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The demands for prototype, tool and mold making are increasing. Only those who can supply high quality output, quickly and flexibly, can succeed against the powerful competition worldwide. Zimmermann is responding to this trend with the new FZU. This 5-axis gantry milling machine is not only extremely compact but, thanks to its thermo-symmetrical design and accuracy, it also provides the ideal entry point to the Zimmermann machine line with maximum productivity. Plastics, casting resins such as Ureol and aluminum are particularly suitable for machining. “This development will enable us to close the gap in the lower weight class,” states Frieder Gänzle, General Manager and Partner at Zimmermann in Germany.
“The basic expectations, which prototype, tool and mold makers need to meet today, have not necessarily changed over the years, they have simply grown,” sums up Frieder Gänzle. Customers in the automobile industry, he notes, especially expect components with almost perfect surface finishes and ever higher accuracies. Manufacturers introduce new models or variants to the market at ever shorter intervals. Whereas prototype, tool and mold makers could previously plan in the longer term, they must respond today to inquiries considerably faster.
“We cultivate a very special relationship with prototype, tool and mold makers,” says Gänzle. “Together, we have evolved consistently in recent years. We are very appreciative of our strong business in this sector.” Zimmermann is continuously exchanging technology information with its user base. In discussions, it has become clear that this sector requires powerful, compact machines with maximum productivity and open time. And, importantly, Zimmermann must offer an attractive price/performance ratio, while meeting all these requirements. “We have evolved even further towards heavy-duty cutting, over the years,” reports Gänzle. “As a result, even the smallest machine in our portfolio, the FZ33 compact, has become more popular. We have continuously pushed it upwards from a technological point of view.” Its focus is on aluminum cutting, but steel can also be machined. This enables Zimmermann to offer customers a very efficient, flexible and space-saving machine, while the corresponding design improvements have also had an effect on the price. “The requirement we were presented was for an entry-level model which rounds off our program at the lower price point,” explains Gänzle. The result is the FZU, a 5-axis gantry milling machine which is optimized for weight and stability.
Pre-assembled machine concept
In contrast to the established FZ33 and other machines that Zimmermann offers today, the company is taking a different path with the FZU. “We can narrow down the special features of this gantry machine to three main characteristics,” describes Gänzle. The first point: “We are following the trend towards modern manufacturing machines and designing them as space-saving, pre-assembled units.” This means Zimmermann assembles the machines in-house and can then transport them to the customer by truck or ship without having to dismantle them. Onsite, they are ready for use in a very short commissioning time; erection and start-up require minimum effort. For the customer, this means quickly available machines which can be installed without constructing foundations. “In the design, we have kept to the usual transport sizes. At the same time, the new FZU achieves a remarkable working range for its size,” explains Gänzle.
It is important to match the machine to the required dynamics. Adverse environmental conditions and long machine running times necessarily give rise to thermal expansion effects. In spite of the customers’ increased accuracy requirements, the machine must always achieve outstanding surface finishes. The Zimmermann engineers have therefore designed the FZU gantry machine to be thermo-symmetrical. This means that the milling spindle, guides and other accuracy-determining components are arranged so that their heating is either compensated or they can expand in uncritical directions. “This is the second important characteristic,” emphasizes Gänzle. The base frame consists of a steel welded construction which forms a continuous U-shape. The machine gantry’s centrally guided Z-slide has an octagonal section – and not a rectangular one like comparable machines – which makes it particularly stable. Thanks to its design, it therefore has impressive rigidity for its size. “With a weight of approximately 35 tons, a length of 3,500mm, width of 7,500mm and a height of just under 5,000 mm, we have been able to build a light and compact machine,” says Gänzle.
In-house head implemented throughout
The third characteristic relates to the new VH10 milling head, which achieves an extremely high power density. “This new development has enabled us to reassess our portfolio,” reports Gänzle. This is because the VH10 head will replace the VH12, which is not a Zimmermann product. Alongside the VH20, VH30 and VH60, the VH10 is now the smallest head in the range. Users will also benefit from the fact that Zimmermann has suitable spare heads in stock and can supply them on request in the event of stoppages, for example, due to a crash. “We strive to respond quickly and provide the customer with optimum support,” emphasizes Gänzle.
Thanks to its slender design, the VH10 spindle head has only minimal interference contours. Compared to the VH12, it achieves almost double the clamping force. This is due to the fact that Zimmermann fits two side cheeks instead of one onto the unit. The VH10 is therefore considerably more stable in operation. In order to minimize throughput times, a powerful 34 kW spindle with a maximum speed of 24,000 rpm is used in the milling head as standard. “The FZU is therefore ideally suitable for the materials typically found in this business sector, such as Ureol, clay and aluminum. In the future, we will also use the new milling head in larger machines on which processers can produce one-to-one models – for example, on our FZ37,” says Gänzle.
Standardized and yet individual
In order to provide a high-quality machine at an attractive price, the designers at Zimmermann have turned their attention to remaining competitive with regard to price through increased component standardization, while at the same time addressing individual customer requirements. As with all machines produced, Zimmermann therefore also relies on a modular system with the FZU. Among other things, this approach enables different size variants and power levels to be produced. There are also numerous equipment options which offer the customer maximum flexibility.
Zimmermann is therefore able to provide a very efficient solution with the new FZU. It is often the little things that give rise to success and customer satisfaction. “We place great importance on details – an aspect which cannot always be measured in the numbers,” explains Gänzle, who cites two examples: “For instance, the machining area is fully clad with stainless steel sheets in order to guarantee maximum resistance to abrasion. The FZU is also the first gantry milling machine to be equipped with our innovative, new NXP 24-inch multitouch controller, which is already used on our FZH horizontal machining center.” Another increasingly important topic is ergonomics. The door is divided asymmetrically to enable components to be easily fed to the machine. A small, easy-to-open door leads into the machining area, while the large door is used for loading. Operators therefore have a relatively large field of view, rapid access to the machining area and ample space for loading – ergonomic advantages which are not to be underestimated. Another detail is that a cabinet has been installed directly in front of the FZU. “This was the idea of one of our designers,” says Gänzle. “The tables, which users in the various plants position in front of the machines to place their accessories and service tools, caught his attention. With our solution, everything which is part of day-to-day operations can be safely stowed close at hand within the machine.” Added to this, there are extraction equipment and special chip management systems. “It is often the simple ideas which make the machine operator’s everyday tasks much easier,” sums up Gänzle.
To provide the best possible support to businesses, Zimmermann concentrates on high-quality and reliable service in close proximity to the customer. After all, this is exactly what characterizes a good relationship between supplier and user. “Customers expect high availability over the entire system lifecycle,” says Gänzle. “We provide comprehensive machine care.” This includes a customer hotline, by means of which users can reach a competent contact person, even outside of normal working hours, as well as a remote diagnosis system that allows a rapid response in an emergency. If mechanical components are defective or malfunction, the machine builder usually guarantees immediate shipment from its factory. In addition, the application engineers work together with the customer to optimize each individual combination of heads, spindles, tools and clamping equipment for the machines. Zimmermann therefore not only sells machines, but also complete solutions. Plans are in process for further upgrades to the stocking and service personnel staff in North America, as well. Zimmermann recently opened a new facility in Wixom, Michigan, near Detroit.
Goal: To be technologically out in front
“We don’t want to be chasing trends; instead, we want to help shape the market,” says Gänzle. “Basically, we therefore aspire not to do the same things as our competitors.” To be technologically out in front, the machine builder never stands still with regards to machine development. The FZU is therefore being continuously optimized – without at the same time losing sight of the price/performance ratio. There appears to be substantial market interest in these machines, according to company research. The initial discussions with users were highly promising. “We are confident of meeting our customers’ requirements with this new development, both in Germany and internationally,” says Gänzle. The statement that the concept of the FZU could be transferred to the other machines in the program underlines how convinced he is of this new solution. Zimmermann will be presenting the machine to a specialist audience at WESTEC 2017, CMTS 2018 AMB in September, 2018. As further indication of emerging market interest, three users have already decided to purchase this new gantry milling machine.
About the company
For more information on this development, please contact the North American headquarters:
Major supplier of multi-spindle machine tools and grinders taps longtime industry pro to lead company to next levels
Schütte (Jackson, Michigan) today announces the appointment of Mr. Jeffrey Reinert as CEO for the North American operations of the company, effective June 8, 2017. Schütte supplies a range of multi-spindle machine tools and grinders for production work in various sectors of the metalworking market, including medical, orthopedic, tooling, contract machining and more.
Jeff Reinert brings over thirty years of related experience to the position, having been involved with all aspects of manufacturing, sales, marketing and management in the machine tool industry. Jeff was most recently the president and CEO for North American Operations at Index, another leading machine tool builder. Jeff held that position for nine years. While at Index, he nearly doubled the sales of the company, reorganized the service, parts and training departments, plus opened a new office in the emerging Mexican market for the company. He was also previously the president of Machine Tools of Indiana, a dealer company he founded in 2001 and ran successfully for seven years.
Jeff attended Vincennes University, Valparaiso University and Purdue, where he studied electrical & mechanical engineering.
In commenting on his new position, he observes, “Schütte has a solid reputation as a builder of top quality, multi-spindle machine tools and, based on that foundation, we plan to accelerate the company’s growth curve to take us into more markets with a decidedly aggressive posture, including greater visibility in the media, at shows and through industry association participation. Complementing this sales growth strategy will be a buildup in our service, engineering and customer support programs.” Jeff also noted the long-range plans for Shütte include upgrades to the current facility in Jackson, Michigan, with more machines on the floor for demonstration of the company’s capabilities, testing and production scenarios for enhancing the customer experience.
“My personal goal is to bring Schütte to the forefront of the industry, in both the multi-spindle and grinding technology arenas. We can shine as a great team, with excellent machines backed by a high-quality group of dedicated individuals. It’s an exciting time and I look forward to meeting the challenges.”
For further information, please contact:
Information-packed site features full standard line of polyurethane products plus custom capabilities and unique calculation tools
Kastalon, a longtime leader in polyurethane products, announces the rollout of its new website at www.kastalon.com. The new site offers a look at the company’s extensive lines of standard products, including rollers, pads, bumpers and sleeves for various uses in materials handling, metals producing and processing, as well as myriad other market applications.
Likewise, this new website details the custom material formulation and production capabilities of Kastalon, as the company has built a reputation for problem-solving solutions, since its inception in 1963.
Also included on the website are a number of engineering tools, which allow prospective customers an opportunity to detail their requirements for prompt quotation. Various materials performance calculation tools are provided on the site and these are among the most popular pages. Full company literature downloads are also offered.
Kastalon brings its decades of manufacturing experience and application engineering to each customer task, providing a high degree of material consistency and product performance to the global markets served by the company.
Inside Sales Manager Lyn Thorne comments, “We have worked for over two years to produce this site and believe it will be very useful to our current and prospective customers alike, as it provides a thorough presentation of our company’s successes and capabilities.”
For more information, please contact:Continue reading
Longtime veteran of steel industry to lead sales and marketing efforts for major coil coater and coatings manufacturer
Effective immediately, Mike Tieri, 59, has been named Vice President of Sales & Marketing at Chemcoaters, Inc., a leading coil coater as well as a manufacturer of proprietary coating chemistries at its sister company, Eco Green, both based in the heart of the American steel industry, Gary, Indiana. This appointment was announced by company president Bill Capizzano.
Mike joined Chemcoaters in 2013, following a long career in steel sales dating back to 1993 at Cresco Steel, then Viking Materials and Kloeckner Metals. Subsequently, Mike was a Sales Manager for Chicago Tube & Iron, Kloeckner and JDM Steel.
Prior to this promotion, Mike served as Director of Sales & Marketing for Chemcoaters and Eco Green, spearheading the efforts on both companies’ sales initiatives, key account management, sales strategy and new business development. He works closely with the company’s ad and PR agency on brand building and development of the messaging to the mills, service centers and OEMs in the industry. Recently, he developed a highly successful campaign for the Chemcoaters coil washing service, using a “Car Wash” theme he developed with the agency. Mike was also honored in 2016 by the Metal Service Center Institute for his innovative and clever social media campaigns.
Mike and wife Jill live in Tinley Park, Illinois, have five children and six grandchildren. They are members of Harvest Bible Chapel in Rolling Meadows, Illinois.
Based in Gary, Indiana, Chemcoaters, Inc. is a leading supplier of green coil coatings, as well as traditional prepaint and protective coil coatings such as dry film lubes and other RoHS-compliant coatings. Virtually no VOCs or HAPs are present in the process. The company’s patented InterCoat® ChemGuard 300 coating is formulated with trivalent chrome vs. hexavalent chrome, making it environmentally friendly in all building, architectural, transportation and consumer appliance applications. InterCoat® ChemGuard 300 coating has superior corrosion resistance, as well. Chemcoaters offers a presentation on their unique and proprietary patented coating that evidences this fact to all interested parties.
For more information, please contact:
Bill Capizzano, President
700 Chase Street
Gary, IN 46404
New catalogs for Mori Seiki, TSUGAMI and Miyano machines offer standard tools from live tooling leader
Heimatec, a market leader in live tooling for the North American machine tool industry, has released a series of four new catalogs showcasing the company’s lines of machine brand specific tooling.
Already offering the most complete line of live tools available in the industry, with over 40,000 designs in its database, Heimatec machine brand specific tooling includes products for the following popular brands:
Heimatec sets the standard for the highest precision and most advanced technology in the machine tool accessory market. The company is acknowledged as a world leader in live tools, angle heads and multi-spindle drill heads.
In addition to its standard tooling and machine brand specific line, Heimatec also offers custom designed tooling. Heimatec tooling experts work directly with customers to design solutions to suit specific requirements for all CNC lathes, helping to solve the most challenging applications in multiple markets served by the company, ranging from orthopedic devices to oil & gas drilling equipment.
Heimatec North American distribution headquarters are located in Prospect Heights, Illinois (Chicago) with world headquarters plus all manufacturing based in Germany. A team of manufacturers’ representatives covers the North American market for Heimatec.
Visit Heimatec at IMTS 2016, Booth # W-2054 in Chicago.
For more information or to receive a PDF copy of the new dedicated tool catalogs, please contact:Continue reading
Customer needed post-assembly validation of fine wire configuration
Exact Metrology, working at the company’s Brookfield, Wisconsin location, has successfully used its ProCon industrial CT scanning technology to validate the position of a wire configuration in the bobbin of an electronic lock assembly for one of its customers.
As techician Sean Plastine explains, “A customer came to us to verify the position of a 0.008” diameter wire inside its electronic lock assembly. The position of the wire could not previously be verified while the components of the lock were being assembled. Inspection of the wire bobbin after assembly was also impossible.”
By using its CT scanning technology on the completed lock assembly, Exact technicians were able to determine the wire’s precise position without the need for disassembly or other compromise on the finished article. Any deviation of the wire’s nominal position could be noted, allowing for subsequent changes in the assembly protocol, as needed.
The CT scan clearly shows the path that the wire pair follows inside the lock assembly.
Plastine adds, “We are very excited by the possibilities of this technology, as it’s opening new doors for our contract services at many existing and many more new customers.”
Exact Metrology is an ISO 9001:2008 and AS9100 Certified Company.
For more information on this application or to arrange a demonstration, please contact:
Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development assistance and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.Continue reading
Product demonstrations and technical presentations from principals impress large crowd at dual open house
On March 17, 2016, Exact Metrology held a tech event in Cincinnati, Ohio with partner company, 3DVision Technologies at both of their offices. Held on St. Patrick’s Day, the event was cleverly titled “Lunch, Learn & Luck,” and had a “March Madness” theme with basketball games playing on multiple widescreen televisions. The event was attended by over 100 people from local area industries, including automotive, aerospace and consumer goods.
Co-Hosted by Steve Young, Exact Metrology co-founder and President, and Todd Majeski, President of 3DVision Technologies, the day included presentations and product demonstrations of the newest products transforming the manufacturing industry in 3D printing and 3D scanning. The informative event provided insight and hands-on experience, while displaying the newest technology that is reshaping the traditional manufacturing process.
The day began at 3D Vision Technologies office, (a provider of engineering solutions & 3D printing for manufacturing companies), with a presentation by Todd Majeski. Majeski discussed the company’s long-term partnership with Exact Metrology, and how both companies work together to improve processes, increase quality, and get their customer’s products to market faster through 3D scanning and reverse engineering. After several presentations and a question-and-answer session, attendees were welcomed into a showcase of 3D printer demonstrations and product displays of printed samples from miniature to lifesize versions, including a skateboard, helmet, and an automotive front grill.
The second part of the tech event was held at Exact Metrology’s office, conveniently located just a short walk away. Participants walked together and, after a St. Patrick’s Day themed lunch, began the afternoon session with a presentation by Steve Young. Young discussed the newest technology in CT (Computed Tomography) scanning systems, which allows users to not only scan the outside of a part, but to actually see inside of it without taking it apart, or damaging the item. Until recently, this technology was used primarily in the medical field but is creating much excitement within a variety of industrial markets now, as it enables manufacturers to check for defects, internal contact points after assembly, porosity and dimensional accuracy, comparing actual scans to point cloud data, CAD files etc. According to Young, this type of 3D scanning has been a “huge success” for his company, which he co-founded with Dean Solberg, who runs the company’s facility in the Milwaukee area.
Products displayed at the event included the P40 Leica Scanner, a long-range scanner, which, according to presenter Jacob Wallace, Processing Engineer at Exact, can be set up and ready to scan in 30 seconds. The scanner has a 150-meter range and will show everything in the surrounding area. Wallace recently scanned an entire office to make an accurate 3D model, complete with windows, doors, ceiling and wall thickness. Other uses of these long-range scanners include collecting topography of roadways (without stopping traffic) and large buildings of 500,000 square ft. or more, to collect information inside and outside of the building, all within a reasonable timeframe.
Josh Schradin, QA Manager, demonstrated the GE Vtomex M CT Scanner with a full rendering of a videogame controller he had previously scanned. Attendees were able to see internal components, including the smallest features on the circuit board. He explained how the scan could also be used to find defects or to process for reverse engineering.
Other products displayed and discussed at the expo were the Romer Absolute 77, an Articulated Arm with a Laser Line Scanner, the Atos Triple Scan, the Artec EVA Handheld Portable Scanner and the NDI ScanTrak Large Volume Laser Scanner.
Exact Metrology ended the afternoon with a St. Patrick’s Day raffle, with two lucky attendees winning a 48” high-def television and a MakerBot 3D printer.
Exact Metrology offers a complete line of portable scanning and measurement technologies as well as contract measurement for 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services, 3D digitizing and training.
For more information on this new equipment, please contact:
Exact Metrology is an ISO 9001:2008 Certified Company.
Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.
“G40 hot dip galvanized with Intercoat® ChemGuard will substantially outperform G235 and offer a much lower overall cost,” states director of sales & marketing Mike Tieri
In a forceful announcement made today, Chemcoaters, Inc. (Gary, Indiana) directly addressed the EQ (Equivalent Coating) controversy with the statement above, attributed to Mike Tieri, Director of Sales & Marketing for the company, a leading green coil coater based in Gary, Indiana.
Elaborating, Mr. Tieri cited the following example.
“For 16 ga coil (0.056 specifically), the zinc coating to a G30 thickness is currently adding $1.90 cwt. By contrast, G235 thickness zinc coating is $11.10 cwt. To apply our Intercoat® ChemGuard to G30 is no more than $4.00 cwt, so the economics are unquestionable. Since G30 is commercially available from many more sources, it means service centers, OEM’s and processors can use a lighter and obviously less-expensive zinc coating thickness, have a metal product that is considerably easier to form and shape, reduce SKU’s, increase inventory turns, increase corrosion resistance (see graphic) and save money immediately. Doesn’t get much better,” Tieri mused. He further noted that this example is not always applicable, given the size of the coils supplied to Chemcoaters.
The InterCoat® ChemGuard product can also remain bare, be painted or welded, plus it’s RoHS compliant and can even be tinted in a spectrum of colorations, according to Tieri.
Chemcoaters, Inc. is a leading supplier of various coil coatings and cleaning services for the coiled metals market. The company’s patented InterCoat® ChemGuard 300 coating is formulated with trivalent chrome vs. hexavalent chrome, making it environmentally friendly in all building, architectural, transportation and consumer appliance applications. InterCoat® ChemGuard 300 coating has superior corrosion resistance, as well. Chemcoaters offers a presentation that evidences this fact to all interested parties.
For more information, please contact:Continue reading
Leader in 3D and CT scanning for industrial, commercial concerns achieves key aerospace supplier metric
On January 28, 2016, Exact Metrology achieved certification as an AS91900 supplier, for its Cincinnati facility. Exact is a leading supplier of 3D and industrial-grade CT scanning equipment and services to myriad industries and commercial concerns. Co-President Steve Young, who heads up the Cincinnati operation for the company, made the announcement today. “In achieving this prestigious certification, our team has great pride of accomplishment, as the AS9100 audit and certification process is extremely rigorous and required an in-depth knowledge by every associate at Exact of job performance scope, expectations, issue resolution protocols and our overall process operation.”
As the certification notes, Exact has its recognition for “…sales and supply of 3D non-contact and contact measuring equipment for inspection and reverse engineering to the commercial, aerospace, medical, automotive and industrial manufacturing industries.”
Expanding on the audit process, Co-President Dean Solberg notes, “Every one of our associates realized something very special during the audit. Namely, because it was necessary that they understood the process and purpose of their work plus the issue resolution scenarios required, they appreciated their roles as interconnected team members at Exact. That’s very exciting to witness and has already raised their level of involvement in day-to-day operations.” He further observed that the audit required a new level of goal orientation, self-evaluation and awareness of improvement possibilities across the entire facility, including operations, accounting, sales, service and especially management.
The AS9100 is a vital certification for the work this facility performs in the aerospace sector.
Exact is a prime supplier of equipment as well as the services that utilize various portable and stationary 3D scanning devices, plus one of the first industrial-grade CT scanners, a unit that can examine the internal geometric and material composition of various substrates on molded, cast and forged products, as well as food ingredients and packaging for seal integrity and safety.
Exact Metrology is also an ISO 9001:2008 Certified Company.
For more information on this development or to arrange a demonstration, please contact:
Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.Continue reading
Dukane Corporation, St. Charles IL introduces a new Laser Welding System that allows clear-to-clear plastic welding without the need of any laser absorbing additives. This system incorporates a recently developed 2-micron laser with a greatly increased absorption by clear polymers and enables a highly controlled melting through the thickness of optically clear parts.
New beam delivery system integrates both a programmable multi-axes servo gantry and a scan head, supported by proprietary LaserLinQTM software, which harmonizes the action of both components moving the beam. This assures highly precise and controllable beam delivery when welding mid-size and large components.
LaserLinQTM also provides users with the ability to break complex weld patterns into separate geometric segments, modify each segment independently and assign different welding parameters to each segment. The CCTV camera integrated within the machine enables a live weld preview on the HMI screen and the ability to directly monitor and record welding cycles for further analysis. All laser enclosures are Class I CDRH certified and utilize laser-safe glass viewing windows.
This Dukane flexible welding system also allows rapid changeover of a wide variety of highly specialized tooling cassettes. The tools, as a standard, incorporate binary tool ID recognition for automatic weld recipe recall. They support multi-cavity function, multiple feature detection, vision systems and independent clamping systems to compensate for part variations.
Manufacturers from various industries including medical, electronics and appliances can benefit from this clear-to-clear laser welding solution.
Dukane Corporation offers a full range of ultrasonic, vibration, spin, hot plate welders, and thermal presses, probes, tooling and software for both OEM and the commercial plastic assembly markets. Dukane is an ISO 9001:2000 certified manufacturer with 24/7 Service. For more information on Dukane’s Laser welding System, and their complete line of plastic assembly solutions, contact Jason Barton, National Sales and Marketing Manager. He can be reached at (630) 797-4902 or visit their web site www.dukane.com/us.