FEATURE ON CNC MILLS & MACHINING CENTRES

Starrag provides Omni Aerospace with precision at altitude

With sunlight glinting off an aircraft wing, it is easy to admire modern aerospace engineering. Behind every precision component, however, lies a combination of advanced technology and strong manufacturing partnerships. This is evident at Omni Aerospace in Wichita, Kansas.

Founded over 25 years ago by CEO John O’Neill, Omni Aerospace produces complex structural components for major OEMs including Boeing, Bombardier and Lockheed Martin. As demand grew for tighter tolerances, lighter materials and faster turnaround, the company invested in Starrag’s ECOSPEED F 1540 machining technology. Installing the first model in 2017 marked a significant step forward.

“The ECOSPEED was a game changer,” confirms O’Neill. “It enabled us to achieve levels of speed and accuracy we simply couldn’t before.”

The machine improved precision, reduced set-up times and eliminated the need for match drilling, enabling consistent production of close-tolerance aerospace parts. The impact was immediate, with revenue doubling and new business secured.

Building on this success, Omni added a second ECOSPEED and integrated both machines into a palletised flexible manufacturing system, enabling continuous, lights-out operation. The machines process demanding aluminium components, including large wing ribs requiring extensive material removal, while maintaining tight tolerances.

In 2025, Omni is expanding again with a third ECOSPEED F 1540, further increasing capacity and improving workflow efficiency. The company is also preparing to extend its capabilities into hard metal machining.

This ongoing investment reflects a strong partnership with Starrag and a shared focus on performance and innovation. As O’Neill concludes: “Starrag has helped us not only meet expectations, but exceed them.”

More information www.starrag.com

Dromafield invests in VMC via machine tool rental scheme

Mills CNC has supplied Dudley-based precision subcontractor Dromafield Engineering with a new DN Solutions fourth-generation DNM 4500 vertical machining centre. Acquired via Mills CNC’s SMART Options rental scheme, the machine was installed to relieve pressure on an older machining centre that had become a potential production bottleneck due to rising demand for high-quality milled parts.

Ben Nightingale, office manager and work scheduling co-ordinator at Dromafield Engineering, says: “It was clear we needed additional milling capacity quickly, as one of our existing machines was struggling to cope with increased workload. This led us to contact Mills CNC.”

Following a visit to Mills CNC’s Technology Campus in Leamington, Dromafield evaluated several options before selecting the DNM 4500. Will Smith, CNC programmer and setter operator, says: “We needed a compact, flexible and high-performance machine. The DNM 4500 offered the right balance for our available space and machining requirements.”

Equipped with a high-torque spindle, 30-tool automatic tool changer and through-spindle coolant, the machine delivers the speed, rigidity and precision required for a wide range of materials and applications.

The SMART Options scheme, which allows manufacturers to rent a machine with flexible end-of-term choices, proved instrumental. “It’s a simple, cost-effective route with no upfront costs,” adds Nightingale.

Shortly after installation, the investment demonstrated its value when a spindle issue temporarily halted production on an older machine. Work was quickly transferred to the DNM 4500, avoiding disruption.

Today, the machine processes small- to medium-batch components for sectors including aerospace, automotive and lifting equipment. With further productivity gains expected from new zero-point clamping systems, Dromafield is well positioned to enhance efficiency and meet growing demand.

More information www.millscnc.co.uk

ALM installs large-capacity 30-taper machining centre

Contract machining firm ALM Engineering Solutions has expanded capacity and advanced its automation strategy following investment in a Japanese-built Brother Speedio W1000Xd2 machining centre. Supplied by Whitehouse Machine Tools, the three-axis machine was installed at the company’s Newton Aycliffe facility at the end of 2025 to enhance flexibility, productivity and lights-out manufacturing.

Established 31 years ago, ALM supplies machined components and assemblies to OEMs across sectors that include medical air filtration, gas generation and entertainment infrastructure. This progressive manufacturing company also produces in-house robotic tooling and assembly-line equipment, as well as architectural hardware.

The investment was driven by capacity constraints, as managing director Tony Thompson explains: “One of the main attractions of the Speedio was the larger bed, overcoming the limitations of our previous 700 mm X-axis machines.”

The 1 m table on the W1000Xd2 has enabled ALM to machine larger parts and increase throughput, while the compact footprint suits the company’s 14,000 sq ft facility.

A key differentiator is ALM’s use of in-house developed collaborative robots, branded ‘Cobots Online’. The Speedio is paired with a mobile cobot, part of a fleet of seven deployed across the shop floor. Designed for rapid set up and relocation, the systems support flexible, unattended operation.

“It’s massive really, giving us 24/7 flexibility,” says Thompson. “We can run machines unattended without weekend overtime.”

The approach has helped boost overall production capacity by nearly 50% over two years without increasing headcount. In addition, the machine’s high-speed performance and ease of use also enabled rapid operator adoption.

Looking ahead, ALM Engineering Solutions is now planning further key investments.

More information www.wmtcnc.com

New technology cycle for DMG Mori machines

At its recent 2026 in-house exhibition in Pfronten, DMG Mori presented the company’s Adaptive Drilling Control (ADC) technology cycle, which it describes as a new milestone in process reliability, quality and ease of use for drilling on universal machining centres.

Deep-hole drilling and gun drilling in particular place high demands on the operator and the machine. The new DMG Mori technology makes the process controllable. ADC transforms a complex technology that was previously based on experience into an actively controlled and monitored drilling process, with measurable standards for process reliability, increased quality and service life, ease of operation, process monitoring, and energy efficiency.

When performing deep-hole drilling,chip jams, misaligned holes, cross holes or tool breakage not only result in scrap but also jeopardise delivery dates and customer relationships. This is especially the case for components with high added value, such as crankshafts, injection systems, turbine components and medical implants.

With the increasing transfer of deep-hole drilling work to universal machining centres, responsibilities are shifting. Highly specific requirements are encountering an environment where not every operator has expert knowledge specific to deep drilling. Classic cycles work with rigid parameters here. As soon as the material, tool condition, or cooling lubricant deviates from the ideal, the process risk increases abruptly.

Adaptive Drilling Control from DMG Mori addresses this weak point. The process is no longer just set, but actively and adaptively controlled. Sensors for pressure, flow and load continuously provide status information, which the ADC cycle uses to control the coolant supply and machining strategy in a closed control loop.

The technology increases process reliability and quality and extends service life by 30%. Energy savings of up to 30%provide a further positive impact.

More information www.dmgmori.com

Next-generation SYIL machining centres in the spotlight

SYIL CNC UK presented an impressive line-up of high-performance machining centres and automation technology at the Southern Manufacturing & Electronics 2026 exhibition in Farnborough earlier this month. Four machines were demonstrated on the company’s stand, all featuring cutting tools from partner TaeguTec UK.

At the heart of SYIL’s exhibition was the unveiling of the redesigned X5 and X7 VMCs, representing a significant evolution in the company’s range. According to the company, the new designs prioritise ergonomics and aesthetics while maintaining the robust engineering that has established SYIL’s reputation for quality at competitive price points. Key improvements include enhanced door operation, optimised swarf removal systems, an upgraded 12-inch Siemens control system and improved visibility.

Visitors to the stand witnessed live cutting demonstrations on both the X5 and larger X9 machining centre. The X5 and X9 showcased TaeguTec’s latest high-feed milling technology, including the Chase4Feed line with its versatile four-corner BLMP inserts designed specifically for high-feed operations. The Chase4Feed’s robust circular insert geometry enables high performance in facing, shouldering, ramping and cavity machining applications, delivering depths of cut up to 2 mm while maintaining smooth surface finish.

Complementing this tool was the TaeguTec WINMILL series, featuring small carbide inserts with V-shaped pocket designs that provide high clamping strength and stability in compact diameter cutters.TaeguTec’s WINMILL line incorporates an enhanced cutting edge design and high rake angle that reduce cutting loads and improve chip evacuation, making it suitable for the precision shoulder milling applications.

Additionally, the latest solid-carbide TEO and TED drilling line from TaeguTec featured prominently, showcasing high-performance drilling. A major attraction on stand E185 was the X7 VMC equipped with SYIL’s KUKA-powered robot loading system. The R1 tending system features a 16-station pick-and-play configuration that enables fully automated part handling.

More information https://uk.syil.com, www.taegutec.com