FEATURE ON BENDING & FORMING

Mate expands line of press brake tooling

Mate Precision Technologies, a global specialist in metal forming and metalworking solutions, has added more than 500 new items across its American precision style, Wila Trumpf style and European precision style press-brake tooling lines. The new additions include a complete selection of Amada fixed-height style profiles designed to increase the efficiency of press-brake operations in complex bending applications.

The Amada fixed-height style profiles from Mate reduce set-up times and are well-suited to bending operations with small production lots and a wide variety of projects. Mate’s fixed-height profiles provide a consistent height for all punch profiles to eliminate the need for multiple set-ups and account for uneven heights. The new Mate profiles also eradicate the need to make the frequent adjustments to the safety beam required when using standard press-brake tooling with uneven heights.

In addition, Mate has expanded its range of punch and die profiles for its Wila Trumpf style and patented American precision style with Maglock press-brake tooling. Using rotating supports to bend up to 40° without marking, the new Wila Trumpf style version of CleanBend is now available in eight sizes. Variable openings range between 8 and 78 mm, with one option that includes an adjustable variable opening between 40 and 100 mm.

Mate has also added new accessories to its press brake line including heavy-duty radius holders and radius inserts, as well as punch adapters and extenders.

“Sheet metal fabricators rely on Mate’s press-brake tooling to make their bending operations more efficient and increase output,” states John Galich, marketing manager at Mate Precision Technologies. “These new additions to our tooling provide our customers with even more options for improving productivity and enhancing their day-to-day operations.”

More information www.mate.com

Creating right-first-time automotive components

Unison has helped a global automotive supplier create in-house capability for the production of right-first-time components. The company in question is responsible for manufacturing boot hinge assemblies for several major automotive manufacturers.

The main component in these assemblies is a bent rectangular steel tube which was previously fabricated and supplied by a subcontractor. To reduce its reliance on outsourcing and ensure total control over accuracy, Unison’s customer decided to invest in an automated manufacturing cell to bring the production of boot lid hinge components entirely in-house.

Unison’s solution involved two all-electric, servomotor-controlled 50 mm Breeze tube bending machines with multi-stack tooling heads. The bending machines are fed by two automatic hopper loaders which perform weld seam detection and datum the tube prior to bending. A robot then unloads the bent parts from each machine and presents them to a four-camera vision inspection system, to measure the parts and calculate corrections.

This closed-loop solution links with the bending machine’s motion control to ensure accuracy and repeatability. Bent components are then transferred by a further two robots into two CNC machining centres, where multiple holes of various sizes are drilled. Once complete, the components are robotically deburred and hung on transfer racks in pairs ready for delivery to the assembly station.

In a high-demand industry, working to ‘just-in-time’ supply principles, the company now has the ability to reliably produce hinge components in-house, with complete control of all aspects of boot lid assemblies. Outcomes include improved quality control with repeatability and tight tolerances, easy tooling changeover and programming to produce different variants, reduced costs, and higher productivity.

More information www.unisonltd.com

SafanDarley to unveil MultiCell at FABTECH 2025

At FABTECH Chicago 2025 this week (8-11 September), SafanDarley will unveil its new MultiCell robotic solution, a versatile addition to the company’s automated bending solutions. Designed for mid-sized products up to 500 x 2000 mm and press forces from 40 to 125 tonne, this compact automation system enables the bending of a wide variety of parts within a minimal footprint.

When the market starts demanding more flexible robotised bending solutions, there is need for a change of perspective. SafanDarley says it has developed the ultimate solution for the mid-sized sheet metal product range by making a cell that fits every demand. This retrofit-capable system ensures that the MultiCell stays cutting-edge, with the ability to install new technology and features as they become available, safeguarding investments for the long term.

Also on display at FABTECH Chicago (Stand A1131) will be the E-Brake 35T Ergonomic — a stand-alone electric press brake that delivers precise bending for small, complex parts. It offers high efficiency and optional automation for rapid product changeovers.

With the Ergonomic implementation, the press brake and its operator work as one. The operator is surrounded by a support table, which is especially beneficial when bending large quantities. The ergonomic ease of operation is optimised because the seating position can be fully adjusted as desired, increasing productivity.

The control system of the new machine is equipped with a new design and is industry 4.0 ready, which means that it can communicate with external systems. Both systems feature SafanDarley’s software tools – including AutoPol, RoboBend and ASC-control – designed for intuitive operation that is accessible to all skill levels.

More information www.safandarley.com

Father and son in fast lane with premium buses

What began four decades ago as a rudimentary bus repair workshop beneath a corrugated iron roof has grown into one of Indonesia’s largest coachbuilding enterprises. Based in Malang, Tentrem Sejahtera built its early success on manual craftsmanship. Now, under managing director Yohan Wahyudi, the company is targeting mass-market scalability – and leveraging Trumpf technologies to take production to new heights.

The vehicle-body manufacturer specialises in crafting custom bus bodies on chassis from renowned brands like Mercedes-Benz, Volvo and Scania, while also producing intercity buses that serve routes across Java, Bali and other islands in Indonesia.

Wahyudi aims to turn Tentrem into Indonesia’s premier bus manufacturer. His vision hinges on getting the right balance between two seemingly contradictory goals: customisation and standardisation. He is determined to optimise production efficiency, but customers must still be able to access unique, tailored products.

“By providing our employees with new machinery and suitable software, we help them instil creativity and innovation in their work,” he says. “We want to match the standards of established OEMs. To do that, we need a proper production line, efficient schedules and clear daily targets.”

Today, Tentrem takes a single sheet of metal, cuts it with the company’s Trumpf TruLaser 5030 and shapes it with a TruBend Center 5030. This new approach eliminates welding entirely, much to the amazement of the company’s customers. The consistent quality offered by Trumpf machines has a wide array of benefits.

“It allows us to oversee the entire production process, so we can prioritise which parts are needed most urgently and which can wait,” explains Wahyudi. “We can also optimise the design of each part by using innovative design formats and manufacturing technologies.”

More information www.trumpf.com

Mogul Mechanical Engineering opts for Selmach

Mogul Mechanical Engineering is a fabrication business based in Cwmbran, from where it fabricates guarding, platforms and ladders for steel erection applications, as well as more complicated fabrications. The company relies on a wide range of machinery supplied by Selmach, including an RVD ER fibre laser cutter, Morgan Rushworth ASBR 2050/190 sheet rolls, PBR 1250/90 sheet rolls, PSR 50/155 section roller, HFP 775/30 H-frame press, BP 2540/25 box and pan folder, and various grinders, drills and punches.

“The main reason we considered machinery investment was that a lot of our work was previously outsourced,” explains Mogul director Ben Harris. “We got by, but we wanted to grow, so we needed machines at hand to make stuff as and when required, without relying on supplier lead times. With Selmach, we found every machine we needed to satisfy 99% of what we do.”

The first machine to arrive on site was the small PSR 50/155 section roller, although a large section roller, the HSR-3/100 is currently on order.

“All the machinery from Selmach has worked out really well – we’ve had no issues at all,” says Harris. “From an advice point of view, we’ve had lots of opportunities to visit the showroom at Selmach and discuss the type of work we do. So we’re always advised the right machine. Selmach typically provides a range of options at varying costs, and then we can look at our budget. We’ve got a good relationship with the sales guys and were able to negotiate a fair deal on a lot of the equipment. The aftercare and service has also been great.”

More information www.selmach.com