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J.D. Bouwman and Cornelius Kiesel

Zimmermann Designs Custom Milling Machines for Large Moldmaker

For a short video on this collaboration between Zimmermann and Commercial Tool & Die, please see:

Zimmermann Milling Solutions, a leading global high-tech supplier of portal milling machines recently designed three custom milling machines for Commercial Tool & Die (CTD).

CTD is a family-owned and operated business with a long-standing reputation of building exceptional and extremely large plastic injection molds. Markets served include automotive, truck cab bodies, construction equipment and others. They have been successfully using Zimmermann machinery since 2018, so when a need arose for new milling machinery, they went directly to Zimmermann. “We reached out to Zimmermann that we needed a world-class milling machine, because that is what they have,” said Darin Hall, Plant Manager, Commercial Tool & Die.

Machining plastic injection molds has specific requirements and Zimmermann worked with CTD for over three years to design and build machines that met those needs.  “We went the extra mile because we knew that this was what Commercial Tool was looking for and we wanted to be the right partner,” said Cornelius Kiesel, President, Zimmermann. The final result was machines with the unique Zimmermann head design with multiple cutting axis to enable CTD to complete projects by speeding up production and improving accuracy without an excessive number of setups.

When J.D. Bouwman, President, Commercial Tool Group, was asked about the collaboration between the two companies and his favorite thing about the new machines, he replied, “We’ve challenged Zimmermann and they’ve really done a great job of responding to those challenges. Our Zimmermann’s have really helped us bring our machining to the next level. We’re able to achieve unattended numbers that we’ve never had before in the shop and that’s really a testament to our relationship with and the quality of the machines and just the overall build quality of the Zimmermann. It’s just a super, super solid machine.” He added, “I know that if we’re looking for a big machine in the future, we’re definitely going to be turning to Zimmermann.”


For more information, please contact:

ZIMMERMANN INC. 
30587 Century Drive
Wixom, MI 48393
Phone:  248-956-8511
www.zimmermann-inc.com
Ms. Lena Kiesel, Marketing Manager
lena@zimmermann-inc.com

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Zimmermann FZ40c is cutting and spraying away extra metal shavings

Zimmermann partners with two moldmakers to help them go “big”

Four large FZ40c portal millings machines providing significant changes to business strategy at Commercial Tool & Die and Franchino Mold & Engineering in Michigan

Zimmermann FZ40c milling machines enabled both moldmakers to grow their business in their home markets of automotive injection molds and die cast diework, in a unique partnership for each moldmaker

It began in 2017, when Commercial Tool & Die (CTD), a division of Commercial Tool Group in the Grand Rapids, Michigan area, contacted Zimmermann at a mold show and IMTS.  This 68-year-old company, founded by the grandfather of the current president, JD Bouwman, was heavily leveraged in automotive and off-highway injection moldmaking, but was seeking to grow into new markets with larger machining capacity.  Meanwhile, over in Lansing, Michigan, Franchino Tool & Engineering was prospering in automotive molds and die cast diework but was seeking to increase their 5-axis machining capability, travel and speed.  The short version of this story is that CTD ended up with three new Zimmermann machines, while Franchino bought the first CTD stock machine from Zimmermann, as it fit their needs quite well, according to Franchino President Mike Heatherington.  

Commercial Tool & Die Looking To Grow

As Plant Manager Darin Hall explains, “We had reached out to Cornelius Kiesel, president of Zimmermann Inc. in Wixom, Michigan, at a mold show and then again at IMTS.  We were impressed with their large CNC 5-axis machines.  CTD had four goals we were seeking to accomplish with our new machine capability.  Namely, we wanted reliability, efficiency to run unattended, rigidity to hold accuracies across a long travel and surface quality to meet our very high standards for automotive products.”  He notes the FZ compact line of Zimmermann appeared to have the essentials they sought at CTD, though some modifications would be needed. 

Company President JD Bouwman elaborates.  “We found in Zimmermann the combination of a great machine with a flexible team who was willing to expand their horizons and ours.  Although the basic version of the FZ40c is an excellent machine, in the end, we made 31 changes that were specific to CTG’s needs, including increased ram, with a goal to purchase three machines for our increased production.”  Bouwman further comments how this enhanced capability would allow CTD to move into new markets and increase share in their home market of automotive.  Today, that process has already yielded positive results, as the company is producing injection molds of much larger size than in the past, thereby opening new segment of automotive, off-highway and commercial building products. 

After the initial investigation, the decision was made to lease an FZ40c to trial the machine.  This portal mill has a work envelope of 197” W x 118” D x 59” H with a feed rate to 2362 ipm.  As the trials proceeded over the one-year lease agreement, according to Darin Hall, “We quickly saw that the machine was very solid and would allow us to strategize differently in our approach to production.”  Concurrently, CTD was realizing their market and manufacturing needs would require some significant changes to the machine, especially the ram height, for use on molds in the off-highway, construction equipment and building products market segments CTD was seeking to penetrate. 

He continues, “We also realized we had a great partner in Cornelius and the team at Zimmermann, both in Wixom and in Germany, where we visited a number of times, as they did here.  These folks were open to our suggestions and worked diligently to affect them.”  Hall notes this lease arrangement was the first in the 68-year history of the company.  “I guess you could say we knew where we wanted to go but weren’t quite sure of the machine design that would get us there.”  The CTD and Zimmermann teams thus began a collaboration that would run nearly three years, culminating in today with three FZ40c gantry mills on the floor at CTD, each with an enhanced rigidity and cast mono-block fork head with unique process cooling for high precision machining, especially on models and molds.  The FZ40c has a base x-axis of 236”, giving CTD the additional size they needed.  Among the changes made to the machine design was an increased ram.

In the end, JD Bouwman concludes, “We had a big machine concept in mind to get us to our goal and the three modified FZU machines were the answer.  Day to day, the machines give us much higher unattended machining numbers, a real testimony to the quality.  Zimmermann has allowed CTD to quote new projects, bigger workpieces and enter new markets, exactly where we wanted to go.”  He expressed a “big thank-you” to Cornelius Kiesel and the Zimmermann team, citing the dedication on both sides over a three-year period resulted in machines “…that simply allowed us to go to a new level as a company and that’s very exciting.”  A future goal between the companies is to build an even bigger machine with increased capacities to reach even higher levels of market participation. 

“Our relationship with Zimmermann is based on true collaboration and we’re mutually assisting the other to accomplish our goals.  That’s as good as a business partnership can be,” concludes Bouwman. 

One additional change to the FZ40c as requested, according to Cornelius Kiesel, and it presented a unique challenge to Zimmermann, he jokes.  “The CTD company color is gold and they requested we paint the machine heads that color for them.  We are machine tool engineers and builders but we took up the challenge and found the right paint for this challenging application.  Looks nice, doesn’t it?” 

Franchino — right place at the right time

That’s an old expression but it’s true in this case.  About an hour east of CTD sits Franchino Mold & Engineering in Lansing, Michigan.  According to company President Mike Hetherington, “Our business is currently about half in automotive injection molds and half in die cast diework for a variety of industries, including construction, stormwater and septic management.  During this recent period in business, with all its challenges, we’ve been flexible in seeking new jobs in various industries and it’s paid off, resulting in a sizable increase in our sales volume.” 

The connection between Franchino and CTD requires a bit of explanation, as Hetherington notes.  “We were on a business trip to Germany, seeking new machine concepts.  We had occasion to tour the Zimmermann factory and, while there, we saw the FZ40C portal milling machine being built for Commercial.  We were looking for that type of machine and had our checklist.  The FZ40C began to check off the boxes and we knew it was the machine for us.  As it happened, we learned the machine was being leased to Commercial down the road from us in the Grand Rapids area and we’d known them for years.  We don’t often directly compete, so we made some contacts and decided to wait for their lease to expire, then we purchased their machine and it was shipped to our facility in Lansing.”  He also mentions several particulars.  The machine needed to work both steel and aluminum molds, be a true 5-axis mill, be able to efficiently rough, semi and finish all in one setup, have an HSK spindle, run 1400 ipm and be up for two shifts reliably.  The FZ40c was found suitable on all these points, according to Hetherington. 

On one job, he notes with a smile, the shop took a roughing cycle from 16 hours to 3 hours, due to the machine’s rigidity, speed and accuracy.  As a bonus, the Heidenhain CNC onboard the Zimmermann machine provided a monitoring capability that enabled the Franchino Machining Supervisor, Chris Cook, to learn the status of the machine remotely. 

Cook cites another example of the company’s use of the Zimmermann FZ40c.  “We run molds for huge septic tanks and the Zimmermann is currently at 3000 hours of run time at 2000 ipm with no issues.”

Hetherington adds the machine purchased from CTD recently ran for two months solid at 90% capacity.  “Looking back, I’d say we were definitely in the right place at the right time, discovering this machine on our trip to Germany.  It’s been a very valuable investment for Franchino, providing reliable production on big workpieces.  It will open up more opportunities for our company in various existing and new markets.”  Hetherington has been president at the company since December, 2020, having gone, as he says, “…from mowing the lawn as a school kid to coming to work here with my engineering degree to engineering manager to VP of operations and now president.”

Franchino Mold & Engineering was founded in Lansing in 1955 by Richard Franchino, whose son and recently retired president Bob began as the first employee, sweeping the floor for $0.25 an hour.  Mike Hetherington is currently working on the construction of an additional 60,000-square foot facility with an 80-ton overhead crane to handle the massive workpieces produced at this shop, which produces molds & dies plus does considerable repair work for its customers nationwide. 


About the company

Zimmermann is based in Swabia (Germany) and is a leading global high-tech supplier of portal milling machines. These are characterized by huge workspaces, substantial machining dynamics and cutting performance. The company, founded in 1933 by Friedrich Zimmermann, now has over 200 employees worldwide. With its product range, our innovative company has one goal above all: to offer the right solution for our customers and thus to be able to guarantee high economic efficiency. “Quality made in Germany and supported locally” is our motto. The company’s special machines are used worldwide in the automotive, aerospace, moldmaking and mechanical engineering sectors.  The company has its North American headquarters in Wixom, Michigan, near Detroit, where it operates a full tech center offering engineering assistance, commissioning, parts and retrofit services, as well as multiple machines for demonstration purposes.  Zimmermann Inc. is headed by President Cornelius Kiesel. 

For more information, please contact:

ZIMMERMANN INC. 
30587 Century Drive
Wixom, MI 48393
Phone:  248-956-8511
www.zimmermann-inc.com
Ms. Lena Kiesel, Marketing Manager
lena@zimmermann-inc.com

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Reinventing yourself pays off

First Zimmermann portal milling machine of the newly designed FZP machine family with thermosymmetrical design offers significant user benefits

Model, tool and die makers must deliver perfect quality at competitive prices under increasing deadline pressure in order to prevail against strong global competition. Zimmermann is responding to this market condition with the newly developed FZP machine line. These 5-axis portal milling machines are customizable, space-saving  and extremely thermostable. These features are ensured by the new thermosymmetrical design with a center-guided Z-slide. Daniel Demlang, technical director at Zimmermann, explains the advantages for the user.

The completely newly developed FZP32 machine: The 5-axis portal milling machine is compact, very flexible – and highly accurate.

“An evolution is a progressive process.  A revolution, by contrast, is a fundamental and lasting structural change of a system – this is exactly what we have done with the development of our new FZP machine line,” reports Zimmermann Technical Director Daniel Demlang. The demands that model, tool and die makers need to meet today have grown steadily. Their customers demand workpieces with near-perfect surfaces and consistently high dimensional accuracy. The key to achieving this goal is manufacturing equipment that minimizes rework to ensure fast delivery times. “Our customers are burdened by increasing cost pressure and the demand for ever higher quality, while simultaneously increasing delivery deadline pressure for components. Reducing throughput times for workpieces was one of our main goals with the newly developed FZP series in terms of design,” explains Demlang. “Stable process control and high machining quality are decisive factors for the cost-effectiveness of our systems.” However, the customizability of our milling machines was not allowed to decline. Machines of the FZP Series are therefore even more flexible, in terms of set-up and design, with a comprehensive range of additional options.

Customizable – not only in length and width

“With our new FZP line, we primarily want to empower customers to compete successfully in the market for the long term,” says Demlang. The developers have placed particular emphasis on the customizability of the machines. Their structure can be varied in length and width with different vertical slides and gantries, thus adapting to a wide range of workpiece sizes. The “lightest” machine in the FZP line is the new FZP32 with a working range of up to X = 10, Y = 4 and Z = 2.5 meters (393” x 157” x 98”). The user can machine block materials, plastics, as well as CFRP, GFRP and aluminum, among other materials. Due to the large working area, it is also possible to mill components completely without reclamping. “The modular design of the machine offers the possibility to consider different options.  Automation solutions, such as a pallet changing system, a positionable rotary table, dust extraction bells and an individualized tool clamping system are all possible,” explains the technical director.

Thermosymmetrically constructed

The machine can be equipped with automation – shown here are changeover slides on both sides.

It was important to the developers to build the FZP line for maximum dimensional accuracy during workpiece machining. This is because changing temperatures in the user’s facility, as well as long machine running times, inevitably influence the machining quality. For this reason, the Zimmermann developers designed these new portal milling machines thermosymmetrically – a concept that was used successfully for the first time at Zimmermann in 2017 in the compact FZU portal milling machine line and was enthusiastically received by customers.

“The idea of the thermosymmetrical design is based on the fact that inevitable thermal influences can be absorbed to a considerable extent by the design of the machine structure,” explains Demlang. In the portal milling machines of the FZP line, Zimmermann has arranged the milling spindle, guides and other accuracy-determining components in such a way that their heating is either absorbed or can expand in non-critical directions. The gantry’s center-guided Z-slide in double-bridge design, for example, has an octagonal cross-section that makes it particularly stable. “With this design, we achieve very high thermosymmetric stability,” says Demlang. Comparable systems usually use complex cooling or software-based compensation for this purpose.  

“Our concept is future-proof, especially when the demands on quality and surface continue to rise,” promises Demlang.  Companies that do not have an air-conditioned machining facility and are therefore particularly exposed to temperature fluctuations in their production will also benefit from this concept. And this is where the new design further scores points, according to Demlang. The design of the structure alone reduces the effects of the influencing variables to a minimum.

Technical Director at Zimmermann, Daniel Demlang: “With our new FZP line, we want, above all, to support customers in being able to compete successfully on the market in the long term.”

VH10: milling head with extraction

The Zimmermann VH10 milling head is used on this new machine line. The fork head is designed in monoblock versions made of cast iron. It is compactly built, has only minimal interference contours, achieves high clamping forces and thus enables stable component machining. Zimmermann optionally equips the VH10 milling head with process cooling via cooling lubricants and minimum quantity lubrication. To reduce throughput times, a powerful spindle with 34 kilowatts (45 HP) at a maximum speed of 24,000 rpm is used as standard in the milling head. “We have now also equipped the VH10 with a dust extraction bell around the milling tool,” Demlang notes. This makes it suitable for abrasive and harmful materials such as GRP or CFRP, which are used in aircraft construction. The dust extraction system captures the dust directly at the point of origin, which greatly reduces contamination of the interior.

Great flexibility by design

Facility conditions are often a challenge for the installation of large milling machines. Free installation space is usually scarce and machine concepts must offer a high degree of flexibility in installation. The Zimmermann developers have applied symmetry not only to the basic structure of the gantry, but also to the complete machine concept. This allows the customer to individually determine specific connections or peripheral attachments. “We can then simply position the peripherals as required by the individual situation without making any major design changes to the new FZP32,” says Demlang. Overall, the ratio of floor space to workspace has been optimized with this new development.

The developers have applied symmetry not only to the basic structure, but also to the complete machine concept.

Zimmermann equips the new machine line with larger tool magazines or even pallet changers on request. This allows users to reduce non-productive time and make their production more automated. Another feature: “Milling-turning applications are increasing, especially in aircraft construction, for example in turbine production,” says Demlang. “For this purpose, we also equip our milling machines with carousel rotary tables on request.”  Regardless of the task the customer needs to perform, Zimmermann’s experts can supply the machines in a customer-specific, optimized way with their modular plant construction kit (MAB).

What’s next?

“We already have the first orders for the FZP32, our ‘light’ entry-level model in the new series,” says Demlang. “Based on the new double-bridge gantry, we will soon launch the new FZP37, a machine in the medium segment, and the FZP42, one in the heavy segment for the mold and die industry.” The heavy-duty FZP42 machine will be in the 1,000 newton-meter (737 ft lb) torque range. “We have taken a forward-looking path with this new machine line,” concludes Daniel Demlang.


About the company

F. Zimmermann GmbH from Neuhausen a.d.F. in Swabia is a leading global high-tech supplier of portal milling machines. These are characterized by huge workspaces, enormous dynamics and cutting performance. The company, founded in 1933 by Friedrich Zimmermann, now has over 200 employees worldwide. With its product range, the innovative company has one goal above all: to offer the right solution for its customers and thus to be able to guarantee high economic efficiency. “Quality made in Germany”. The special machines are used worldwide in the automotive, aerospace and mechanical engineering sectors.  The company has its North America headquarters in Wixom, Michigan, near Detroit, where it operates a full tech center offering engineering assistance, commissioning, parts and retrofit services, as well as multiple machines for demonstration purposes. 

For more information, please contact:

ZIMMERMANN INC. 
30587 Century Drive
Wixom, MI 48393
Phone:  248-956-8511
www.zimmermann-inc.com
Ms. Lena Kiesel, Marketing Manager
lena@zimmermann-inc.com

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FZ33 milling head in action

Zimmermann Hosts Open House

 

Machine tool builder of various mills introduces new moldmaking machine

Sit down area of the open houseWixom, Michigan-On July 24-25, Zimmermann Inc., the North American affiliate of Zimmermann GmbH in Germany, hosted an open house at its headquarters here for its customers and prospects in North America. Among the crowd were many major suppliers to aerospace and automotive, as well as other large part producers for the OEM, media from the industry, suppliers and other associates of Zimmermann. Machines were on display, highlighted by the company’s FZ33, a compact and highly flexible 5-axis gantry mill designed specifically for moldmaking.

Presentations were given throughout the event, which also featured displays from a number of Zimmermann business partners, including Mapal, Keller, Siemens, Zoller, Heidenhain, Fischer, Tebis, Unisorb, Weiss and Haimer.

The open house was hosted by Zimmermann GmbH President Frieder Gänzle, as well as Zimmermann, Inc. President Cornelius Kiesel and his team for North American engineering, sales and service.

Gänzle commented, “We are very committed to success in the American moldmaking market, as we have experienced good results in aerospace and other large component production for years here.” Kiesel echoed that sentiment, “Our customers are growing in number in the moldmaking industry, owing to the solid stability of our machines, with their highly flexible programming capability and swivel 5-axis head, that allow very fine finishing on the mold surfaces, as well as intricate pocket machining with a high degree of accuracy and repeatability.”

One of the main suppliers to Zimmermann for CNC is Heidenhain and Gisbert Ledvon, the company’s marketing manager who attended the event, observed, “Zimmermann is a very good customer, as they work closely with us and their customers to produce CNC programs for application-specific purposes. They also put on a very fun event!”

As a testimony to the long-lasting quality of Zimmermann milling machines, a unit built over 20 years ago was also on display. This machine is currently being retrofitted for resale to an interested customer. (Interested parties may contact Cornelius Kiesel at Zimmermann for details.) The machine is well suited to the aerospace industry, where Zimmermann offers its portal milling machines for spars and stringers for all commercial aircraft currently in use.

All attendees enjoyed the food, evening entertainment and collegiality at the event.

 


For more information, please contact:

Zimmermann, Inc.
30587 Century Drive
Wixom, MI 48393
Phone: 248-305-9707
www.f-zimmermann-inc.com
Attention: Lena Kiesel, Marketing Manager

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Zimmermann Introducing New FZU 5-Axis Gantry Mill

 

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.

gantry milling

Frieder Gänzle, General Manager and Partner at F. Zimmermann GmbH: “We don’t want to be chasing trends; instead we want to help shape the market.”

“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

gantry milling

With the FZU, Zimmermann is developing an extremely compact universal machine for prototype, mold and tool making with an attractive price/performance ratio.

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.

Thermo-symmetrical design

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

gantry milling

VH10 spindle head design from Zimmermann, with 34kW and 24,000 rpm standard performance in a rugged design.

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.

Comprehensive service

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

  1. Zimmermann GmbH is headquartered in Neuhausen a.d.F., Germany, and is one of the world’s leading suppliers of high-tech milling solutions. The machines have huge working areas, tremendous dynamic performance and enormous cutting capacity. Founded in 1933 by Friedrich Zimmermann, the company now has over 200 employees, with subsidiaries in the USA and China. The innovative company has one primary goal for its range of products: being able to offer the right solution to its customers and so ensure high profitability: “Quality made in Germany”. Its specialized machines are in use throughout the world in the aerospace and automotive industries and find many special applications. Zimmermann Inc. is the North American headquarters, based in Wixom, Michigan (Detroit) and is a full-service operation with machines, application engineering, sales and service personnel on staff to serve the company’s growing markets in the U.S., Mexico and Canada.

For more information on this development, please contact the North American headquarters:

ZIMMERMANN INC.
30587 Century Drive
Wixom, MI 48393
Phone:  248-956-8511
www.zimmermann-inc.com
Ms. Lena Kiesel, Marketing Manager
lena@zimmermann-inc.com

 

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