Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Zimmermann Machining Solutions, a leading global high-tech supplier of portal milling machines, recently sold an FZP27 portal milling machine to Max Eickworth.
Located in Bremen-Arsten, Germany, the company handles test equipment construction, fixture construction, model making, toolmaking, CAD/CAM and metrology. With a manufacturing range both broad and specialized, Max Eickworth designs, manufactures and tests equipment for the automotive, aerospace, wind energy and shipping industries.
Celebrating 106 years of quality, precision and reliability, the company purchased a CNC 5-axis gantry machine FZP27 to expand their production capabilities. Equipped with a machining center for large volume components in aluminum or ureol, the machine features a robust construction with a top travelling gantry for precise material processing. Its working range is 118.11 – 787.40 inches in the X-axis, 98.43 – 157.48 inches in the Y-axis and59.06 – 78.74 inches in the Z-axis. The spindle power is 24 kW at 18,000 rpm with a Heidenhain TNC7 control. Various 2-axis milling heads are available including the S2, C2, C3 and VH10.
Its sophisticated, well-engineered modular system ensures optimum adaptation to every machining case and workpiece size. Applications range from 1:1 models in automotive design to large aircraft parts and boat hulls, all the way to components for railcar manufacturing. The machine can be used for both prototypes and production parts.
Cornelius Kiesel, president of North America for Zimmermann said, “This is the fourth portal milling machine Max Eickworth has purchased from Zimmermann. A clear sign of trust, quality and proven cooperation.”
About the company
Zimmermann is based in 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 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, transportation, off-highway 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
Today, Zimmermann’s high-precision portal milling machines are complex digital systems. Control systems, industrial PCs and internal networks must be secured in such a way that neither malware can impact nor adjacent company networks are endangered. Cyber resilience is fast becoming an integral part of modern machine tools.
What distinguishes machine security from cyber security? The former protects the operator from hazards posed by the system. Safety features prevent mechanical or electrical risks and ensure that people are not harmed. “Cyber security, on the other hand, affects the entire digital network of a machine,” explains Christian Gaarz, Head of Software Development & Commissioning at Zimmermann. “All networked components with IP addresses must be secured in such a way that no unauthorized access from the outside is possible. Such an intervention could change processes, cause production to fail and have serious consequences go unnoticed – such as data loss or falsified production parameters. This is particularly critical for components that will later be used in safety-relevant applications such as commercial and military aviation.”
Christian Gaarz has been employed by Zimmermann for about four years. In his role, he and his team are responsible for everything that brings the company’s portal milling machine systems to life digitally: from drives to sensor technology and software solutions. In this way, he ensures that mechanical components are turned into a functional, process-reliable overall solution with top-of-mind security in place. Zimmermann is based in Germany and operates under Frieder Ganzle, Managing Director, who has fully supported the integration of cyber resilience into the machines designed and built by the company.
Clear regulatory requirements
The regulatory requirements are clearly defined. The Cyber Resilience Act (CRA) stipulates how digital products and systems are to be secured. Together with the Machinery Regulation (EU) 2023/1230 and the NIS 2 Directive, a clear European legal framework is being created. “For us as a mechanical engineering company, this means that cyber resilience is no longer a voluntary additional service, but a regulatory obligation,” reports Gaarz. “We must meet this binding framework for compliance as early as 2027.”
The requirements already take effect in the development phase of the machines and have a direct impact on design, software architecture and documentation, the company’s key concept being “security by design”. This means machine safety aspects are not added retrospectively, they are an integral part of machine development from the very beginning.
Zimmermann systematically prepares for these requirements. The company is represented among various industry specialist working groups and collaborates closely with control manufacturers such as Heidenhain and Siemens, as well as external specialists. Gaarz notes, “Especially for a medium-sized mechanical engineering company such as Zimmermann, it is crucial to bundle regulatory know-how to develop practical solutions. At the same time, we are adapting internal processes and training our staff in a very targeted manner.”
Structured implementation
A look at the development process shows how Zimmermann implements these requirements in a highly practical way. First, the company analyzes which requirements are relevant for the respective machine configuration. Based on this, network architectures are reviewed, segmented and supplemented by suitable security mechanisms. Industrial PCs as well as the main CNC on the machine are secured, software vulnerabilities are assessed with clearly defined processes for updates and documentation. “We want to minimize digital attack surfaces without impairing the dynamics or precision of the machines,” explains Gaarz.
In special machine construction, complexity remains high. Although each system is based on an existing Zimmermann series, it differs in detail such as milling head, peripherals, automation or other specific motion and material handling equipment. This means that each system is also configured individually. The electrical plan and the respective equipment are used to create a separate topology with several channels, axes, drives and safety functions. Each axis requires precise parameterization. Mechanical differences have a direct effect on the control behavior. Cyber security must therefore be integrated into existing structures and must not limit the performance of the machine.
Virtual parallel world
While cyber resilience strengthens security, Zimmermann also wants to further leverage efficiency potential. To this end, the machine manufacturer plans to use digital twins: The virtual environment allows collision checks, parameterizations and software adjustments to be carried out at an early stage. The time for commissioning on the factory floor is reduced, as some of the tests are carried out digitally, in advance. Risks are minimized and processes stabilized. This results in very concrete advantages for the customer. In addition, operators can be trained in advance. In the event of service requirements, fault status can be reproduced in the digital model, so that causes can be identified more quickly. The digital twin supports both machine productivity and process reliability.
AI as a digital assistant
Artificial intelligence (AI) complements this development. Zimmermann is building an internal knowledge database that will be evaluated with the help of AI. “In pilot projects with control manufacturers, we are investigating how AI can support us in programming or analyzing error messages more quickly,” says Gaarz. “In the future, recurring tasks can be accelerated and proposed solutions generated.” The technical responsibility remains with the engineer. Zimmermann understands AI is an assistance system whose results must be checked and validated. Transparency and traceability are crucial. AI could also be used to create a digital twin more quickly. This also makes it possible to implement the structural development process of a machine more efficiently.
The guiding principle “Beyond Precision” describes this claim comprehensively, as Zimmermann shows how traditional precision is redefined in a networked industry – as an interplay of mechanics, intelligence and digital responsibility. For North American President of Zimmermann, Cornelius Kiesel, “This development is an expression of technical responsibility.”
When components are manufactured that will later be used in highly sensitive applications, this concept underlines the importance of holistically conceived precision. With the consistent integration of cyber resilience, simulation and AI, the machine manufacturer is strengthening its role as a technology partner for high-precision, large-scale machining and creating the basis for long-term investment security in an increasingly networked industry.
“We see precision not only as a mechanical quality feature, but also as a holistic claim that combines cyber safety, digitalization and engineering expertise,” Kiesel sums up.
About the company
Zimmermann is based in 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 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, transportation, off-highway 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
Zimmermann, a leading global high-tech supplier of portal milling machines, will feature a 5-axis portal milling machine for lighter weight machining applications aimed at large structures at its booth. IMTS will be held September 14-19, 2026, in Chicago.
With FZU22, Zimmermann adds a machine that’s capable of machining various workpiece shapes, sizes, and materials. Aluminum, plastic, wood and other substrates can be processed, as well as finishing carbon fiber reinforced and other composite materials. The overhead gantry provides precise production of models and molded parts. A standard machine includes a toolchanger for 24 tools and a CNC from Siemens or Heidenhain for full motion control and tracking, while a specially developed 5-axis milling head with a 15kW spindle can mill complex contours and tight pockets in large molds.
The FZU22 boasts a substantial working range, from 71″ to 98″ in the X-axis, 118″ to 138″ in the Y-axis, and 49″ in the Z-axis. A feed rate of 2,756ipm in the X- and Y-axes is standard while the acceleration on the machine is max. 118 in/sec2 to 197in/sec2. With a compact footprint of 11ft x 15ft, the machine fits in any small space available in a shop with minimal foundation requirements. ISO 230-2 accuracy is provided. A choice of milling heads is offered on the machine to suit a variety of applications.
Optional equipment includes touch probe, tool measuring system, work area cover, tool changer, chip conveyor, mist/dust extraction system, minimum quantity lubrication and a vacuum system.
The machine to be displayed at IMTS also features an ultrasonic system for cutting aerospace insulation.
Visit Zimmermann at IMTS 2026 in the South building, Level 3, booth 339336.
About the company
Zimmermann is based in 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 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, transportation, off-highway 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
Since 1992, Sawyer Composite has specialized in producing Advanced Composite laminates and assemblies for aerospace. Based in Fort Worth, Texas, the company is ISO 9001 and AS9100 certified, providing customers turnkey solutions in the design, engineering, manufacture and qualification of advanced composite tooling and structures.
In 2024, the FZU22 portal milling machine was launched by Zimmermann onto the U.S. market and Sawyer was among the first customers. After a little over a year in operation, J.R. Tubb, CNC programmer at Sawyer, shares an initial assessment in the following Q&A…
Question: What challenges were you looking to solve when investing in a new portal milling machine?
Tubb: Our older machines increasingly struggled with accuracy, throughput and downtimes. The FZU22 provided immediate improvement. It runs reliably, delivers impressive precision, and its rigid monoblock design allows for significantly faster machining. As a result, our throughput has increased and the amount of required rework has dropped considerably.
Question: What impressed you most about the FZU22?
Tubb: The enclosed workspace is a major advantage. When milling composite materials, the carbon dust stays within the machine and doesn’t reach sensitive components. We’re also very pleased with the minimum-quantity lubrication (MQL) system. It has reduced our lubricant consumption, leading to lower costs, less waste and a much cleaner working environment. On top of that, the Siemens Sinumerik ONE CNC control system can be operated quickly and intuitively, just perfect for our 5-axis machining at Sawyer.
Question: What impact does the new machine have on daily production?
Tubb: We have a program for a component that runs on every machine. When we machined this part on the FZU22, we finished almost 30 minutes faster and with much better surface quality. The finishing work now takes only half as long. An outstanding result and perfect interaction between operator and machine. As another example, we had a series of aluminum plates to machine. Thanks to Zimmermann and their service team advice, we now achieve the required tolerance on the first run, without necessary adjustments or rework. That saves a tremendous amount of time and resources. Choosing the FZU22 was absolutely the right decision for our company.
Cornelius Kiesel, president of North America for Zimmermann believes the FZU22 is a perfect example of productivity without compromise, as it offers compact, precise state-of-the-art control technology. The results obtained by Sawyer demonstrate how well the FZU22 performs in practical operations as well as across multiple industries. “By implementing the FZU22, our customers can make their manufacturing more flexible, accelerate processes and improve quality at the same time. The strong performance in the U.S. market reinforces our promise of going ‘beyond precision’.”
Kiesel added, “The example of Sawyer shows that, despite the current circumstances, there is significant potential in the North American market and customers are willing to invest when quality and service meet expectations.”
About Zimmermann
Zimmermann is based in 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 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.
Zimmermann, 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 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, transportation, off-highway and mechanical engineering sectors.
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
Since 1958, Schütz has focused on the processing of metal and plastic materials. The company headquarters in Selters, Germany not only makes new products but also develops and builds various machines and production lines in-house, employing 7,000 people across 55 production and service locations worldwide. Recognized as a leading international producer of industrial packaging for liquid filling products, the Schütz portfolio includes Intermediate Bulk Containers (IBC’s), canisters and drums.
“Almost everyone knows it, the Intermediate Bulk Container (IBC),” explains Eduard Tom, machining specialist at Schütz. “With the invention of the IBC, our company founder revolutionized liquid packaging and the transport sector. Today, there are many variants of IBC’s and we are the world leader in their production.” A typical Schütz IBC consists of a multi-layer inner container and a robust steel cage with a pallet base, now used worldwide in the chemical and food industries. The inner container is made from HDPE (High-Density Polyethylene). “The container is produced by blow molding,” says Tom. “For that process, we manufacture all our molds and tools in-house. Even the smallest deviations can lead to material defects later,” Tom adds. “We’re working in the thousandth dimension range.”
The previously used machines were increasingly reaching their limits: failures, quality deviations and extensive reworking processes had led to significant delays. Looking for a solution, Schütz connected with Zimmermann, the portal milling machine builder, at a trade show.
After extensive testing, the company finally selected two machines: an FZP42 for rough machining and an FZP37 for precision finishing. Both offer motion ranges of 4,000 x 3,500 x 1,500 mm. The FZP42 is equipped with the powerful dual-axis fork head VH60 and a 63-kW spindle, while the FZP37 features a slim VH30 head and a 70-kW spindle, ensuring optimum accessibility when machining fine structures. The result? Increased dynamics, shorter machining times, and outstanding surface quality.
The special construction concept, a thermo-symmetrical box-in-box design, ensures maximum stability. “This construction minimizes thermal influences and the machine geometry remains constant,” explains Rüdiger Hellwig, Sales Manager at Zimmermann. “This keeps the tool precisely positioned at all times, which is reflected in long-term accuracy and stability.” In addition to this unique construction, the machine’s dynamics were also compelling for Schütz. Due to a lower moving mass, it can operate faster and with greater precision, according to Hellwig.
Thanks to the 5-axis technology, cooling channels can be drilled flexibly and with perfect contour accuracy into the molds. This enhances tool cooling, reduces cycle times and significantly boosts long-term process reliability.
This technology was on display when Schütz used the FZP42 to rough one half of the mold from a 2.2-ton aluminum block, while the FZP37 performed the finishing and drilling operations. This opens up new possibilities in tool manufacturing as cooling channels can now be positioned more flexibly and closer to the contour. The system is no longer limited to fixed angles, enabling bores with an inclination of 0.6 degrees over 1.4 meters. Consequently, part quality is improved and cycle times are noticeably reduced. As Tom noted, “With the new Zimmermann machines, we now have entirely new options for adapting the cooling channels in the tool, so we’re significantly more flexible now.”
The configuration features a combined cooling and lubrication system, high-pressure pumps for deep-hole drilling, minimum-quantity lubrication, chip conveyor and air cooling, as well as a 121-position tool changer. The machines operate almost around the clock, says Tom. Thanks to significantly reduced rework, processing times and overall effort in tool manufacturing have dropped substantially, he notes.
To simplify service, each Zimmermann machine is equipped with a QR code. Scanning the code automatically generates a service email with all relevant machine data, enabling the Zimmermann support hotline to respond quickly and efficiently.
About Zimmermann
Zimmermann is based in 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 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.
Zimmermann, 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 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, transportation, off-highway and mechanical engineering sectors.
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
Substantial increase of 30% in production resulting from large workspace, cutting capabilities and new generation Heidenhain CNC onboard
Wixom, Michigan- Zimmermann, Inc. has installed and commissioned its FZU37 portal milling machine, with a 5m x 4m x 1.5m workpiece capacity, at Century Tool, a major tool and die manufacturer in Fenton, Michigan and part of the Tooling Tech Group. The machine has already proven its worth, according to the customer’s Director of Manufacturing, Tom Bradford, who notes, “The table size, speed and accuracy of this Zimmermann machine have already increased our capabilities by 30% or more.” Bradford and the operator on the machine, David Hawes, further note the benefits of the Heidenhain TNC7 control, one of the first machine tool installations in America for this advanced CNC, as a key factor in production planning, CAD/CAM integration, cycle performance and data logging. The CNC also features a visual simulator of the cutting path for cycle validation and in-process monitoring.
According to Cornelius Kiesel, President of Zimmermann, Inc., his company was approached for the discussion of a new machine, which would be replacing an existing, smaller machine that was no longer in operation, plus expand the capabilities of other machines on the floor at Century. “We determined the spec of the new machine and its tasks for Finishing and Semi-Finishing. The primary goal was to cut down the immense number of hours for such processes on the very large workpieces at Century, while enabling them to run the roughing process on their existing equipment.”
Kiesel continues, “To keep things simple, we selected the FZU37 machine, so the foundation of the replacement machine could be filled up to make it flush without a major foundation rework. After several conversations and a few adjustments on the accessories, we were able to lock in the layout. These layout improvements allowed us to go even wider for a total of 5000mm x 4000mm x 1500mm (197” x 157” x 59”) of travel, which was 79% more travel in the same amount of floor space. The FZU37 was subsequently ordered with the state-of-the-art spec for an advanced machine shop such as Century, including our Tool Changer, Top Cover, mist extraction, high-pressure coolant, Tool Laser, Touch Probe and more. Century Tool also wanted to step up their control to the new generation Heidenhain TNC7.”
Lastly, Kiesel notes, “Zimmermann also integrated an extended Spindle housing for deeper cavities plus the side walls were raised to create enough clearance and the machine table reinforced for the challenging molds our customer expected to be produced on this machine. When all these machine parameters got worked out and finalized, we completed the machine rather quickly, commissioned it, did the training onsite and helped Tom and his team start up.” Tom Bradford cited Alfio Campagna, project manager for Zimmermann, for his critical help in getting the machine into production at Century, as this was the first Zimmermann portal mill purchased by the moldmaker.
Bradford also commended the Heidenhain team, who provided three days of training on the CNC at their Chicago location and two more onsite at Century. Operator Hawes commented that he had substantial experience on Heidenhain controls, so the training went quickly for him, though the new control has numerous new features, including its Smart Programming, a graphical programming feature that allows the user to draw contours directly onto the touchscreen, after which the CNC converts the result into a Klartext (German for clear text) program. Century uses Visi as its main CAD program and Tebis as its CAM software and Bradford noted the seamless matching of these programs with the onboard CNC software to configure programs and posts made startup and run a smoother process.
In addition, the new CNC offers the user its Component Monitoring feature, which can protect the spindle bearing from overloading, while also detecting increased component wear in the drive train, all while the machine is running. This feature provides valuable data for predictive maintenance and evaluation of the process capability of the machine. This is vital at Century, who uses the Zimmermann machine exclusively for large, one-off mold prep, often removing over 90% of the material from a workpiece, over multiple days of machining.
Also, the ergonomics of the CNC are extremely user-friendly. Screen layouts and touchpad controls can be adapted to suit user preferences.
Finally, the intuitive contour programming is enabled by symbolic gestures on the touchscreen. Since Klartext remains the main format for files and exporting from the Heidenhain control, existing NC programs can continue in use.
Currently, the Zimmermann machine at Century is running on two shifts, often remotely tended in a low-light or lights-out mode.
Tom Bradford comments on the Zimmermann machine performance. “We do a lot of large tools for compression molding of composites and other substrates. We work for a variety of industries, from automotive to heavy truck, off-highway to agriculture, power sports to infrastructure such as water tanks. Century specializes in Class-A exterior body panels, so the surface finish is critical. During the very long runs we do on the Zimmermann, maintaining tight tolerances is key and the machine plus its onboard control technology make that happen for us.”
Brian Czapla, Director of Sales at Century, adds, “The trend toward high-strength, lightweight composites and large dimensioned, unitized parts for auto and heavy truck make this machine a real asset in our operation.”
In use, the typical workpiece on the Zimmermann is P20 steel, the industry standard for molds, as well as various aluminum materials. HSK 63 and HSK 80 are the primary toolholder types, used for cutting and laser touch probing here. Standard carbide cutting tools and inserts are typical, as well.
Bradford further notes, “As a tooling source, we serve the Tier One and OEMs in the manufacturing space. We have a strong reputation in automotive and heavy truck and we’re looking to expand into aerospace and other consumer products as well. As Brian noted, our core strength in composite molds gives us a real advantage in entering these other markets. The Zimmermann machine helps us achieve superior RA finishes with consistent quality, even on much larger structures.”
Century Tool is part of the Tooling Tech Group. With roots that go back over 40 years, Tooling Tech Group (TTG) has grown to be a leading manufacturer of tooling in the United States. They provide solutions for thermoform molding, high compression composite molding, blow molding, rotational molding, die casting and stamping, as well as custom automation systems for assembly, joining and inspection applications in a variety of industrial sectors. TTG comprises Century Tool, Century Automation for post-molding materials handling and assembly strategies, Die Cad for tooling design & simulation, Majestic for production of stamping dies, Tooling Technology for turnkey cast & billet aluminum tooling solutions, Alpha Integration for assembly automation and G&H Tool & Mold for high-pressure die cast molds.
About Zimmermann
Zimmermann is based in 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 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.
Zimmermann, 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 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, transportation, off-highway and mechanical engineering sectors.
About Century Tool
Our skill in machining complex geometries and exacting tolerances has positioned Century Tool as a premier composites mold supplier capable of meeting the exceptional surface quality required by manufacturers in the automotive, marine, agriculture, and other industries.
Our Team has mastered the production of molds capable of delivering excellent surface finishes required by Class-A exterior body panels. We have provided the tools used for high-visibility, high-demand vehicles like the Corvette, Jeep, and the Ford Bronco.
About Tooling Tech Group (parent company of Century Tool)
Tooling Tech Group has combined a growing number of industry-leading automation and tooling brands, pooling their collective knowledge and experience to support our efforts to design and build the most innovative automation and tooling solutions for our customers’ greatest manufacturing and product challenges.
Tooling Tech Group is the largest provider of tooling in the United States with 600+ employees, 12 modern facilities and over 1-million square feet of manufacturing space across five states.
We build custom tooling for a variety of applications including thermoforming, compression molding, blow molding, die casting, and stamping, as well as secondary equipment and automated solutions for these applications. We have experience in many industries including automotive, appliance, lawn and garden, agricultural, aerospace, marine, and off-road vehicle industries, among others.
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
Or
CENTURY TOOL
200 South Alloy Drive
Fenton, MI 48430
Phone: 810-629-0784
www.toolingtechgroup.com
Ms. Amy Stegmuller, Chief Commercial Officer
astegmuller@toolingtechgroup.com
With the FZ rack magazine ZIM Rack, Zimmermann has developed a compact tool changer for its portal milling machines which can be expanded to accommodate several thousand tools. This modularity allows clients to tailor the system precisely to their production without requiring additional storage space.
Tool availability plays a major role in ensuring uninterrupted production for customers. Whether it’s a machine demanding challenging materials or very different components, the right tools must be available quickly and easily due to the high level of wear or diversity. To solve this need, Zimmermann created its own tool changer.
The basic version offers 60 positions and can be expanded in increments of 30 up to several thousand. The operating principle is independent of the number of tools. Thus, the operating personnel have enough space to change all the tools before starting work and to work with them uninterrupted until the next shift. This eliminates the need for a separate storage area.
The tools are stored horizontally in the holders and can be removed via a manipulator. Unlike a conventional chain system, not all tools are moved, but only the necessary ones. Customers can adapt the ZIM Rack to their production. Since both the machine and the changer are from the same source, Zimmermann provides better and faster support when needed.
To see short video of the ZIM Rack, visit: https://www.youtube.com/watch?v=F0a4ygvGqEY
About the company
Zimmermann is based in 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 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, transportation, off-highway 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
With the FZU22, Zimmermann enters the lighter weight 5-axis gantry mill applications at an attractive price point
With the introduction of FZU22, Zimmermann has added a 5-axis portal milling machine for the machining of various workpiece shapes, sizes and materials. Aluminum, plastic, wood and other substrates can be processed, plus the machine is ideal for the finishing of carbon fiber reinforced and other composite materials. The overhead gantry provides precise production of models and molded parts. The standard machine includes a toolchanger for 24 tools and a CNC from Siemens or Heidenhain for full motion control and tracking. A specially developed 5-axis milling head with 15kW spindle is suitable for machining contours and tight pockets in large molds.
First machine of the FZU22 type being used for aerospace composite cutting.
As Zimmermann Inc. President Cornelius Kiesel observes, “With this new machine, being introduced in our booth at IMTS to the North American market, Zimmermann enters a new arena, that is, the lighter weight machining applications for large structures at an economical price. Our recent acquisition of a company in Germany allows us to partner with a reliable source for this type of machine, enhanced by the unique features which have made Zimmermann a standard in the aerospace and large mold market segments.”
The FZU22 boasts a substantial working range, from 71”-98” in the X-axis, 118”-138” in the Y-axis and 49” in the Z-axis. A feed rate of 2756 ipm in the X- and Y-axes is standard while the acceleration on the machine is max. 118-197 in/sec2. With a compact footprint of 11’ x 15’, the machine fits in the corner of any shop. ISO 230-2 accuracy is provided. A choice of milling heads is offered on the machine to suit a variety of applications.
Optional equipment is offered on the FZU22, including touch probe, tool measuring system, work area cover, tool changer, chip conveyor, mist/dust extraction system, minimum quantity lubrication and a vacuum system.
The machine to be displayed at IMTS also features an ultrasonic system for cutting aerospace insulation.
About the company
Zimmermann is based in 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 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, transportation, off-highway 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. This year, Zimmermann Inc. is celebrating 20 years in business.
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
With the FZG, Zimmermann introduces a portal milling machine with a low rail gantry
With the new machine line FZG, Zimmermann has added a 5-axis portal milling machine with a low rail gantry to their portfolio, which is well-suited to process particularly long components. Accessible from the side, the FZG allows easier loading and unloading processes. The developers were utilizing the well-proven thermo-symmetrical portal concept and modified its basic design, resulting in a distinct benefit. With the FZG, the user will receive a stable system which provides the highest precision, even when processing large and long components.
“Especially in future-oriented industries such as the aerospace, energy or rail sector, producers must be able to efficiently process large and, above all, particularly long components. We have recently received many more requests with these exact requirements,” reports Daniel Demlang, technical leader at Zimmermann. To meet the needs of the market, the machine manufacturer developed this new machine series, the FZG, in line with customer specifications. For this line of machines, the engineers relied on the innovative concept of the thermo-symmetrical design, which has already proven its worth with the Zimmermann machine lines FZP and FZU. However, the engineers redesigned its base structure. “We lowered the machine onto ground level, enabling the portal to be moved horizontally in almost any desired length,” explains Mr. Demlang. Zimmerman can adjust this design for any custom application. Therefore, the line is suited for processing complete components, such as wing structures for the aviation industry, entire railway wagon side sections for the rail sector, tanks in the energy sector, exterior components for the aerospace industry as well as components for the defense industry.
With the new FZG machine line by Zimmermann, large and long components can be manufactured with highest precision.
The proven modular system from Zimmermann acts as the base structure of the new FZG line. It offers many different length and height variants as well as extensive equipment options, such as process cooling with minimum quantity, lubrication or an onboard movable vacuum dust extraction system for abrasive materials and plastics. An onboard movable tool changer is standard. The energy supply and covers are recessed into the floor.
“The thermo-symmetrical design makes the machine less vulnerable in adverse environmental conditions,” continues Cornelius Kiesel, president of Zimmermann in America. The idea behind this is that incurring thermal influences can be substantially absorbed by the machine structure itself. “To achieve this, we appropriately designed and intelligently arranged all structural and drive unit components, guides and other components responsible for accuracy, for all the machines in our extended portfolio. This way, the structure can expand in non-critical directions,” says Kiesel. The centrally guided Z-slide of the portal in double-bridge construction makes the machine particularly stable. By using this design, Zimmermann achieves very high rigidity. Since there isn’t any possibility of one-sided temperature rise, accuracy is greatly increased, thus making the machine line suitable for very high-precision applications.
“For us, this combination of thermo-symmetrical machine design and the modified base structure was a logical next step,” says Mr. Demlang. Because the core machine relies on proven technology, this development was possible in a relatively short timeframe. Additionally, the synergetic benefits of the FZG, due to the existing portfolio, also have a positive impact on the profitability of the machine.
About the company
Zimmermann is based in 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 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, transportation, off-highway 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
With the FZU/FZP42 machine line, Zimmermann Inc. offers users efficient 5-axis portal milling machines for heavy workpiece machining. The specific aspect of these improved machines is a thermo-symmetrical design, incorporating a centrally-guided Z-slide. This particular construction, as well as the guide layout, increases machine stability, while also saving weight – resulting in a more dynamic, productive and energy-efficient machine.
“We have developed suitable machine designs for light processing, such as composite materials or aluminum used in aerospace, as well as for highly dynamic heavy machining,” reports Cornelius Kiesel, president at Zimmermann Inc. in Detroit, the U.S. operation of F. Zimmermann in Germany. While further developing its machine portfolio in the last several months, heavy machining for automotive, other transportation and off-highway are gaining an even higher priority in the company’s market targets. At the same time, Zimmermann is on the cutting-edge in its traditional segments, explains Frieder Gaenzle, CEO of F. Zimmermann. “We are focusing less on classic heavy machining, using large tools and high material removal rates per cut. Instead, the FZU/FZP42 model range provides tool and mold makers with a 5-axis system for highly complex components, which enables more dynamic milling of free-form surfaces.”
Dynamic heavy machining is precisely the challenge in this new market segment. Because the more difficult it is to process the materials, the higher the requirements for rigidity in the machine, Kiesel further notes. Weighting in at several tons on average, the machines are quite massive. How can this massive design deliver great dynamics, so that users can work even more productively?
“Our machines mill out contours with a maximum speed of 60 m/min and may accelerate with 3 m/s2, if needed. “This resembles a motorcyclist, accelerating in a curve to run it more dynamically,” says Kiesel. Despite the acceleration, the machines must be able achieve very high accuracy as well as high-quality surfaces. “This connection of dynamics and heavy machining may be compared to a truck, loaded with stones, performing in a Formula 1 race,” Kiesel muses.
Thermo-symmetry for more precision
In order to achieve this result, Zimmermann is setting up its complete machine portfolio thermo(load)-symmetrically. This occurs because changing ambient temperatures, as well as processing temperatures, inevitably influence machine geometry featuring a portal design. The idea behind a thermo-symmetrical design is based on the ability to substantially absorb incurring thermal influences, achieved by the design of the machine structure itself. Considering this factor, Zimmermann engineering has appropriately designed and intelligently arranged the machine structure and drive unit components and guides, as well as other components responsible for accuracy, for all machines in this newly developed portfolio. In this way, the machine structure may expand in directions that are non-critical.
The centrally guided Z-slide of the portal in double-bridge construction has a large cross-section which makes it especially stable. Using this design, Zimmermann achieves a very high degree of rigidity. Since there is no possible one-sided temperature rise, accuracy is greatly increased, as well. With this structural design, the machine manufacturer constructively reduces the effects of error-inducing variables to a minimum. Due to the fact that less leverage forces apply in comparison to a serial design with a classic guide layout, Zimmermann has increased rigidity of the FZU/FZP, without having to increase the cross- sections of the components. Because less mass needs to be moved, the machine works faster and more dynamically. “Moving less mass also requires less energy. This results in clear cost benefits”, states Kiesel. Additionally, the thermo-symmetrical design makes it possible to omit complex cooling circuits, which also has a positive impact on cost reduction.
By offering the new FZU/FZP42 machine lines, Zimmermann seeks to gain a better foothold in heavy machining. For a long time, the machine manufacturer only occasionally sold systems in this market segment. This has changed following these new developments. “We are already seeing the first successes in the market, says Kiesel. “We were able to sell three ‘heavy’ machines in the first quarter alone.” The company’s customers are equally convinced about the technical data and the price-performance ratio. “A particular customer only wanted to purchase one of our machines for post-processing, since they were already using a heavy machining system provided by a competitor. During the discussions, they then spontaneously decided on a second machine from Zimmermann,” notes Kiesel.
Among the new customers for this line is an automotive manufacturer, who required a new machine for their tool making, in order to process large sheet-metal forming tools and to replace older systems. In the end, Zimmermann was able to successfully assert itself against the competition with its FZU42 machine. The customer realized that this innovative machine concept will enable them to meet their requirements to a high machining accuracy with excellent surfaces on their tools. The high tool weights of up to 40 tons do not pose a problem for the FZU42 system, because the components are not being moved. The movement system, consisting of the portal, Z-slide and milling head, can operate with consistently high dynamics, regardless of the tool weight.
Flexible setup
“We were able to successfully impress the customer with our concept and our price-performance ratio,” says Kiesel. Another important aspect adds to this scenario. The FZU system does not require a solid machine foundation and can therefore be placed flexibly on the factory floor. Extensive construction, which creates high costs and disrupts manufacturing, are completely eliminated.
“We continue to develop and are able to find the right answers for many applications, concludes Frieder Gaenzle. “We have the right overall package. We offer these improved machine concepts in all market segments. Besides the machine structural upsides, these improvements include fitting mounts for the spindles, milling heads for the tools and an extensive service package for our customers.”
About the company
F. Zimmermann GmbH in Germany is a leading global high-tech builder of portal milling machines. These machines are characterized by large workspaces, substantial machine dynamics and cutting performance. The company, founded in 1933 by Friedrich Zimmermann, now has over 250 employees worldwide. With its product range, this innovative company has one goal above all: to offer the right solution for its customers and to be able to guarantee high economic efficiency. “Quality made in Germany” is its motto. Zimmermann special machines are used worldwide in the automotive, aerospace, off-highway, moldmaking and transportation 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