommodate future expansion. For SIVAplan and Leuze, meanwhile, the project demonstrates how sophisticated intralogistics and sensor technology can combine to deliver safe, reliable and autonomous production processes.

More information www.leuze.com

LATEST TOOLING SOLUTIONS HELP MAKE DIFFICULT MATERIALS ROUTINE

Industry research from Deloitte shows that manufacturers continue to invest heavily in improving efficiency and resilience, with greater attention on productivity, process stability and making better use of existing capacity. For global cutting tool and machining solutions specialist Sandvik Coromant, this supports its approach of working closely with customers to improve performance directly within production. The company’s ongoing partnership with Merx, a precision subcontract manufacturer based in Söderköping, Sweden, is a case in point.

Fortune Business Insights reports that the global superalloys market is projected to grow significantly from $8.78bn in 2026 to $22.44bn by 2034. As demand increases across sectors that rely on high-performance components, manufacturers require specialist knowledge, stable processes and the confidence to work with these challenging materials, something Merx has been building for decades.

Since Hans Hammargren and his co-founder started Merx in 1989, the company has grown from a small operation into an established high-precision manufacturer, supplying customers across the energy sector and other demanding industries.

Today, Merx employs around 75 people and operates a growing number of CNC machines, producing components where reliability is critical and tolerances are often measured to the thousandth of a millimetre. The company is now preparing for its next phase of growth, with plans to expand its facility by around 1000 m² and add more machines to increase production capacity.

“We’re growing, and we need to keep improving at the same time,” says Hammargren. “That applies to both production and how we work with our partners.”

A key part of Merx’s offering is its ability to machine complex materials that many subcontract manufacturers choose not to work with. One of the most demanding materials is Inconel 718, a heat-resistant superalloy widely used in turbine and energy applications, and where components need to perform reliably under extreme conditions.

The material’s strength and resistance to heat make it suitable for these environments, but the same properties create challenges in machining. Cutting forces are high, heat builds quickly at the cutting edge and tool wear occurs quickly, often reducing tool life to only a few minutes. This places pressure on both process stability and cost, where even small inefficiencies can have a significant impact on overall production.

“It’s a material many companies say no to,” adds Hammargren. “For us, it’s part of what we do, but it requires the right approach.”

Merx has worked with Sandvik Coromant in different ways since its early years, initially through distributors and later through direct collaboration. In recent years, the relationship has developed further, moving from a traditional supplier setup to a more integrated partnership.

Long-term relationships are important in this industry,” remarks Haris Karsic, account manager at Sandvik Coromant. “It’s through ongoing collaboration that you build an understanding of the customer’s production and can make improvements that actually hold up over time.”

This evolved collaboration has been driven by a combination of improved agreements and increased technical involvement. Engineers from Sandvik Coromant now visit the site regularly, working directly with Merx’s production teams to test tools, optimise parameters and identify improvements.

“It’s a very hands-on collaboration,” explains Hammargren. “They’re here in our production environment, working with our people and helping us solve real problems.”

The impact of this partnership is particularly clear in the machining of Inconel 718, where the introduction of Sandvik Coromant’s CoroDrill DE10, an exchangeable-tip drill for high-volume hole making, has led to measurable improvements in performance. Trials carried out in production showed a 48% increase in productivity, alongside a 32% reduction in cycle time per component.

What’s more, the total cost per component was reduced by approximately 51%. This saving was achieved through a combination of longer tool life, improved cutting data and more stable machining conditions.

Tool life doubled during testing, increasing from 20 to 40 components per cutting edge, while engagement time per component decreased from 1 minute 31 seconds to 0.93 minutes. These changes allow more parts to be produced in less time, improving both output and cost efficiency.

“When you look at the total economy, it becomes very clear,” says Hammargren. “It’s not about the price of a single tool, but how much you can produce and how stable the process is.”

In addition to cutting performance, the collaboration has focused on improving how tools are managed and used within production. One of the changes has been the introduction of Sandvik Coromant’s CoroPlus Tool Supply tool inventory system, which provides controlled access to tools and detailed usage tracking.

The system has improved organisation on the shop floor by allowing operators to access specific tools quickly and efficiently. Unlike previous solutions, where entire drawers were opened, the new system provides access to individual compartments, making it easier to locate the correct tool and reducing unnecessary handling time.

“It’s much clearer and easier to use,” adds Hammargren. “Our operators prefer it, and it saves time in daily work.”

The system also provides more detailed reporting, giving better visibility into tool consumption and usage patterns. This capability allows Merx to monitor costs more closely and make more informed decisions about inventory and process improvements.

The collaboration has also introduced measures that contribute to more efficient use of materials and resources. Through Sandvik Coromant’s buyback programme, used carbide tools are returned and reprocessed, reducing waste and supporting a more circular approach to production.

Reconditioning services are also used to extend tool life, allowing tools to be reused without compromising performance. While the focus remains on efficiency and cost, these steps also help reduce waste and lower the overall environmental impact of machining operations.

“Sandvik Coromant has encouraged the recycling of cemented carbide for several decades,” notes Karsic. “Recovering and reusing materials is a practical way to reduce waste while maintaining performance, and it’s something we continue to develop together with our customers.”

Merx is continuing to expand its operations, with increased production space and additional machines planned over the coming years. As capacity grows, maintaining consistent performance across all processes becomes increasingly important.

The company is therefore continuing to work closely with Sandvik Coromant to evaluate new tooling solutions and refine existing processes step by step. Changes are introduced only when they deliver measurable improvements, ensuring that production remains stable while performance improves.

For Merx, the relationship with Sandvik Coromant is based on ongoing cooperation rather than individual projects. The combination of technical support, on-site collaboration and proven results has helped strengthen production in some of the most demanding applications.

“The technical competence and the support we receive are the most important factors,” states Hammargren. “That’s what helps us move forward.”

As manufacturing requirements continue to evolve, this type of collaboration is becoming increasingly important. For Merx, it provides a practical way to improve performance while supporting long-term growth in a competitive and demanding industry.

With the global superalloys market continuing to grow, manufacturers working with demanding materials like Inconel 718 will face increasing pressure to deliver both precision and efficiency. Success depends not only on the right tools, but also on specialist knowledge, stable processes and the right people behind them, exactly the kind of long-term partnership Merx has built with Sandvik Coromant.

More information www.sandvik.coromant.com

Funding for project to 3D-print superalloy jet engine parts

Alloyed Ltd has secured funding from the Aerospace Technology Institute (ATI) Programme for a £1m project to accelerate development of ABD-1000AM, a next-generation nickel-based superalloy designed specifically for additive manufacturing.

The project, delivered in collaboration with aircraft engine specialist ITP Aero and Cranfield University, aims to further enhance the material’s performance and manufacturing readiness. ABD-1000AM has been engineered to withstand the laser powder bed fusion process without cracking, overcoming a key challenge associated with high-temperature nickel alloys.

The material is expected to play an important role in future ultra-efficient jet engines, where complex, lightweight components must operate reliably in the extreme temperatures and harsh conditions found within combustion systems.

Support from the ATI Programme will help accelerate adoption of high-performance 3D-printed aerospace components and strengthen the UK’s position in advanced manufacturing technologies.

“Alloyed has been fortunate to partner with the ATI in several key technology areas, ranging from new material design to digital software platforms that support additive manufacturing adoption,” says Dr David Crudden, chief metallurgist and head of new market development at Alloyed. “ABD-1000AM is the world’s highest-temperature nickel-based superalloy designed for additive manufacture. We’ve identified significant demand for the material and believe it has the potential to be a game-changing technology for gas turbines in aerospace propulsion and industrial power generation.”

Cranfield University will contribute its expertise in high-temperature materials degradation and protective coatings, while ITP Aero will provide specialist knowledge in advanced combustor technologies for commercial and defence aviation applications.

Rob Mitchell, director of engineering at ITP Aero UK, says the project demonstrates the value of collaboration between academia, SMEs and industrial partners in shaping the future of aerospace technology and accelerating the development of next-generation propulsion systems.

More information www.alloyed.com

HII places order for second Nikon SLM Solutions NXG 600E

Nikon SLM Solutions, a global specialist in laser powder bed fusion (L-PBF) metal additive manufacturing and a unit of Nikon Advanced Manufacturing, reports that HII’s Newport News Shipbuilding (NNS) division has placed a second NXG 600E order. The move further strengthens its advanced manufacturing capabilities in support of US Navy shipbuilding and the Maritime Industrial Base (MIB).

The order builds on a previously announced NXG 600E acquisition and reflects HII’s continued investment in large-format metal additive manufacturing to enable production of large, complex components and replacement of legacy castings for critical naval applications. Through close collaboration with HII, Nikon SLM Solutions will lead parameter development and process maturation for L-PBF production of NiAlBr components, expanding material capability for additive manufacturing within US Navy supply chains and supporting long-term maritime readiness.

“This second NXG 600E order reflects HII’s leadership and long-term commitment to advancing the maritime industrial base through additive manufacturing,” says Hamid Zarringhalam, CEO of Nikon Advanced Manufacturing and chairman of the board at Nikon SLM Solutions.

He adds: “Expanding critical materials capabilities such as nickel-aluminium-bronze is a foundational part of Nikon Advanced Manufacturing’s holistic approach, combining scalable platforms, material and process development, and US-based production and support. Together with HII, we’re enabling additive manufacturing to move from isolated applications to a repeatable, industrial capability that supports US Navy shipbuilding at scale.”

More information www.nikon-slm-solutions.com