hp tooling 2026-#1

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2026 – 1 

■ Economical drilling done smart ■ Combined drilling & deburring saves time ■ In-house coating pays off ■ 

■ Success in China ■ New standards in aerospace engineering ■ New life for old machinery ■

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Sustainable opportunities in process 

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Circular economy in the industrial 

production process 

Topics H 2 

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editorial 

Eric Schäfer 

editor-in-chief 

What’s coming up? 

What does 2026 have in store for the international tool 

and machine tool industry? Anyway, it’s set to be a busy year 

for trade fairs, with major exhibitions taking place in 

key markets around the world. The recently concluded 

IMTEX in India got things started. This will be followed 

by TMTS in Taiwan, showcasing how AI is driving 

innovation and sustainability in manufacturing. Later on 

SIMTOS will take place in South Korea, a country with a 

strongly export-oriented mechanical engineering industry. 

A similiar situation can be seen in Germany, where 

GrindingHub – the international hub for grinding 

technology and superfinishing – will take place in Stuttgart, 

in May. As reported on page 18 of this issue, the successful 

trade fair will hold its first event in America in 2027: 

GrindingHub Americas, which will be dedicated exclusively 

to grinding technology. In fall 2026 IMTS will also take 

place in the USA, a country characterized by dynamic 

market development, not least due to its strong domestic 

market. This will almost coincide with AMB in Germany. 

After that, BiMU will head to Italy, followed by JIMTOF 

in Japan at the end of October. The economic environment 

in Japan is challenging, but the outlook for special-purpose 

machinery is positive. 

By then it will be clear whether it has been a successful year 

for the industry and whether the trade fairs have provided 

the necessary impetus. You can find more information about 

these and other international trade fairs in our preview of 

upcoming events and in our market reports. 

Tool and machine tool manufacturing is a key industry 

in the global economy, and “the journal of hp tooling” is 

dedicated to this with all its high-precision machining 

processes, also apart from trade fairs. We will continue to 

showcase innovations in machine tools, tools, machining 

processes and components in our international trade 

journal. It is available in both the print edition and on digital 

channels, as well as in current, targeted newsletters. 

Stay tuned to find out what’s going on! 

Eric Schäfer 

editor-in-chief

table of contents 

cover story 

Poly – poly – or what? LACH DIAMANT looks back on 100 years 

Diamond contra diamond? A reflection on the versatility of diamonds 6 

materials & tools 

Economical drilling done smart 10 

Superior chip control during grooving and parting off 12 

A real game changer for efficient and reliable machining 13 

processes 

Combined drilling & deburring saves time and ensures safety 21 

On course for growth: in-house coating pays off 22 

Minimum quantity lubrication makes “green” production possible 24 

Understanding the role of abrasive technology in modern manufacturing 

written by Tom Dustman 26 

machining center 

Evermore counts on cylindrical grinding machines from STUDER 32 

Machining of difficult-to-cut and brittle materials 35 

Fast and economical machining of structural components 37 

New life for old machinery 38 

components 

Are software-defined CNC machines now entering job shops? 

written by Dr. Yavuz Murtezaoglu 42 

Compact space marvel with many features 44 

CAM Assist now used by over 1,000 machine shops globally 

to accelerate CNC programming with AI 47 

Making reverse engineering routine with seamless scan-to-CAD workflows 49 

news & facts 14 

fairs 5, 18, 19, 20 

impressum & company finder 51 

4 no. 1, 2026 February

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 15-19, 2026) 

bauma Shanghai, China 

(November 24-27, 2026) 

CCMT Beijing, China 

(April 21-25, 2026) 

EPHJ Geneva, Switzerland 

(June 16-19, 2026) 

FABTECH Toronto, Canada 

(June 9-11, 2026) 

current status 

2026 





FEIMEC Sao Paulo, Brazil 

(May 5-9, 2026) 

FILTECH Cologne, Germany 

(June 30-July 2, 2026) 

glasstec Düsseldorf, Germany 

(October 20-23, 2026) 

GrindingHub Stuttgart, Germany 

(May 5-8, 2026) 

Hannover fair Hanover, Germany 


HIMTEX Hyderabat, India 

(August 20-24, 2026) 

IMTS Chicago, USA 

(September 14-19, 2026) 

JIMTOF Tokyo, Japan 


MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 18-21, 2026) 

METALEX Bangkok, Thailand 


MSV Brno, Czech Republic 


SIAMS Moutier, Switzerland 


SIMTOS Seoul, South Korea 


sps Nuremberg, Germany 


Stone+tec Nuremberg, Germany 

(Juni 17-20, 2026) 

Surface Stuttgart, Germany 

Technology (May 5-7, 2026) 

TMTS Taichung, Taiwan 

(March 25-28, 2026) 


















trade fair dates as by end of January 2026; we are not responsible for reliability of these dates 

no. 1, 2026 February 

5

cover story 

Poly – poly – or what? 

Diamond contra diamond? 

A reflection on the versatility of diamonds 

Horst Lach, born in 1940, 

runs the company 

LACH DIAMANT® – founded 

in 1922 by Jakob Lach – 

together with his son, 

Dipl.-Ing. Robert Lach. 

In the 1950’s engineering ingenuity made it possible to 

recreate this natural process in synthesis. The manufacturer 

General Electric succeeded in cultivating the so-called 

“Man Made TM ” diamond under almost 6,900 bar atmospheric 

pressure and at 3,500⁰ Celcius; a development which would 

lead to another industrial revolution within the quickly 

growing serial production industry. 

We cannot imagine today’s world without diamonds. Their 

hardness and invincibility make them a crucial cost-reducer 

for many tool applications in the industry – and their brilliance 

and everlasting beauty makes them fitting jewellry for 

our so much appreciated women. 

It starts with gemstones 

When preparing for the article “Diamond contra diamond?”, 

in 2021, I immediately (regrettably) found information on 

diamonds as much sought-after gemstones. For example, no 

buyer of a polished diamond (brilliant) with a weight of half 

a carat (1 ct = 0.2 gram) would expect that he only has to pay 

“double the price” for a whole carat. The value is not only 

determined by size and purity, the buyer must also take the 

extreme rarity of finding large diamonds into consideration. 

For generations this was typical for the gemstone business 

with natural diamonds. 

Of all companies, the “contra” aspect is now offered by a 

company formerly associated with “De Beers”. Produced in 

synthesis, or “in the laboratory”, the diamonds appear to have 

the purity of colour and clarity (factors of classification) of 

polished natural diamonds (brilliants); there is even a choice 

between white, blue or pink. And best of all: anyone, purchasing 

directly from this consortium, can calculate the price 

based on the carat weight from 0.25 to 2.0. 

for example: the price for 

0.25 ct = 200 US $ 

0.5 ct = 400 US $ 

1.0 ct = 800 US $ 

et cetera, so that a 2-carat diamond would cost 1,600 US $. 

The troubled sales people at the diamond exchanges in 

Antwerp and London and jewellers should know that all of 

these “laboratory diamonds” are marked as such with microscopically 

small imprints in order to prohibit “fraudulent” 

mix-ups with natural diamonds. 

Diamond contra diamond – for example, natural diamond 

compared to polycrystalline diamond blades (PCD) 

Diamond contra diamond; for example a single natural 

diamond dresser compared to a diamond dressing roll 


cover story 

for the first time at the Hanover trade show 

in spring 1973. With them, efficient turning 

machining of copper commutators (and their 

baked-in synthetic mica) was made possible 

for the first time. 

Once again a new technology was born. 

Compact diamond blocks – PCD – were the 

basis for the development of cutting tools, 

superior to carbide tools, for “faster turning, 

drilling and milling with synthetic 

diamonds”. 

As early as 1973 polycrystalline turning tools replaced the overturning 

of copper lamellas of rough and fine polished copper commutators 

Within the industry, the “contra” isn’t playing out as drastically 

In 1957 – after synthetic diamonds became first available – they were initially 

used as diamond grain for the development of new synthetic-resin bond 

diamond grinding wheels, and for the first time also for pre-grinding 

carbides. During the 1960’s, 1970’s and the 1980’s a multitude of innovations 

swept over the market, some of which could only be implemented within 

the industry with certain delays. 

What particularly comes to mind are polycrystalline synthetic diamonds 

(PCD), available since 1973. Simply put, they are synthetic diamond grains 

in a cylindrical shape which – under pressure and heat and combined with 

catalysers tungsten and cobalt – are pressed onto a round carbide plate (as a 

substrate), very similar to diamond synthesis. 

The first PCD plates had a diameter of only 3.2 mm. However, when they 

were mechanically segmented into rectangles, they were the basis for the 

so-called PCD cutting tools, successfully presented by LACH DIAMANT 

Turning of copper commutators is another 

“contra” argument in this reflection. Until the 

use of the first PCD dreborid® turning steel, 

copper commutators were turned exclusively 

with natural diamonds during fine polishing. 

With the result that I had to take my first car 

to the repair shop every 750 km to have the 

wiper motor exchanged; otherwise, the wiper 

could have failed during the next rain. 

And today? Problems with windscreen wiper 

motors? No thank you. PCD turning means 

they should last multiple car-lifetimes. 

A similar “contra” – clearly in favour of PCD – 

can be reported of turning motor pistons. Until 

the 1970’s I could observe high class automobiles 

broken down by the roadside when I 

was driving to the Hanover trade show, apparently 

due to piston seizure. At that time expert 

drivers were convinced they had to “break in” 

their brand-new cars on this route. If the 

motor could stand it, it was a good car… 

The introduction of polycrystalline cutting 

tools in the aluminum processing automobile 

industry also uncovered this “contra” 

in piston manufacturing as well as the insight, 

that the surface quality achieved during 

turning with polycrystalline cutting materials 

– instead of the thus far used natural diamonds 

– allowed for a perfect lubricating film 

which immediately prevented piston seizure 

to the greatest possible extent. 

Another argument in our reflection on 

“diamond contra diamond” brings composite 

and wooden materials and their respective 

industry into focus. 

Indirectly, carbide is partially involved in 

this example of “contra”, since diamond is 

also present in the grinding wheel for carbide: 

pars pro toto. 

PCD chip milling of glass fiber reinforced plastic (GRP) during an experiment 

in 1974 – compared to diamond-tipped tools, very little dust formation 

Early on, after the successful use of PCD 

turning, drilling and milling tools, other 

non-ferrous materials, such as aluminum and 


7

cover story 

PCD tool during front facing 

of an aluminum rim 

A diamond cut-off wheel, 

electroplated with diamonds during the 

cutting of a GRP (glass fiber reinforced 

plastic) component 

copper as well as some plastic materials were tried in experiments. 

Examples are soft and hard plastics, glass fiber and 

carbon fiber materials, electrographite carbons and miscellaneous 

wooden materials. 

The photo on the previous page was taken during these 

adventurous times. It shows a PCD end milling cutter during 

the chip machining of a GRP component. 

When the second productronica was held in Munich in 

1977, PCD tools for sawing/scoring/milling/drilling were 

demonstrated to an astonished audience on an Amacher 

electronic circuit board machine, which had been purchased 

especially for this purpose. It was so successful that for the 

time being – until the discovery of spark erosion – expectations 

of the relevant industry had to be disappointed. 

Other industries had now become just as curious and 

further experiments and construction continued diligently. 

For example, machining of carbon fiber components for the 

aircraft industry, which in turn should initiate revolutionary 

successes in the development of spiral drills, especially 

for one manufacturer. And a real “contra” should become 

clear during the machining of composite materials. A pro 

and contra for some imminent problem solutions. While 

using the same diamond material, different production 

and tool technologies created controversies. For the first 

time, PCD tools and the already “tradition-rich” diamondcoated 

electro-plated tools were in competition with one 

another. 

Special advantages of electro-plating 

Almost all profiles projected onto steel bodies can be coated 

with diamond and re-coated after wear in service. The 

diamond grains applied to the surface of the steel body allow 

good removal rates – depending on grain size – which is especially 

advisable for deburring tasks. They are versatile in use, 

like cut-off wheels up to high diameters, or for cutting GRP 

and other hard materials. 

The disadvantage: dust formation which must be extracted. 

LACH DIAMANT provides a special solution for hollow 

drills, featuring extraction directly at the tool. 

Special advantages of PCD 

As far as the geometries of the composite component to be 

machined allow, turning and milling operations can be performed 

efficiently and without any problems, and can therefore 

be recommended accordingly. Profile and drilling tools 

can constructively be equipped with PCD cutting edges, 

which is especially advantageous for larger production numbers. 

Further advantages result in comparison with electroplated 

diamond tools, e.g., grooving tools with exact tolerances 

for corners and radii for serial production. Chips, 

produced during machining, can be extracted very well. 

PCD blades can be reground several times. 

Diamond tools have become an intrinsic and valuable 

part in the world of technology, especially during the last 

50 years. The list of examples above could easily be extended 

– innovative spirit and (positive) thinking outside the box 

will con tinue to enrich “pro and contra” in many industries 

and many applications. For example, let’s think of the natural 

diamond as a single tool for dressing and profiling of grinding 

wheels – it was replaced as a single point dressing tool by 

a chain of innovations in serial production. Roughly in the 

order of the following developments: by the multi-point 

dresser, the Diamant-Fliese or rather dressing plate and – up 

to date – by diamond dressing rolls. 

When we focus at last on the diamond itself, we wonder 

whether it will really stay the hardest of all things? Personally, 

I am not so sure about that. A “contra” could be in the making 

here too. Recently the press featured a “glass” which supposedly 

could score even the surface of a diamond… 

Horst Lach 

further information: www.lach-diamant.de 


AI era × diamond tools for 

semiconductor manufacturing 


At the 2026 TMTS Taichung Machine Tool Show, 

King Ming Precision Tool Co., Ltd. will showcase its 

latest PCD (polycrystalline diamond) cutting tools. 

The company will present advanced machining solutions 

for hard and brittle materials. 

To address the challenges commonly encountered when machining 

silicon carbide, sapphire, aluminum oxide, tungsten 

carbide and other hard-brittle materials – such as insufficient 

efficiency and unstable accuracy when using diamond 

grinding pins or carbide tools – King Ming has launched a 

full series of PCD micro-diameter helical tools. The product 

lineup includes end mills, ball mills, drills and spot 

drills designed to meet a wide range of micro-machining 

requirements. 

The new PCD micro-diameter helical end mills feature a 

spiral cutting edge and multi-flute design. Compared with 

traditional diamond grinding pins, they significantly reduce 

cutting resistance, increase machining speed and shorten 

processing time – greatly enhancing productivity and competitiveness. 

With a high precision tolerance of ± 0.005 mm, 

these tools provide accuracy levels that grinding pins cannot 

achieve, making them ideal for machining hard-brittle 

materials. 

For drilling applications on ceramics, monocrystalline 

silicon (wafers) and tungsten carbide molds, King Ming 

also offers PCD micro-diameter helical drills. With diameters 

as small as 0.2 mm, these drills effectively solve the 

long machining time associated with diamond grinding-pin 

drilling and ensure both precision and efficiency with their 

± 0.005 mm tolerance – delivering faster and more reliable 

micro-hole machining. 

King Ming’s comprehensive diamond cutting tool solutions 

are widely used across AI smart manufacturing, semicon ductor 

wafers, 3C panels/mobile devices, precision machinery, 

aerospace parts, automotive and motorcycle components, 

and bicycle components. 

further information: www.tmts.tw 

Efficiency without compromise 

Gühring is adding a powerful, solid carbide 

circular milling cutter to its grooving tool range. The 

tool not only scores with perfect surface qualities and 

long tool lives, but also impresses with significantly 

smoother running compared to the competition. 

The solid carbide circular milling cutter features an innovative 

geometry: the combination of positive chip and axis angles, 

innovative uneven pitch and large chip spaces ensures 

maximum running smoothness and low cutting forces. This 

allows higher cutting parameters to be achieved and machining 

times to be reduced. And all this without compromise: 

users also benefit from excellent results in terms of surface 

quality. 

The circular milling cutter ensures short, controlled chip 

breaking, guaranteeing optimal chip removal. For this reason 

the tool ensures a reliable process when turning and milling 

internal contours with high cutting data and longer tool lives, 

making it an efficient alternative to groove turning. 

Strong as standard, flexible as a special design 

The circular milling cutters are available in all common 

designs and dimensions as standard, which means that users 

benefit from fast delivery times. Furthermore the circular 

milling cutters are designed with application-oriented undersizes 

(e.g. d1 = 7.8 mm for holes with a diameter of 8 mm), 

which allows holes and internal radii to be machined close to 

contour and effectively. 

further information: www.guehring.com 


9


Economical drilling done smart 

The secret to the success of the machining company 

Zerspanungstechnik Mangner GmbH in Bad Laasphe, 

Germany, is targeted investment in optimization. 

Drilling has been made more efficient thanks to a 

large tool package from MAPAL. The package is made 

up of 110 TTD replaceable head drills along with a big 

stock of solid carbide heads. 

When Mike Mangner started his company in a small rented 

hall in 2013, tools still had to be changed by hand. The young 

company developed quickly. Just one year later the company 

bought its current and set up the first Hermle machines. As 

a traditional contract manufacturer, most of Mangner’s customers 

come from the tool and mouldmaking industry. The 

company offers them services like pressure die casting, sand 

casting and modelmaking. Most of the work is destined 

for the automotive industry. Apart from this parts are also 

produced for general machine engineering. Mangner’s 

customers come from all over Germany, but usually from 

their region. 

Meanwhile 15 machining centers can be found on the shop 

floor, most of them from Hermle. From the smallest 5-axis 

machine to the machining center for components as large as 

1 x 1 m, they cover a wide spectrum of components, two machines 

for every operator. Programming takes place directly 

at their workplaces. Mike Mangner’s optimization philosophy 

involves having many identical machines in operation. 

A next step in the standardization process involves making 

as many of the same tools as possible available for these machines. 

“With this concept, we are in a strong position and 

can employ our operators flexibly”, Mike Mangner explains. 

Examining the drill head of a TTD tool (from left): 

Dominik Geßner (production manager, Mangner), 

Uwe Rein (regional sales manager, MAPAL), 

Mario Schäfer, (assistant production manager, Mangner) 

and Mike Mangner (managing director, Mangner) 

Hirth serration from MAPAL enables high torque 

Dominik Geßner switched to Mangner as a production 

manager two years ago, bringing along his experience 

and contacts. MAPAL and their regional sales manager 

The Hirth serration of the TTD drill from MAPAL 

ensures the drill heads sit very securely; this enables 

optimal torque transfer as well as high changeover and 

radial run-out accuracies 

The large tool package from MAPAL for Mangner includes 

a total of 110 TTD replaceable head drills with diameters 

from 12 to 45 mm and lengths of up to 12 x D 



Uwe Rein was among them. Geßner advocated the use of TTD replaceable 

head drills, which he had come to know and appreciate over the years. 

The TTD replaceable head drill is the primary application for the TTS 

(Torque Transfer System) interface. The interface owes its stability to the 

radially arranged Hirth serration with 12 or 18 teeth, depending on the diameter 

of the adapted solid-carbide drill head being used. Due to the serration’s 

form closure, variable geometries of the replaceable head are possible. In 

addition, optimal torque transfer and high radial run-out and change-over 

accuracy are ensured. 

The replaceable drill head is secured by a threaded pin affixed to the side of 

the tool holder. This allows the drill bit to be changed directly in the machine. 

The positioning aid integrated in the serration ensures that the chip flutes 

and coolant transfer from the tool holder to the replaceable drill head match. 

With its cutting-edge geometry, the drill head has a quality and performance 

level similar to solid carbide drills. 

Machining time reduced 

“The true advantage of these drills comes into play in hardened materials, 

which it can machine reliably”, Geßner reports. “We achieve a long tool life 

here, which reduces our throughput of drill bits.” At Mangner bores used 

to take place prior to hardening. By eliminating the need for an addi tional 

clamping step, set-up time has been reduced. This increases efficiency in 

manufacturing, thereby providing the company with added value. 

The previously used tool system had a particular weak point: if a solidcarbide 

drill head broke off, the drill bit holder was usually also damaged. 

In Geßner’s experience this has never happened with MAPAL. After breakage, 

work could always continue with a new drill head, limiting any resulting 

damage. “I primarily considered changing the tool system from a cost perspective”, 

says Mike Mangner, explaining why he chose MAPAL. 

More economical and sustainable 

Mangner uses the drills above all to pilot deep bores as well as complete bores 

for cooling, so-called coolant boost. While the normal lead geometry of the 

cutting edge is 140 °, MAPAL also offers variants for special applications. A 

180 ° tip can execute countersink bores, for example, which would otherwise 

only be possible with a milling cutter. Ball-nose drills enable radii at the end. 

Geßner reports that if handled with care, the drill heads can be reground up 

to three times by MAPAL. “This is very sustainable and lowers the average 

price per tool.” 

The tool package delivered by MAPAL includes diameters from 12 to 

45 mm, whereby the tool lengths are 3 x D, 5 x D, 8 x D and 12 x D. “We cover a 

certain diameter range with replacement head drills in increments of tenths”, 

Geßner specifies. “The tools would be unaffordable with drills made entirely 

of solid carbide.” The many sizes reflect the various requirements of manufacturing. 

Series of up to 100 parts are rare here. Typical lot sizes are between 

one and ten pieces. The material is often heat-resistant 1.2343 steel, but 

special materials, steel with varying degrees of hardness and aluminum are 

also processed. 

After the successful deployment of TTD drills, the cooperation between 

Mangner and MAPAL is set to continue. Reamers are already in use. Test 

finishing with milling cutters is also taking place. Uwe Rein thinks that 

high-feed cutting could be the next step. 

further information: www.mapal.com 

FILTECH 

June 30 – July 02, 2026 

Cologne – Germany 

The Filtration Event 

www.Filtech.de 

Platform 

for your 

success 

600+ Exhibitors 

Delivers 

solutions for 

current 

and future 

challenges 

Your Contact: Suzanne Abetz 

E-mail: info@filtech.de 

Phone: +49 (0)2132 93 57 60


Superior chip control during 

grooving and parting off 

Paul Horn GmbH has introduced a new chip breaker 

geometry for the 274 tool system especially for grooving 

and parting off on sliding-head lathes. 

The sintered chip breaker geometry 1A optimizes chip control 

during turning, ensuring a high level of process reliability. 

The universal geometry is suitable for machining various 

materials. The indexable insert with two cutting edges is 

available in three cutting widths of 1 mm, 1.5 mm or 2 mm. 

Maximum grooving depth is between 3 and 6 mm. The insert 

is available in TH35 and IG35 grades. An extensive range of 

holders is available for adaptation to different types of lathe. 

A comprehensive range of holders is available for System 274 

HORN/Sauermann 

The geometry ensures a high level of process reliability 

thanks to optimal chip control 

When machining turned parts of small diameter, the center 

height of the tool must be precise. Even small deviations 

in the center height have a negative effect on the quality of 

the workpiece when machining very small parts. Ideally the 

machine operator should be able to index the insert without 

having to re-adjust the center height. With System 274, 

Horn offers excellent repeatability of less than 0.02 mm when 

turning the double-edged insert. This is made possible by 

precise peripheral grinding of the insert in conjunction with 

the stable insert seat. 

further information: www.horn-group.com 


A real game changer for 

efficient and reliable machining 


The trochoidal cutters (TPC) from LMT Tools 

offer outstanding cutting performance, extremely 

short machining times, and long service life, and are 

considered a key technology for efficient and reliable 

machining in a wide range of materials. The machine 

manufacturer TMQS from Büchen tested them 

in practice and used the TPC M for the first time in its 

production – with outstanding success. 

tangential transition, and a particularly wear-resistant cutting 

corner. The chip breakers ensure optimum chip removal 

and significantly reduce vibration, which has a positive effect 

on tool life. The cutting edges are located along the entire 

length of the tool and are almost completely immersed 

in the workpiece. This allows very large feed depths to be 

achieved. In the TMQS application, a feed depth of 35 mm 

was achieved with the TPC M – with a cutting edge length 

With their maximum axial engagement (Ø 3 x and Ø 5 x) and 

carefully coordinated geometries, the milling cutters in the TPC family 

deliver flawless performance in a variety of machining applications 

TMQS uses the TPC M from LMT Tools to machine a workpiece 

made of titanium 3.7165. Starting from a raw size of 

60 x 60 x 255 mm the wall thickness is reduced to 2 mm by 

roughing. The company had already been working with 

trochoidal milling cutters, but the switch to the TPC M has 

now resulted in a significant leap in performance: machining 

time has been cut in half, while tool life (235 min) and 

metal removal rate (approx. 40 mm³/min) have doubled. The 

result: higher productivity, lower unit costs and more stable 

pro cesses. “The TPC milling cutters from LMT Tools are a 

real game changer for us”, emphasizes Nico Brandt, CEO at 

TMQS. “We now manufacture complex titanium components 

faster, more economically and with significantly higher 

process reliability.” 

Optimized tool geometry and 

excellent chip removal 

The TPC M was developed by LMT Tools specifically for trochoidal 

milling in titanium and is precisely tailored to the 

process-specific requirements. The high-performance tools 

feature multiple cutting edges, multiple chip breakers with 

of 38 mm (12 mm tool diameter). A special cutting edge 

geometry with defined edge preparation and the latest coating 

enables high cutting speeds and guarantees maximum 

cutting performance and feed rates. Another advantage is 

the 2 mm long cutting edge. This allows the TPC M to be 

reground several times without compromising the maximum 

depth of cut. 

Excellent trochoidal milling in a 

wide range of materials 

“The TMQS application impressively demonstrates the outstanding 

performance of our HPC milling cutters. These 

powerful tools achieve the best milling results in any material 

and take trochoidal milling to a whole new level”, says 

Carsten Wegner, technical consulting and sales at LMT Tools, 

summarizing the advantages. In addition to the TPC M for 

titanium also cutting lengths of Ø 3 x and Ø 5 x are available 

for cast iron (ISO-K), steel and stainless steel (ISO-M), as well 

as high-temperature steels and superalloys. 

further information: www.lmt-tools.com 


13

news & facts 

Horn (Shanghai) Trading Co. Ltd. expands 

Horn (Shanghai) Trading Co. Ltd. was founded in 2012, 

sales activities began as early as 2013. For this purpose 

an office with an area of approximately 450 m 2 was 

rented on the ninth floor of a building in downtown 

Shanghai. 

Today HORN employs 26 people in China and achieved a 

sales volume of around € 12 million in 2025. Due to econo m ic 

growth and the increasing number of employees the office 

had become too small. Because of the growing and therefore 

heavy weight of the warehouse, a seminar room was used as 

storage space to reduce the floor space load. Therefore further 

growth was only possible at a very slow pace. 

On December 9, 2025, the HORN branch moved within 

the same district in Shanghai. The new, very modern space 

covers approximately 850 m 2 , making it almost twice as 

large as the previous location. In addition to more space for 

staff and storage, the entrance area includes a showroom. 

The new office space also contains professional training 

rooms that can be divided as required. 

The relocation of Horn (Shanghai) Trading Co. Ltd. marks 

another important step in the company’s growth in China 

and is also a clear commitment to the location. Markus Horn 

and Andreas Vollmer were together on site with their 

The relocation of Horn (Shanghai) Trading Co. Ltd. marks 

another important step in the company’s growth in China 

and is also a clear commitment to the location 

colleagues from Horn Shanghai for the inauguration. 

Li Xiayang, director of the district government in Shanghai, 

attended the event also. 


Call for application 

EMVA Young Professional award 2026 

It is the goal of the European Machine Vision Association 

to support further innovation in industry, to contribute 

to the important aspect of dedicated machine vision 

education, and to provide a bridge between research 

and industry. The EMVA Young Professional Award 

is an annual award endowed with 1,500 € to honor 

the outstanding and innovative work of a student or 

a young professional in the field of machine vision or 

image processing. 

The EMVA specifically encourages students and young scientists 

to focus on challenges in the field of machine vision and 

to apply latest research results and findings in computer vision 

to the practical needs of industry. Applicants for the award 

2026 are hereby invited to submit their work. The board of 

directors of the European Machine Vision Industry will 

select the winner of the award among all papers. 

The criteria of the works to be presented are: 

→ Outstanding or innovative work in the field of vision 

technology. Industrial relevance and collaboration with a 

company during the work is required. The targeted 

industry is free of choice. 

→ The work (master thesis or PHD thesis or equivalent 

level research) must have been undertaken within the last 

18 months at, or in collaboration with, a European 

institution. Meanwhile the student may have 

entered the professional field. 

To apply submit the following materials to the EMVA president, 

Dr Chris Yates, at ypa@emva.org until April 5, 2026: 

→ a two-page abstract summarizing the innovation 

and the intended commercial benefit 

→ a one-page CV 

→ a copy of the master thesis or PhD thesis; if not 

yet finished or under publication restrictions 

→ please provide at least one accepted publication 

→ supportive letters of research supervisors and/or any 

collaborating company are welcomed but not mandatory 

The winner of the award will be announced at the EMVA Business 

Conference 2026 in June 18-20 in Stockholm, Sweden, 

giving the opportunity to present the awarded work to the 

machine vision industry leaders and special press representatives. 

In addition to the honor of the EMVA award endowed 

with 1,500 € and the publicity for the research work, is a free 

conference pass for the EMVA Business Conference, the coverage 

of all travel cost to Stockholm and a free pass for the 

European Machine Vision Forum in autumn 2026. 

further information: www.emva.org 


news & facts 

Switching to recycled materials 

Horn is gradually switching its packaging to recycled 

materials with immediate effect. The change from black 

to grey packaging is visually noticeable. The yellow 

labels are also largely made from recycled materials. 

Plastic packaging is an indispensable part of our modern society. 

It protects products, extends their shelf life and enables 

efficient logistics. But plastic packaging is also the subject of 

controversial discussions regarding its environmental impact 

and sustainability. Recycled material plays an important role 

in reducing the consumption of new raw materials and minimizing 

the environmental impact of plastic packaging. The 

reused plastic waste is from various sources, including used 

plastic packaging and industrial waste. Keyword: recycling. 

There are various recycling methods, such as mechanical 

recycling, chemical recycling and energy recovery. Mechanical 

recycling is the most common, but has its limitations 

in terms of the number of recycling cycles. It is not easy to 

say how often plastic can be recycled. It can be assumed that 

most plastics can generally be recycled several times through 

mechanical recycling. 

Most of the materials currently pass through the cycle once. 

The mixing of input materials from different sources ensures 

that the material quality of the end product is high. Quality 

control ensures that the recycled material meets the requirements. 

However, this development has not yet reached the 

same level as, for example, with PET (water bottles). For 

HDPE and PP this is only possible to a limited extent, as 

most of the material currently entering the cycle still is virgin 

material. It will take some time before 100 % of the material 

is permanently recycled. 

The dark grey recycled packaging that Horn purchases is 

processed by mechanical recycling and then compounded. 

This means that the shredded recycled material is melted 

down and processed with additives so that the material properties 

always remain the same. These additives help to stabilize 

and optimize the physical and chemical properties of 

the recycled material. This is important in order to keep the 

Horn is converting all its packaging to recycled materials 

HORN/Sauermann 

manufacturing processes stable. Through targeted measures 

and the right selection of additives, the performance of the 

recycled plastic can be stabilized and, if necessary, significantly 

improved. 

If the quality of the plastic can no longer be reproduced, it 

is further processed for less demanding applications or, as a 

last resort, sent for energy recovery to generate energy. 

Ultimately the goal is to maximize the recyclability of 

plastics while minimizing the use of new plastic in order to 

reduce the environmental impact. 

Arguments in favor of plastic packaging 

made from recycled plastic 

1. Environmental protection: 

the use of recycled plastic reduces the need for new 

plastic, which lowers the consumption of fossil raw 

materials (oil, gas, etc.) and reduces CO₂ emissions 

2. Resource conservation: 

recycled materials help conserve natural resources 

by minimizing the need for new raw materials 

3. Waste reduction: 

the use of recycled plastic produces less waste, as the 

raw material is kept in the cycle, thereby reducing 

energy recovery and landfill (abroad) 

4. Energy savings: 

manufacturing products from recycled plastic often 

requires less energy than producing new plastic, 

which leads to a lower environmental impact 

5. Circular economy: 

the use of recycled plastic promotes the concept 

of a circular economy, in which materials are 

continuously reused and recycled instead of 

ending up in a linear system 

6. Regulatory requirements: 

many regions have increasingly stringent regulations 

and incentives for the use of recycled materials, 

encouraging companies to adopt more 

sustainable practices 

7. Innovation: 

the development and use of recycled plastic promotes 

innovation in the packaging industry, which can lead 

to new, sustainable solutions 

8. Consumer acceptance: 

due to upcoming regulatory requirements, more and 

more companies are striving to reduce their carbon 

footprint, which supports the use of recycled plastics 

“The switch to packaging made from recycled materials is 

simply the next logical step in our understanding of sustainability. 

As a family business we don’t just think in terms 

of quarters and annual financial statements, but in terms 

of generations”, says Markus Horn, managing director of 

Paul Horn GmbH. 



15

news & facts 

Open, flexible and scalable 

The world’s leading drive specialist SEW EURODRIVE 

and TTTech Digital Solutions, software and automation 

expert, announce their strategic cooperation. 

The cooperation aims to integrate SEW EURODRIVE’s 

axis and drive systems into the software-based control and 

auto mation platform UBIQUE® in order to offer customers 

an open, modern and forward-looking concept for their 

machine automation. 

Through this cooperation SEW EURODRIVE combines its 

many years of expertise in drive technology with the digital 

expertise of TTTech Digital Solutions in the field of real-time 

control and automation. The UBIQUE® (“cloud-driven automation”) 

platform combines OT and IT and offers functions 

such as real-time motion control, cyber security, safety, 

web HMI, I/O, and Edge/IIoT. The combination of SEW 

EURODRIVE axes and UBIQUE® creates an open, integrated 

system that offers machine builders and plant operators 

a powerful and flexible solution for modern automation 

require ments. UBIQUE® users get direct access to the 

MOVI C automation kit from SEW EURODRIVE and all 

associated gearmotor solutions. UBIQUE® makes customers 

independent of special hardware such as IPCs, servo controllers 

or HMI platforms in the long term, while the combination 

of proven mechanical drives and modern control systems 

shortens development times. In addition UBIQUE® covers 

the entire product life cycle – from the axis to the cloud, 

including edge devices, remote maintenance and lifecycle 

management. The cooperation thus supports the transition to 

“software-defined factories,” networked systems, and sus tainable 

production. Neither is security is neglected: UBIQUE® 

is cyber secure according to IEC62443 and supports the implementation 

of EU machinery regulation 2023/1230. 

“By integrating our products into UBIQUE® we enable our 

customers to think about their automation solutions in an 

open, flexible and scalable way. In doing so we are consistently 

pursuing our strategy of integrating drive technology into 

digital ecosystems”, says Dr. Hans Krattenmacher, managing 

Von links: Alois Holzleitner (TTTech Digital Solutions), 

Dr. Hans Krattenmacher (SEW-EURODRIVE), 

Christoph Trappl, Hans Wimmer 

(beide TTTech Digital Solutions) 

director of innovation mechatronics at SEW EURODRIVE, 

summarizing the benefits for customers. 

Christoph Trappl, managing director of TTTech Digital 

Solutions, adds: “The cooperation with SEW EURODRIVE 

opens up complete new solutions for machine builders in the 

field of motion control. The consistency of UBIQUE® enables 

users to change and archive all parameters and configurations 

from the motor to the cloud – naturally in accordance 

with IEC62443 cyber security standards.” 

In a first step, selected machine and production line customers 

of SEW EURODRIVE will be able to use the integration 

of UBIQUE®-based control solutions – including edge 

functionality, remote monitoring and lifecycle management. 

At the same time both companies are developing a joint engineering 

roadmap to offer standardized, modular automation 

packages in the long term. The plan is to make the solution 

available not only for new systems, but also for retrofitting 

existing systems. 

further information: www.sew-eurodrive.de 

Coated abrasives leadership strengthened with the 

acquisition of Hermes North America 

WALTER Surface Technologies, a global leader in 

productivity and safety solutions for the metalworking 

industry, has announced the acquisition of 

Hermes North America, a leading supplier of coated 

abrasives with a strong reputation for technical excellence 

and customer-focused performance. 

This strategic acquisition ensures business continuity and 

long-term stability for Hermes North America customers 

and employees, while expanding WALTER’s existing expertise 

in coated abrasives. The addition of Hermes strengthens 

WALTER’s position in key market segments, particularly in 

belted products that serve a wide range of finishing, robotic 

and automation applications. 

“WALTER and Hermes share a deep commitment to quality, 

reliability and customer success”, said Marc-André Aubé, 

CEO of WALTER Surface Technologies. “This acquisition 

is not only about expanding our coated abrasives offering 


news & facts 

today – it’s a long-term investment in growth and innovation 

as customers automate their processes. Our long-term 

vision is to keep driving innovation, sustainability and value 

creation so our customers can continue to work better, faster 

and more efficiently for decades to come.” 

Tony Sarles, general manager of Hermes North America, 

added: “Joining WALTER represents a new chapter of 

strength and stability for Hermes North America. With 

WALTER’s support, we will continue to serve our customers 

and partners with the same dedication and technical expertise 

they have come to expect – now backed by a stronger 

foundation for the future.” 

The acquisition also reinforces WALTER’s position as 

a leader in metalworking surface treatment and finishing 

solutions across North America. Hermes North America 

will continue to operate from its current headquarters, while 

WALTER plans to integrate Hermes’ high-quality abrasive 

products into its lineup quickly, ensuring customers have 

seamless access to a broader range of solutions across its distribution 

network. The Hermes European Group will remain 

independent as a trusted partner and supplier. The transaction 

is immediately effective, and all customer and supplier 

activities will continue without disruption. This acquisition 

represents WALTER’s ongoing commitment to providing 

best-in-class productivity and surface finishing solutions 

for customers. 

further information: www.walter.com 

A quarter century of precision, innovation 

and partnership 

Vollmer Japan celebrated its 25 th anniversary, marking 

a quarter century of successful company history. Since 

its founding in the year 2000 the Japanese subsidiary 

of the Vollmer Group has stood for the highest precision, 

technological innovation and trusted partnerships 

with customers throughout Japan. 

Vollmer Japan is based in Ageo, around 40 km north of 

Tokyo. Since 2022 this modern competence center has served 

as the company’s headquarters, offering a spacious showroom 

showcasing various Vollmer machines. Customers can 

experience the latest technologies live, test them on-site and 

receive individual consultation – an important contribution 

to making precision and quality tangible in Japan. Previously, 

Vollmer Japan was located for many years in Saitama City 

before moving to the larger site in Ageo. This relocation has 

significantly expanded the company’s capacities in service, 

training and customer support. 

Since March 2025 Vollmer Japan has operated additionally 

a new service hub in Nagoya, providing customers in 

western Japan with fast technical support, spare parts supply 

and training. With this site Vollmer has strengthened its 

nationwide presence and ensures optimal service coverage in 

all regions. 

To mark the anniversary Vollmer Japan invited around 115 

guests to a celebratory event. Representatives from industry, 

trade and the Vollmer Group gathered to look back on 25 

years of continuous growth, technological progress and 

close customer relationships. 

Among the highlights of the evening were great speeches 

by Carl Moser, managing director of Vollmer Japan, and 

Tobias Trautmann, managing director of the Vollmer Group. 

Both emphasized the importance of trust, continuity and 

innovation as the foundation of the company’s successful 

development. 

Numerous congratulations rounded off the celebration – a 

clear sign of the strong and valued relationships Vollmer Japan 

The entire Vollmer Japan team together with managing director 

Tobias Trautmann at the anniversary celebration in Japan; 

a strong team standing for precision, commitment 

and partnership since 25 years 

has built over the past 25 years. “This anniversary is not 

only a look back but also a promise for the future”, said Carl 

Moser. “We will continue to do everything we can to provide 

our customers in Japan with innovative solutions and the 

highest precision – with the same passion that has driven us 

for 25 years.” 

Tobias Trautmann also underlined the importance of the 

Japanese site for the Vollmer Group: “Vollmer Japan exemplifies 

our international values – quality, trust and sustainable 

partnership. The team has played a major role in successfully 

establishing the Vollmer brand in Japan.” 

Looking ahead Vollmer Japan remains a reliable partner 

for innovation and precision in manufacturing – today and in 

the future. 

further information: www.vollmer-group.com 


17

news & facts 

fairs 

First trade fair for 

grinding technology in the Americas 

The Duke Energy Convention Center in Cincinnati, Ohio 

Launching in 2027, GrindingHub Americas will be the 

first and as yet only trade fair in America dedicated 

exclusively to grinding technology. 

Organized by the VDW (German Machine Tool Builders’ 

Association), Messe Stuttgart and Swissmem (Swiss Association 

of the Machinery, Electrical and Metal Industries), the successful 

concept first established by GrindingHub Stuttgart in 

Germany is now being brought to the American market. 

International grinding technology manufacturers 

plan to serve the US market 

The initiative for GrindingHub Americas once again came 

from the manufacturers. “Well-known companies from 

the grinding technology sector, together with representatives 

of their US subsidiaries, asked us to develop a trade 

fair concept for the American market based on the model of 

GrindingHub in Stuttgart. It should be clearly structured 

and focused on grinding technology. We are delighted to be 

able to fulfill this request with our trusted partners Messe 

Stuttgart and Swissmem, also showing that the companies 

have great confidence in us”, reports Dr. Markus Heering, 

managing director of the VDW. Roland Bleinroth, president 

of Messe Stuttgart, adds: “America is one of the most dynamic 

industrial markets in the world. Together with our 

American trade fair partners we are convinced that the new 

GrindingHub Americas will become the ideal platform for 

the grinding technology sector and international cooperation 

in one of the most important global markets.” The products 

and services on show cover the entire spectrum of grinding 

technology: from grinding machines and tools through to 

automation, measurement technology, digitalization and sustainable 

production solutions. The event will have a strong 

focus on innovation, and opportunities for international 

market leaders and local experts to meet up and exchange 

information, with the advantage that everyone is brought 

together in one location. Key areas of focus of the new trade 

fair include live demos and technologies that increase productivity, 

reduce costs and redefine precision. 

Cincinnati as an ideal location 

GrindingHub Americas is aimed specifically at decisionmakers 

and purchasing staff from forward-thinking industries 

such as the automotive industry, aerospace, defense, 

medical technology and mechanical engineering. Cincinnati, 

in the heart of the Midwest industrial cluster, offers the ideal 

infrastructure and proximity to important production sites 

in the United States – especially for the automotive and aerospace 

sectors. 

“GrindingHub Americas in Cincinnati is ideally located in 

the immediate vicinity of GE Aerospace and numerous automotive 

suppliers. There we can demonstrate to key customer 

industries the capabilities of the international manufacturers, 

which can make a valuable contribution to the success and 

competitiveness of US industry”, says Markus Heering, explaining 

the choice of location. 


fairs 

news & facts 

First board meeting highlights the 

importance of the new trade fair 

The first board meeting with leading grinding technology 

companies took place in Cincinnati at the beginning of 

November 2025. Among the participating companies and 

board members are enterprises such as Action SuperAbrasive, 

Anca, Norton Saint-Gobain, Rollomatic, Star SULLC, 

Supertec Machinery, United Grinding North America and 

Vollmer America. 

“Industry experts agree there is a need for a trade fair in the 

Americas that focuses specifically on grinding technology 

and related processes. Strong partners have joined forces on 

the board to make the first GrindingHub Americas 2027 in 

Cincinnati a reality”, emphasizes board chairman Phil Kurtz. 

“Our board will ensure that the trade fair offers manufacturers 

a platform to present their innovative solutions to a 

specialist audience that is specifically looking for process 

optimization.” 

GrindingHub Americas will take place on May 18-20, 2027, 

at the Duke Energy Convention Center in Cincinnati, Ohio. 

Under the motto of “Where precision meets progress” the 

trade fair is positioning itself as an unmissable event for anyone 

who wants to set new standards in the world of grinding 

technology. 

further information: www.grindinghub-americas.com 

BI-MU: a 70-year history 

The 35 th edition of the exhibition will be in the limelight 

From October 13 to 16, 2026, fieramilano Rho will 

host the 35 th edition of BI-MU, the leading Italian 

trade show dedicated to the industry of metal forming 

and metal cutting machine tools, robots, automation 

systems, digital and additive manufacturing, auxiliary 

and enabling technologies. 

Promoted by UCIMU-SISTEMI PER PRODURRE, the 

Italian machine tools, robots and automation systems manufacturers’ 

association, and organized by EFIM-ENTE FIERE 

ITALIANE MACCHINE, BI-MU is the only trade fair for the 

sector in Italy with international appeal, the first one to open 

up to the world of connectivity for the industry. Once again 

the exhibition will update its product offering to meet the 

needs of the market, featuring a special edition by which it 

will celebrate its 70-year history. 

In this connection 35.BI-MU has chosen “Where it all 

begins” as slogan for the new edition, which is intended to 

emphasize the central role of machine tools, enabling most 

manufacturing processes. The slogan also highlights the long 

and enduring tradition of this exhibition. 

The trade show has been organized uninterruptedly for 

70 years, becoming the reference event for the operators of 

the manufacturing industry, who visit its halls to view the 

technological product offering on show and plan their investments. 

35.BI-MU is also a sustainable event, managed 

and organized according to the principles of environmental, 

economic and social sustainability, with ICIM ISO 20121 

certification. 

The spotlight of the exhibition will be on the latest generation 

of digitalized and interconnected machines and technologies, 

which have integrated 4.0 solutions and automation 

systems, capable of enabling processes typical of the digital 

factory. 

BI-MU will give special attention to seven technological 

themes: RobotHeart, dedicated to robotics, automation, 

components, systems and artificial intelligence, sponsored 

by SIRI (Italian Robotics and Automation Association); 

AMItaly, focused on the entire additive-manufacturing supply 

chain (machines, materials and post-processing software) 

sponsored by AITA (Italian Association of Additive 

Technologies); BI-MU Digital, regarding digital solutions 

for the smart factory, advanced software, technologies for 

connectivity, data management and data security, sensors 

and self-adaptive systems; metrology and testing, offering 

measuring instruments, testing machines, machine vision; 

Power4Machines, dedicated to components for mechanical, 

electrical and pneumatic power transmission, sponsored by 

FEDERTEC (Association of the Italian Production Chain of 

Mechatronic Technologies and Components for Fluid Power); 

heat and surface treatments, focused on plants and systems 

for improving the performance of materials. A new theme in 

this edition will be Tool Tech, centered on advanced tools for 

efficient, high-precision production. 

The exhibition product offerings will be completed with an 

overview of revamping & retrofitting, showcasing a selection 

of machines and systems which have been properly reconditioned 

and upgraded, to meet the needs of a market that is 

complementary to that of “new” equipment. 

further information: www.ucimu.it 


19

news & facts 

fairs 

TMTS 2026 returns to Taichung 

The Taichung International Convention and Exhibition Center (TICEC) 

Organized by the Taiwan Machine Tool & Accessory 

Builders’ Association (TMBA), the Taiwan International 

Machine Tool Show (TMTS 2026) will grandly return 

from March 25 th – 28 th , 2026. One of the major highlights 

of this edition is the show’s return to Taichung – 

the heartland of Taiwan’s machine tool industry. 

The Taichung International Convention and Exhibition Center 

(TICEC), located at the core of the precision machinery cluster, 

will serve as the TMTS venue for the first time. This not 

only showcases the industry’s unique “Showroom-to-Factory” 

advantage but also provides international buyers with a 

seamless exhibition and procurement experience. 

As a crucial hub in the global machine tool supply chain, 

Taichung hosts numerous leading brands and key component 

manufacturers. By choosing Taichung as its home, TMTS 

2026 offers exhibitors and buyers a highly professional and 

comprehensive environment while significantly enhancing 

the efficiency of procurement. 

After viewing the latest technologies and scheduling meetings 

at the exhibition hall, international buyers can immediately 

visit nearby factories to gain deeper insights into equipment 

performance, tour production lines, and even operate 

the machines themselves. This integrated “Exhibition-to- 

Factory” model accelerates decision-making, increases order 

conversion rates, and sets TMTS apart from other global 

trade shows. 

The newly built Taichung International Convention and 

Exhibition Center (TICEC) is equipped with world-class facilities 

and infrastructure. Certified as a “Diamond-Level Green 

Building” the center incorporates sustainable concepts into 

its energy efficiency, natural lighting and spatial design. 

Stra te gically located in the Shuinan Smart City, TICEC offers 

excellent accessibility – close to major highways, the port, the 

airport and the Taichung high-speed rail station – while connecting 

seamlessly with key industrial zones in Taichung, 

Changhua and Nantou. This provides strong support for the 

expanding global business opportunities of Taiwan’s machine 

tool industry. Surrounded by major developments such 

as the Shuinan transit hub, central park and the soon-to-open 

Taichung Green Museumbrary, TICEC benefits from comprehensive 

transportation and urban infrastructure. This 

makes Taichung a prime destination for business meetings, 

inter national networking and incentive travel, combining 

industrial strength with cultural and environmental quality. 

With TMTS 2026 returning to Taichung the exhibition will 

not only showcase the latest global machine tool trends but 

also leverage its “manufacturing-base” advantage to deliver 

a procurement experience that truly connects buyers with 

the production front line. Taichung’s role as the powerhouse 

of Taiwan’s machine tool industry will once again be highlighted 

on the world stage through TMTS. 

further information: www.tmts.tw 


Combined drilling & deburring saves time 

and ensures safety 

processes 

The change from manual deburring to tools integrated 

directly into the CNC machine is worthwhile – 

especially when drilling and deburring are combined 

into one single tool. Thanks to a combination tool 

from HEULE Precision Tools, pso GmbH was able to 

increase process reliability and reduce machining time. 

pso GmbH in Diepoldsau, Switzerland, stands for high-precision 

machining incorporating state-of-the-art equipment. 

Since its foundation in 2016 the company has quickly developed 

into an efficient partner in milling, turning and measuring 

– with innovative and customer-specific manufacturing 

and quality control. With this focus pso GmbH positions 

itself not only as a manufacturer of individual parts, but also 

as a reliable service provider for serial production, consistently 

meeting and further developing the requirements of 

its customers in mechanical and plant engineering. Accordingly 

manufacturing processes are optimized for efficiency 

and process reliability wherever possible in order to reduce 

throughput times and manual rework. 

From manual processing to a 

process-reliable automated solution 

New innovative approaches were required for the production 

of two workpieces that are ultimately used in the energy 

industry. Previously the burrs on the four holes were removed 

by hand on both sides using a standard countersink 

tool, however, this carried the risk of forgetting to deburr 

some areas, which in turn could lead to customer complaints. 

Manual machining also meant that the deburring results 

were not consistent. In addition the process was very timeconsuming 

and took up around an hour of an employee’s 

Three workpieces come out of the machine ready-to-go in a single 

clamping: manual deburring processes have been 

replaced by the VEX combination tool from HEULE 

The VEX combination tool 

machines the workpieces with remarkable 

process reliability and enables finishing directly on the machine 

time every day. Around 12,000 pieces of one workpiece were 

required annually, and as many as 15,000 pieces of the other, 

a total of around 108,000 bores that needed to be deburred 

on both sides. It quickly became clear to managing director 

Philipp Sonderegger that a superior solution was needed. 

As an experienced machinist he contacted the deburring 

specialist HEULE, whose headquarters are located just ten 

minutes away from his production facility. Together with the 

Swiss representative, Eisenbart GmbH, various solutions were 

evaluated. The positive aspect for finding a solution was that 

the drill diameters were identical for all bores. The first option 

was the SNAP chamfering tool, which reliably removes 

burrs by chamfering both edges of the bore after the drilling 

process. The mechanical tool could be easily integrated into 

the available machine and the existing process. This completely 

eliminated the manual operation, which greatly 

improved process reliability. 

Combining saves a lot of time 

As an experienced problem solver HEULE had another solution 

ready for pso GmbH: the VEX combination tool, which 

combines drilling and deburring in a single tool and thus in 

a single operation. This eliminates the need for another tool 

change, further reducing the cycle time. The responsible persons 

at pso GmbH were enthusiastic and initial tests were 

carried out. The tedious process step of manual deburring 

was eliminated, and process reliability increased significantly. 

The cycle time per workpiece was reduced to just 17 seconds, 

and the service life is also impressive: the blade has lasted for 

15,000 operations. 

Philipp Sonderegger is convinced: “If we review our processes 

again, we will definitely consult HEULE for advice and 

solutions. Not only is process reliability much higher, but we 

have also been able to reduce the cycle time to a fraction of 

what it was. Our employees can now focus on the tasks that 

challenge them.” All of these results are in line with pso GmbH 

and its high standards for optimized production. 

further information: www.heule.com 


21

processes 

On course for growth: in-house coating pays off 

A HiPIMS coating system from technology 

leader CemeCon makes a major 

contribution to future viability: the flexi - 

bility of the system and the process offers 

tool manufacturers security and opens 

up new customer groups in rapidly chang - 

ing markets. 

In addition, complete process control remains 

in one hand with in-house coating – in the 

company’s own. 

The machining industry is undergoing radical 

changes – and at a rapid pace. As one of 

the most important customer industries, the 

automotive industry in particular is facing a 

profound transformation. Falling production 

figures and the shift towards electromobility 

are fundamentally changing the requirements: 

fewer components are needed – and 

these differ significantly from previous ones. 

At the same time the range of materials being 

used is growing, with materials that are difficult 

to machine dominating increasingly. 

Additionally there is a growing demand for 

perfect surfaces and extremely tight manufacturing 

tolerances. 

An in-house HiPIMS coating system allows tool manufacturers to benefit 

from an almost unlimited variety of coating materials, maximum reaction 

speed and complete flexibility, even for small batches 

The challenges for tool manufacturers are growing 

One thing is certain: economic success can only continue to be secured by 

those driving changes themselves with suitable tool solutions and targeted 

investments. This puts them in a position to be a reliable partner to their 

customers on an equal technological footing, and to open up additional 

areas of performance. It is also a way for European suppliers to withstand 

the high price pressure and increased predatory competition. 

“Standard” is no longer enough under these conditions! In many cases the 

key is absolute specialization: “high-quality tools that are precisely tailored 

to very specific and demanding applications can definitely be marketed 

successfully”, says Dr.-Ing. Christoph Schiffers, CemeCon product manager 

technology, summing up many discussions with tool manufacturers. “Our 

HiPIMS systems provide optimal conditions for this. They enable manufacturers 

to coat their own tools according to their customers’ requirements, 

while retaining complete control over every stage of the process.” 

Ever smaller and more precise tools have 

highly complex requirements – homogeneous 

and smooth HiPIMS coatings are 

perfect for this 

HiPIMS expands entrepreneurial horizons 

CemeCon’s equipment is more than just high-tech: in addition to the latest 

HiPIMS technology and all peripheral systems for pre-treatment and cleaning, 

comprehensive know-how transfer is included as well. “Tool manufacturers 

receive practical training directly on the machine in live operation – 

this ensures smooth implementation,” says Christoph Schiffers, emphasizing 

the sustainable added value. Users work with exactly the same process technology 

and software that CemeCon has been developing, testing and using 

on a daily basis for over 35 years in its own coating center with around 

50 systems. At the same time the system remains flexible – open for individual 

in-house developments and customer-specific adaptations. 

Thanks to HiPIMS an almost unlimited variety of coating materials, 

maximum precision and limitless flexibility are possible. This process, an 


processes 

HiPIMS users can 

access tailor-made 

solutions for tools 

for machining high-strength steels 

or aluminum alloys and other nonferrous 

metals without any change 

in technology 

HiPIMS coatings such as FerroCon®Quadro enable a dense, 

homogeneous layer structure of up to 12 µm on cutting tools 

advancement of sputtering, enables the use of almost any 

chemical element as a coating material. The resulting coating 

is extremely smooth, dense and fine-grained, offering unprecedented 

material toughness – an enormous advantage for 

interrupted cutting with milling tools. The residual stresses 

can also be finely adjusted, which is crucial for achieving a 

homogeneous coating on complex cutting edge geometries 

and micro-tools. 

Inspiring old and new markets 

HiPIMS’ flexibility and universality enable tool manufacturers 

to keep pace with changes in their core market, helping 

them to shape these changes. One example of this is the future 

trend towards lightweight chassis components made of 

high-strength materials or aluminum, which are increasingly 

replacing traditional components made of carbon steel and 

standard castings in the automotive industry: HiPIMS users 

can already access SteelCon® as a tailor-made solution for 

tools for machining high-strength steels as well as AluCon® 

for aluminum alloys and other non-ferrous metals today – 

and entirely without changing technology. Another innovation 

that CemeCon customers can benefit from directly: the 

recently developed AlCrN-based HiPIMS coating material 

MultiCon® especially for milling and drilling steels between 

30 and 50 HRC. With a smooth surface without any droplets, 

previously being unavailable on the market, it ensures particularly 

high process stability and wear resistance. 

HiPIMS also opens up the potential to broaden the range of 

services in toolmaking and gradually establish itself in new 

target markets, like the growing market of medical technology. 

However, mini and micro-tools for dental or other medical 

implants require complete different coatings than cutting 

tools for the production of combustion engines, for example. 

Materials such as titanium or cobalt-chrome and tool dimensions 

in the tenth of a millimeter range quickly push traditional 

processes to their limits. 

HiPIMS enables process-reliable solutions that are unique 

on the market: extremely smooth, adhesive, dense and homogeneous 

coatings that reproduce precisely even the most delicate, 

sharp-edged cutting geometries. “Even the smallest 

flaws in the coating would have a fatal effect on the tiny 

geometries”, emphasizes Christoph Schiffers. “With HiPIMS 

such droplets are ruled out by the process and maximum precision 

is guaranteed!” 

Advancing technology, 

strengthening customer relationships 

In-house coating gives tool manufacturers a decisive competitive 

advantage: those having the in-house HiPIMS coating 

system can supply their customers much faster and more 

independently. “This means that even high-quality special 

tools can be offered in small batches with the shortest delivery 

times – even overnight if required”, explains Christine 

Hammer, head of sales Europe. “This speed and reliability 

strengthens customer loyalty and also pays off economically.” 

The current challenges in machining require new answers. 

“By using their own HiPIMS coating system companies can 

ensure independence and speed, as well as achieving clear 

technological differentiation”, Christine Hammer sums up. 

“Investing today creates the basis for a future-proof market 

position – despite changing requirements. This opens up 

business opportunities into new markets and application 

areas that we may not even know about today.” 

further information: www.cemecon.de 


23

processes 

One-of-a-kind service from MAPAL Indonesia 

Minimum quantity lubrication makes 

“green” production possible 

MAPAL in Indonesia has paved new trails to modernize 

a major client’s production. The Aalen-based 

tool manufacturer’s subsidiary not only supplies an 

automotive supplier with tools for use with minimum 

quantity lubrication (MQL), but has also taken over 

distribution and service for the facilities. 

Astra Otoparts is one of Indonesia’s biggest automotive suppliers. 

Founded 1976 the company’s clients are primarily 

numerous well-known automotive and bike manufacturers 

from Japan, South Korea and Europe. The group consists 

of 54 manufacturing and trading companies in total. One of 

these is Astra Otoparts’ Nusametal division, which manufactures 

components starting with aluminum die casting 

through to mechanical machining all the way to the finished 

product. 

Like many other companies in the country Astra Otoparts 

is faced with growing requirements for environmental action. 

The government is pushing industrial companies, particularly 

the automotive industry, towards “greener” production. 

This fits perfectly with Astra Otoparts’ image: in recent years 

the company has set itself apart time and again with environmental 

initiatives for causes such as clean water, reforestation 

and biodiversity. Most recently species conservation efforts 

focused on protecting the Javan gibbon. 

High productivity in a compact space 

Stricter environmental requirements were not the only cause 

of concern for Astra Otoparts’ Nusametal division when considering 

the future of production, however. The plant is located 

in North Jakarta, like Astra Otoparts’ headquarters, 

one of the island nation’s most densely populated areas. 

Although the company is growing, the demand for more efficient 

processes with better quality and increased production 

capacity with existing machinery remains a challenge. That’s 

where MAPAL came in. 

The Indonesian MAPAL subsidiary was founded in Jakarta 

in 2014 and now provides its services at three further locations 

on Java. Clients are primarily from the automotive sector, 

with scooter manufacturers a major focus in Indonesia. 

MAPAL Indonesia also often assists machine manufacturers 

in projects for Japan and India. Solutions developed in tandem 

with automotive specialists in Jakarta have also been 

carried over to production facilities in Taiwan, Vietnam and 

Thailand. 

Minimum quantity lubrication 

as a productivity lever 

At a seminar Astra Otoparts’ Nusametal division became 

aware of the MQL technology. MAPAL was presenting the 

A finish machining toll with Ø 32 mm 

and pcd cutting edges for finishing the 

fitting bore with a P7 tolerance 

©MAPAL 

use of PCD tools with MQL, which promised a huge improvement 

in aluminum machining. Besides the known advantages 

of MQL machining, it results in better surface finishes 

particularly during the precision machining of aluminum alloys 

compared with machining using conventional cooling 

lubrication with emulsion. Reasons for this are the better lubricating 

effect of the MQL media and the absence of small 

particles that a conventional cooling lubrication system cannot 

filter out. 

Minimum quantity lubrication has enjoyed a boom in the 

industry since a few years, in the spirit of resource protection 

and energy efficiency. MAPAL offers almost all its tools 

also in versions for MQL and labels them with a green mark. 

Aspects of these “green” tools include modification of the 

cooling channels to ensure optimum supply of the MQL liquid 

to the tools’ cutting edges and guide surfaces. 

The MQL switch project 

At the Nusametal division the potential of the technology for 

the company’s own production was recognized immediately. 

The use of MQL would cut coolant costs, increase productivity, 

reduce the consumption of water and improve the condition 

of the production floor, which is rare on Java Island. 

Lower energy consumption also reduces the company’s own 

carbon footprint. Nusametal’s strong interest culminated in 

a joint project with MAPAL Indonesia aimed at re-tooling 

existing machinery to MQL. The company DropsA was also 

involved as the MQL equipment manufacturer. 


processes 

Astra Otoparts’ 

Nusametal division 

uses devices with a 

1-channel MMS 

system from DropsA 

©DropsA 

tools are used for pre-machining and fine machining and 

are each equipped with several PCD cutting edges. Face 

milling cutters with exchangeable PCD inserts and PCDtipped 

form cutters are also used. Drills and forming taps 

are made from solid carbide. In comparison to competitors’ 

tools, the machining time could be reduced by around 20 % 

by using the MAPAL tools. 

Rachmad Basuki, engineering department head at 

Astra Otoparts’ Nusametal division, states: “The collaboration 

between engineers from Astra Otoparts’ Nusametal 

division and MAPAL Indonesia has played a pivotal role 

in enhancing tool design and driving internal improvements 

at Astra Otoparts’ Nusametal division. This partnership 

has boosted overall production performance, showcasing 

the power of cross-functional engineering synergy. The 

advanced technologies and innovative solutions introduced 

through this collaboration have become a catalyst for further 

improvements across the production area. These include 

layout optimization, automation initiatives, and the development 

of jigs and fixtures, among other enhancements. The 

use of PCD tools with MQL has led to faster machining times 

and thus higher output, improving daily production volume 

considerably.” 

The fact that DropsA has no presence in Indonesia was 

initially a major stumbling block. After some consideration 

MAPAL Indonesia ultimately took over the import and 

installation of the MQL equipment. Up to this point the 

team in Jakarta had no experience whatsoever with minimum 

quantity lubrication. “We knew this would be a challenge, 

as we first of all had to get to know the device and 

acquire knowledge on its installation, use and repair”, says 

Andreas Wasisto, managing director of MAPAL Indonesia. 

At DropsA in Frickenhausen and Milan, employees of 

Nusametal and MAPAL Indonesia got to grips with the 

technology. 

For DropsA, like the tool manufacturer, the partnership 

is unusual and hitherto unique in this form. Sales director 

Frank Müller describes a fruitful collaboration and good relationship 

between the two companies. “MAPAL is a very good 

partner for us, because the tool manufacturer is very close 

to the client and the experts there contributed a great deal 

of know-how”, he says. 

Connecting the 1-channel MQL systems to the existing 

BT30 machines from Fanuc Robodrill proved relatively unproblematic. 

Chip removal, chip cleaning, MQL device placement, 

maintenance and the use of appropriate lubricants also 

needed to be taken into account. This aspect was achieved in 

close collaboration between MAPAL Indonesia, Nusametal 

and their sister firm Astra Otoparts division Winteq. 

Crankcase covers produced faster 

The pilot project was a success. Astra Otoparts’ Nusametal 

division initially used the re-tooled machines to manufacture 

crankcase covers for scooters made by a Japanese manufacturer. 

Every day the company produces around 11,000 

of these aluminum components on a total of 24 machines, 

which are configured in six production lines. The MAPAL 

Thanks to the switch to MQL even more benefits were evident 

in production. The workspace stays much cleaner. The 

components are dry after machining, meaning the laborious 

washing process can be omitted. Longer tool life and the associated 

reduced machine downtime contribute to higher 

productivity and reduced tool costs. 

“The MQL project at Astra Otoparts’ Nusametal division 

is one of our company’s most valuable projects”, underlines 

Mr. Willy, deputy chief operation officer of Astra Otoparts’ 

Nusametal division, explaining that the implementation that 

began on the CVT Transmission Cover production line has 

since been further expanded to other production lines. 

Currently 24 of 150 machines operate with the MQL 

system which is set to expand annually. Mr. Willy adds: “The 

excellent collaboration between MAPAL Indonesia and our 

engineers resulted in an innovation combining MQL technology 

and PCD cutting tools on the BT30 CNC machine. 

This has significantly increased productivity and reduced 

production costs, enhancing our company’s competitive advantage. 

We are very grateful to MAPAL Indonesia for their 

excellent service and support, and we look to continuing our 

long-term cooperation and collaboration to innovate in our 

tooling systems and tooling management.” 

MAPAL Indonesia is DropsA’s official sales partner 

MAPAL Indonesia is now DropsA’s official sales partner and 

can therefore offer complete manufacturing solutions with 

MQL equipment and the right tools. A corresponding agreement 

was signed at MAPAL’s booth at AMB 2024. Andreas 

Wasisto hopes the result will be more widespread use of MQL 

technology. DropsA and MAPAL are already discussing 

applying the Indonesian model to more countries. 

further information: www.mapal.com 


25

processes 

Beyond the grit: 

Understanding the role of abrasive technology 

in modern manufacturing 

written by Tom Dustman 

director of sales, Americas at Sunnen Products Company 

In the world of precision manufacturing, precision 

bore honing abrasives do more than polish a surface, 

they shape the way components perform across their 

entire lifecycle. From ensuring the seal integrity of 

aerospace hydraulics to fine tuning combustion chambers 

in remanufactured automotive engines, abrasive 

technology quietly plays a critical role in producing 

parts that are safer, more efficient and longer lasting. 

Despite their widespread use, engineered abrasives are frequently 

misunderstood as simple one-size-fits-all tools that 

are easily interchangeable. This oversimplification masks the 

true potential of abrasive technology. To understand the full 

impact of precision bore honing abrasives, it helps to think 

of them not as consumables, but as engineered cutting tools 

with performance characteristics that must match, and even 

anticipate, the demands of new materials and applications. 

Precision beneath the finish 

While several finishing methods like grinding and lapping to 

roller burnishing exist, abrasive honing remains a go-to solution 

for achieving high precision surface finishes and tight 

dimensional tolerances. Unlike high speed grinding, honing 

is a low speed, high accuracy process that reduces heat distortion, 

eliminating the “white layer” of stressed metal, leaving a 

crosshatch pattern ideal for lubricant retention. 

The advantages of precision bore honing abrasives are obvious 

in critical applications like hydraulics, where a single 

burr or imperfect bore can lead to leakage or system failure. 

In automotive remanufacturing applications the demand for 

higher power density and lower emissions has driven tighter 

tolerances amongst more complex surface requirements. 

Bore finishes that once required only a single roughness 

parameter now must meet up to five separate metrics. These 

tighter specifications place higher demands not only on 

machine tools, but on the engineered abrasives themselves. 

The rise of superabrasives 

One of the most transformative advancements in the past 50 

years has been the emergence of “superabrasives”, specifically 

those composed of industrial diamond and cubic boron 

nitride (CBN). These materials are tougher than traditional 

silicon carbide or aluminum oxide, and offer approximately 

100 times the tool life of conventional precision bore honing 

abrasives. When bonded in a metal matrix they retain cutting 

performance much longer, minimizing tool changes and 

reducing downtime in automated production lines. 

Precision bore honing superabrasives have also unlocked 

the ability to finish increasingly tough materials, like Inconel 

in energy sector components or compacted graphite iron 

(CGI) in remanufactured engine blocks, that would quickly 

degrade conventional engineered abrasives. In these cases, 

material hardness isn’t the only challenge. Different materials 

demand engineered abrasives tailored not just by hardness, 

but also by grit concentration, bond type and geometry. 

This complexity has given rise to a new class of precision bore 

honing abrasives that are no longer off-the-shelf tools, but 

tightly engineered products tailored to specific applications. 

Side-by-side view of traditional and superabrasive materials, 

including aluminum oxide, silicon carbide, cubic boron 

nitride (CBN) and industrial diamond – each tailored for 

different material hardness and applications; clockwise from 

top right: brown aluminum oxide, cubic boron nitride (CBN), 

diamond abrasive and black silicon carbide 

Many commodity abrasive suppliers focus on minimizing 

cost, often sourcing low grade abrasive particles with weak 

crystal structures. These materials may meet basic specifications 

on paper, such as grit size or shape, but under the 

microscope their internal structure tells a different story. 

Microfractures and inconsistencies lead to premature breakdown, 

unpredictable wear, and erratic performance. 


processes 

By contrast, engineered abrasives consider a broad spectrum 

of variables: 

→ particle type and hardness: 

for example on the Knoop hardness scale, industrial 

diamond ranks around 7400, CBN around 4700, 

silicon carbide at 2600 and aluminum oxide at 2100 

→ crystal structure and coating: 

tin or copper coatings can enhance bonding 

and wear resistance 

→ bonding materials: 

glass, ceramic and metal matrices affect how the 

abrasive responds under pressure and heat 

→ grit concentration and shape: 

tighter packing densities and varied geometries 

influence chip load and consistency 

Choosing the right combination of these factors determines 

not just whether a part can be honed, but how efficiently, how 

precisely and how repeatedly it can be done. 

Standard CBN is the normal 

CBN that Sunnen sells, the 

other three are alternative 

CBN grades that were 

compared for performance 

CBN-550 is the standard 

Sunnen CBN, the other 

two shown are alternative 

CBN grades 

New materials, new challenges 

As industries shift toward lighter, harder and more wear 

resistant materials, especially in aerospace, energy, and EV 

applications, abrasive technology must keep pace. Hydraulics 

manufacturers, for instance, are under increasing pressure to 

meet “zero leak” mandates. This level of precision requires 

not only a matched piston-to-bore fit, but also burr free cross 

holes that can only be achieved through optimized honing. 

The need for longevity and performance consistency also 

feeds into broader sustainability goals. Longer lasting engineered 

abrasives mean fewer changeovers, less scrap and 

more uptime – crucial in continuous manufacturing environments. 

Manmade materials like “seeded gel” aluminum oxide, 

engineered from scratch rather than mined, have added 

another layer of control. These synthetics feature uniform 

crystal structures and custom engineered bonds, offering improved 

wear resistance and surface consistency in a growing 

range of applications. 

With more than a century of experience in bore sizing and 

surface finishing, Sunnen has contributed to the evolution of 

abrasive technology by integrating materials science with process 

engineering. Rather than viewing engineered abrasives 

A honing tool applies engineered abrasives to create the 

distinctive crosshatch pattern that improves oil retention and 

reduces stress in internal combustion engine bores 

as off-the-shelf consumables, the company approaches them 

as precision tools that must be matched to specific performance 

requirements. Over time, Sunnen brought abrasive 

manufacturing in-house, allowing for greater control over 

quality and consistency. Rather than relying on patents the 

company has developed proprietary processes that guide 

how it selects particle types, bonding methods and abrasive 

geometries. This internal expertise supports both standard 

catalog offerings and highly customized solutions, depending 

on the application. 

One distinguishing factor is how Sunnen’s precision bore 

honing abrasives are developed alongside its honing machines 

and control systems. This co-design approach helps 

ensure that the abrasive performs reliably within the larger 

system, particularly in applications where precision is nonnegotiable, 

such as engine cylinder bores or aerospace hydraulic 

valves. In practice this alignment can support more 

stable tool life, reduced downtime and more consistent results 

across production batches. 

Where abrasive technology is headed next 

Looking ahead, advancements in synthetic precision bore 

honing abrasives, coatings and bonding systems are expected 

to continue reshaping the industry. Precision will only grow 

in importance as sectors like EVs, aerospace and renewable 

energy demand tighter tolerances and tougher materials. Simul 

taneously the rise of automation and data driven manufacturing 

will place a premium on predictable tool life and 

repeatable performance, attributes that only high quality, engineered 

abrasives can deliver. As manufacturers reevaluate 

their processes through the lens of productivity, sustainability 

and material science, engineered abrasives are no longer 

just the end of the line. Precision bore honing abrasives have 

become vital contributors to solutions, performing as cutting 

tools themselves and subtly shaping the future of precision 

manufacturing. 

further information: www.sunnen.com 


27

processes 

Efficient and flexible complete machining of 

V8 and V12 diesel engines 

Tatra Trucks, the oldest manufacturer of road and 

off-road vehicles and the second oldest manufacturer 

of lorries with internal combustion engines in the 

world, is bringing its engine production up to the 

latest standards. A production cell with three Heckert 

HEC 800 machining centers, automated by a pallet 

system, increases efficiency, and reduces the space 

requirement to almost a quarter. 

Tatra, an automotive manufacturer from Kopřivnice, 

Czech Republic, started producing carriages as early as 1850 

and has been making cars since the end of the 19 th century. 

Today it is mainly the heavy Tatra trucks that impress with 

their off-road performance, high reliability and outstanding 

utility properties – even in extreme weather conditions such 

as frost and desert temperatures. 

One of the special features of the vehicles is the Tatra concept, 

a chassis with a central support tube and individually 

suspended semi-axles, which makes it possible to mount 

a chassis with any number of axles, from 4x4 to 12x12 and 

more. The direct air-cooled V8 and V12 diesel engines of the 

Tatra T3 series with supercharging and intake air cooler are 

also among the USPs. 

Production takes place at the company’s headquarters in 

Kopřivnice, Czech Republic. The complete chassis for the 

T158 Phoenix vehicles, which are available with various 

superstructures such as containers, concrete mixers, tanks, 

and special superstructures, is produced there. In addition, 

vehicles from the T815-7 Force series are produced, which 

are available in both civilian versions (e.g. as fire engines, 

etc.) and military versions. Technology and process manager 

Martin Kappler explains: “We manufacture almost all components 

for our Force series vehicles ourselves: the complete 

chassis, cabin, engine and gearbox.” Tatra’s production portfolio 

also includes the Tactic series of medium-sized vehicles, 

which are designed exclusively for military purposes. 

Automated production cell replaces transfer line 

As far as the engine equipment is concerned, Tatra Trucks 

lets its customers choose from several options. Liquid-cooled 

engines from proven manufacturers and Tatra’s own V8 and 

V12 engines in various power variants are available. The latter 

have been manufactured on a transfer line in Kopřivnice 

since 1980. “Despite its age the technical condition of this 

plant is still good”, says Martin Kappler, “but the energy costs 

are extremely high, as is the consumption of coolants. That’s 

why we decided to switch engine housing production to a cell 

with automated machining centers.” 

He also argues that the changeover from V8 to V12 on 

the transfer line takes a long time, usually several production 

shifts: “In view of the flexibility required today, the new 

production cell also impresses in this respect. With our universal 

fixture we are quick to retool and can customize any 

motor housing. This means that we are much more efficient 

with the machining centers, even if the pure machining time 

of a motor housing on the transfer line is shorter.” 

As a result, in 2024 the production managers at Tatra Trucks 

decided to order a Heckert HEC 800 from Starrag as the basis 

for the planned production cell – supplemented by an automation 

solution in form of a Fastems FPC3000 system. 

25 years’ experience with Heckert machines 

A historical decision: Tatra replaced an ageing machining 

center back in 2017. Its original task was cutting base surfaces 

and machining index holes, which is required for clamping 

and positioning the cast parts in the transfer line. Libor 

Kalíšek recalls: “After comparing several suppliers we decided 

in favor of a Heckert HEC 800, as it seemed the most suitable 

and offered a wider range of machining applications.” 

Since then Tatra has been using the Heckert HEC 800 to 

pre-machine 8- and 12-cylinder motor housings. The lower 

housing section is completely machined in a single operation, 

Tatra’s own V8 and V12 engines are built in Kopřivnice 

in various power variants 

Special tool for in-line machining of the 

crankshaft bearing seats of the Tatra V12 engine 


processes 

Tatra trucks impress with their off-road performance, 

high reliability and outstanding utility properties 

including the index holes and all holes for attaching the oil 

basin. Technologist Dušan Kelnar adds: “We also rough machine 

the motor housing surfaces on the Heckert HEC 800 

and drill holes that cannot be machined on the line. Before 

we send the pre-machined housing to the transfer line, the 

motor housing is completely reworked, including the various 

covers, the pump seat, etc.” Dušan Kelnar points out that 

he and his colleagues have been familiar with the machine 

manufacturer Starrag and the Heckert centers since a long 

time: “We bought the first Heckert CWK 630 for machining 

gearbox housings 25 years ago.” In the following years 

Tatra invested regularly in further Heckert machines: two 

CWK 630s for machining axle housings, three CWK 500s 

for swing arms and wheel reduction housings and two 

CWK 500s for components in the Tatra Tactic series. By 2017 

three HEC 630 and two HEC 500 machining centers had replaced 

other old machines also. “That’s why we have extensive 

experience with Heckert machines”, emphasizes Kelnar. 

“These machines have proven themselves thanks to their 

design, reliability and long-term accuracy.” 

Production cell is expanded step by step 

The new Heckert HEC 800, which was delivered at the beginning 

of 2025, is the basis for the production cell that has now 

been put into operation. The machine has special equipment, 

including, for example, a travel path extended to 2,050 mm in 

the Z-axis, an NC-axis in the spindle for controlling special 

tools and a magazine for long tools up to 1,250 mm. 

Process manager Kappler explains: “The cell takes over the 

complete machining of our 8- and 12-cylinder motor housings 

and is replacing the transfer line increasingly.” The 

blanks are cast parts made of copper-alloyed GG20 cast iron 

with dimensions of around 1,200 x 600 x 700 mm and a weight 

of around 400 kg. Complete machining is carried out in four 

clamping processes with special hydraulic clamping devices 

developed and manufactured by Starrag. 

The Heckert HEC 800 machining center guarantees 

optimum results in the economical machining of large 

and heavy motor housings 

In a second step the production cell will be expanded soon 

to include an identical Heckert HEC 800 machine. And in a 

third expansion stage Starrag is integrating the eight-yearold 

Heckert HEC 800, which is currently still responsible for 

the external pre-machining of the cast blanks. 

A flexible pallet storage system, which consists of a shelf 

with twelve pallet spaces and a linear conveyor, automates 

the production cell. The latter handles the pallet transfer 

between the machines and the machine setup stations. The 

pallet storage system will also be further expanded as the 

number of machines grows. 

Enormous increase in space productivity 

Martin Kappler compares the two production systems: “Our 

transfer line had recently a capacity of around 1,600 units 

per year, which we are currently only utilizing half of. Our 

production cell will also reach this quantity in the final 

expansion stage in two-shift operation, which is important 

for us. Because we expect demand to grow strongly. We can 

cover any further increase in demand with a third shift if 

necessary.” 

His enthusiasm for the new production solution is primarily 

due to its high level of efficiency. There are several reasons 

for this, as Kappler emphasizes: “Thanks to the automation 

our new production cell can be operated by a single employee. 

Compared to the previous transfer line the operating costs 

are considerably lower, and the space requirement of the production 

cell is just over a quarter at 570 m².” 

Purchaser Libor Kalíšek, who initiated the purchase of the 

Heckert HEC 800, has since retired. His successor Tomáš 

Holčák also praises the cooperation with Starrag: “All offers 

and negotiations were at a high technical and commercial 

level. We greatly appreciate the fact that Starrag supplies us 

with turnkey machines, as a fully functional unit comprising 

machine, tools, fixtures, technologies, testing and handover. 

The technical support, service and maintenance are also 

excellent.” Based on the positive experience, further projects 

to modernize and rationalize production are already being 

planned. 

further information: www.starrag.com 


29

processes 

New standards in 

aerospace engineering 

In the field of aerospace engineering, precision and 

safety are paramount, especially for critical Class-A 

components like rotating engine parts. These highly 

sensitive components, whose failure could have sever 

consequences, demand not only exceptional process 

accuracy but also the highest levels of stability and 

traceability. With its state-of-the-art stream finishing 

technology, OTEC offers a groundbreaking solution 

to meet these challenges while significantly boosting 

productivity. 

Efficiency and safety through 

innovative technology 

OTEC’s finishing systems set new benchmarks by enabling 

seamless integration with production databases. This ensures 

that the systems always operate with precise, com ponentspecific 

process parameters. Manual errors are eliminated, 

and scrap rates are drastically reduced. 

Given that sensitive components like turbine disks can 

cost up to € 60,000, this level of process security is invaluable. 

The technology is further enhanced by comprehensive traceability 

at the serial number level, documenting every step of 

the process. 

The process stability of OTEC systems is guaranteed by intelligent 

media management, which monitors parameters 

such as rotational speeds, water and compound dosing. Unlike 

outdated machinery there is no need for constant adjustments 

to process times, as these remain stable. This makes 

the technology not only efficient but also low-maintenance. 

Unmatched capability for 

large component processing 

A key competitive advantage of OTEC is its ability to process 

large and heavy components in an automated and reproducible 

manner. The SF-HP system, specifically designed for 

such applications, is currently a global leader and enables 

integration into Industry 4.0 environments. 

This combination of technical innovation and industrial 

connectivity is unique and sets the standard for the next 

generation of manufacturing. For smaller components, the 

SF series also offers optimal solutions and can be integrated 

seamlessly into nearly any process. 

Success stories and market relevance 

The success of this pioneering technology is evident in nu mer - 

ous completed projects. For instance, a renowned German 

manufacturer replaced older systems with OTEC solutions, 

leading to significant process improvements. Approvals from 

major international OEMs further confirm the technological 

edge of OTEC systems. By the end of 2026 it is expected that 

Workpiece in SF-HP 

three of the world’s largest OEMs will adopt OTEC systems 

for engine applications. 

“Our technology has already been approved by leading 

aerospace companies. It not only ensures the highest quality 

but also reduces long-term costs by minimizing scrap”, said 

Adrian Kofler, Aerospace applications manager at OTEC. 

OTEC also offers the ability to develop customized solutions 

tailored to specific requirements, making it an ideal 

choice for companies with unique needs. These groundbreaking 

advancements in the aerospace industry clearly 

demonstrate that OTEC technology will play a vital role in 

increasing efficiency and reducing costs. With its innovative 

approach and focus on quality, OTEC will continue to be a 

leader in the industry. 

Future-proof solutions for a dynamic industry 

One of the biggest challenges in the industry is the ongoing 

decline in skilled labor qualified for manual processes. At 

the same time the market demands absolute process reliability 

and more efficient production methods. OTEC addresses 

this with an automated and process-stable alternative to outdated 

systems. The trend toward digitalization and the reduction 

of manual labor not only opens new opportunities 

for customers but also ensures long-term competitiveness. 

The development of cutting-edge turbine disk processes, 

created in close collaboration with an American OEM during 

the COVID-19 pandemic, underscores OTEC’s innovation 

and flexibility. Within just twelve months, a universal 

and validated process was established, which today serves 

as a benchmark. 

further information: www.otec.de 


Mazak unveiled first 

NEO INTEGREX Multi-Tasking machines 


Yamazaki Mazak unveiled at EMO 2025 its new 

j-series NEO range from its flagship INTEGREX 

range of Multi-Tasking machines to support customers 

shift to high mix/low volume manufacturing. 

The new INTEGREX j-200 NEO and the second spindle 

INTEGREX j-200S NEO models are built upon the ethos 

of the original multi-tasking j-series models first launched 

in 2010. Ideally suited for general subcontract work, as well 

as automotive, autosport, aerospace and medical industries, 

the models offer a productivity upgrade for turret lathe 

users looking to increase profitability by reducing set-up and 

lead times. 

Crucially the renewed specification for the NEO machines 

delivers a significant increase in productivity, machining 

accuracy and environmental performance compared to previous 

models. 

The INTEGREX j-200 NEO was among the range of 20 

machines that Mazak showcased at EMO 2025, where the 

firm was set to exhibit under the theme “Experience innovation, 

empower your future”, highlighting the benefits of a 

real partnership between machine manufacturer and user. 

A key highlight with the new INTEGREX j-200 NEO machines 

is the new, compact milling spindle which uses a builtin 

Mazak spindle motor to provide a considerable increase 

in both power (18.5 kW) and torque (59.7 Nm) to cope with 

a broad range of materials and applications. The compact 

nature of the new milling spindle, compared to the previous 

generation, reduces workpiece interference and increases 

the working envelope of the machine. 

The main turning spindle, fitted with an 8” chuck, features 

a powerful 18.5 kW, 326 Nm built-in motor, with an integrated 

cooling circuit in the headstock, to delivery high material 

removal rates whilst achieving stable machining accuracy. 

With a Ø 65 mm bar capacity and a Ø 480 mm maximum 

swing, the j-200 and j-200S NEO are the idea platforms for 

both automated bar work and robot-fed components. 

To facilitate the machining of more complex workpieces, 

the INTEGREX j-Series NEO machines now offer 0.0001 ° 

indexing resolution on the B-axis as standard. A larger 36- 

tool magazine – with an option of increasing to 72 – significantly 

reduces set up time between component runs, while 

offering three times the tool capacity of a turreted lathe with 

significantly lower tooling costs compared to driven-tool 

holders. 

The INTEGREX j-200S NEO is also available with a 15 kW 

second spindle offering up to 167 Nm of torque, which can 

The INTEGREX j-200 NEO was one 

of the highlights on the Mazak stand at EMO 2025 

help reduce set-up times for workpieces that require phase 

alignment. Both machines are available in 1000 U bed lengths 

while the tailstock variant is available in 500 U bed length. 

Continuous machining accuracy is enhanced through the 

addition of the Ai Thermal Shield function, which uses advanced 

algorithms to automatically determine compensation 

according to fluctuating temperatures, thus improving process 

stability for automated production. 

Improved environmental performance is a hallmark of the 

NEO series, and the INTEGREX j-200 NEO and j-200S NEO 

are no different. Both models have achieved 10 % energy 

saving through the use of inverter-driven hydraulic and 

chiller units, only running when required. A reduction in 

compressed air requirements has also helped lower energy 

consumption. 

The new machines are controlled by Mazak’s SmoothG 

control system. Housed within an ergonomic control panel 

with 19” touchscreen display, it combines MAZATROL conversational 

programming with G-code programming to offer 

operators the best of both worlds. Users are also able to 

program the machines via a 3D Model using the 3D Assist 

Function, a feature unique to Mazak. 

Both machines are compatible with MAZATROL DX, a new 

productivity software that provides users with the capability 

to remotely optimize their production process, and includes 

features such as the ability to generate rapid automated quotations, 

automated part programming, virtual machine simulation 

and machine process analysis and optimization. 

further information: www.mazak.com 


31


Success in China: 

Evermore counts on 

cylindrical grinding machines from STUDER 

Evermore has been manufacturing high-quality 

precision machine components in China for over two 

decades, for sectors such as automotive or medical 

technology. Thanks to precision cylindrical grinding 

machines from STUDER, the company has been able 

to significantly increase manufacturing efficiency and 

product quality. 

Wearing his work jacket with the dynamic Evermore logo, 

operations specialist Chen stands in a modern machine hall 

in the north of the Chinese metropolis Jiaxing and attentively 

watches the control panel of an S31 cylindrical grinding machine. 

Along with many other machines, it hums industriously 

in the meticulously organized hall with its green floor 

and yellow supply channels on the wall. “The STUDER machine 

works reliably and has a very high machining accuracy, 

the waste rate is low”, says Chen. The experienced expert has 

been working for the manufacturer of high-quality machine 

components for 18 years and is currently monitoring the production 

of Evermore’s C6 type tool holders. 

A few dozen meters away from the machine room, it suddenly 

becomes quiet. Polished workpieces gleam here, reminis 

cent of a museum: conical shapes made of high-alloy steel, 

tool holders and chucks for tools such as drills. It’s Evermore’s 

showroom, designed in the company’s light green colors, and 

two men stand in front of one of the parts, engaged in animated 

conversation. “Our customers appreciate the uncompromising 

quality of our products, both in terms of geometry 

and surface finish”, says one of them. It’s Barry Liao, the 

general manager of Evermore. Whether precision components 

for the automotive industry, computer electronics, hydraulics, 

medical technology or other areas of metal process- 

ing, the company has built an excellent reputation regionally 

and internationally over more than two decades. 

Success through trusting partnership 

This successful journey began in the year 2000 when Liao’s 

father founded the subsidiary company in Jiaxing. Initially 

focused on manufacturing precision machine accessories 

such as CNC chucks, tool systems and tool holders, Evermore 

steadily expanded its portfolio and invested in advanced manufacturing 

technologies and optimized production and 

man agement processes. During this time China as a whole 

has developed into a world-leading technology and industrial 

nation, and Evermore has been able to hold its own in this 

demanding competitive environment thanks to its high standards. 

“Our success is also inseparably linked to the close 

cooperation with STUDER”, says Liao. 

Standing next to him in the showroom is Wu Kui, sales 

manager & senior sales technology support from UNITED 

GRINDING China, who looks after STUDER customers in 

the country. He visits at least once a month, and the two men 

have known each other since many years and have developed 

a trusting relationship over the time. “With the extensive 

expertise of our specialists we were able to competently 

advise Evermore from the beginning on which machines and 

configurations are suited best for their individual products 

and production processes. I personally trained some employees 

here on STUDER machines”, Wu recalls. Thanks to 

this guidance it was possible, for example, to implement multiple 

grinding functions, the grinding of precise internal and 

external contours or non-round geometries and end faces in a 

single machine, which has significantly increased production 

efficiency. 

Mr. Chen, a senior operator of Studer grinding machines, has 

been working in Evermore since 18 years, his responsibilities 

include operating Studer grinding machines and 

maintaining the equipment 

C6 tool holder with PSC interface; 

these were machined with S131 and S31 



Universal 

cylindrical grinding machine STUDER KC33 

CNC universal internal cylindrical grinding machine 

STUDER S131 during grinding process 

S131, S31 and KC33: 

several STUDER machines in operation 

It is therefore not surprising that several cylindrical grinding 

machines from STUDER are in use at the modern production 

site of around 14,000 m 2 (150,700 ft 2 ) with 230 employees. 

And each of them plays an important role in the production 

process. Two S131 CNC universal internal cylindrical grinding 

machines have a permanent place in Evermore’s machine 

park. One of them makes high-precision internal bores in 

polygon shaft components, while the other grinds internal 

threads for miniature adjustment screws. The S131 is particularly 

compact and features high-quality grinding technology 

such as the innovative StuderGuide® guideway system, highprecision 

axis drives with linear motors, an extremely fast 

direct drive of the grinding spindle turret, or the automatic 

swiveling function of the workpiece table. 

He now walks with Wu Kui out of the showroom into the 

machine hall, where specialist Cheng is still monitoring today’s 

production. After the greeting and a brief status update, 

anecdotes are exchanged in a friendly atmosphere. It quickly 

becomes clear: success depends not only on the machines 

but also on the trusting cooperation of the people involved. 

“For us it is enormous important to support our customers as 

quickly and competently as possible. Anyone who purchases 

a STUDER machine also receives excellent customer care”, 

says Wu. The general manager nods in agreement and recalls 

a situation some time ago when a machine had to be urgently 

set up for a new customer order: “The technical team from 

STUDER gave extremely professional advice that significantly 

optimized our production process.” 

Meanwhile, the S31 cylindrical grinding machine is respon - 

sible for grinding precise external diameters of polygon shaft 

components. This model is ideal for small to medium-sized 

workpieces with a maximum weight of up to 150 kg (330 lbs) 

and can be adapted for different requirements thanks to its 

modular system. The swiveling wheelhead with a high-resolution 

B-axis of 0.00005 ° allows external, internal and face 

grinding in a single setup. And the stable machine bed made 

of solid Granitan® S103 reduces vibrations and thermal influences 

to a minimum for repeatable excellent surface quality. 

Finally, a KC33 reliably produces the external threads of 

the adjustment screws. This economical STUDER universal 

cylindrical grinding machine is manufactured in China and 

is appreciated for its versatility, precision and reliability. 

More efficient production and 

higher competitiveness 

“We chose STUDER machines because they enable precise 

machining with dependable process reliability. They produce 

virtually no scrap parts”, explains Evermore’s general 

manager. This, along with the reduction in processing times 

through fast setup and retooling, simple operation and automation 

options, has significantly reduced production costs. 

“And in addition to this, the quality of our products is at a 

higher level thanks to STUDER. All of this has significantly 

increased our competitiveness”, adds Liao. 

Innovation ensures continued success 

For the future Liao expects that this collaboration will become 

even more important. Many of his customers in industries 

such as automotive, electronics or medical sectors 

require increasingly precise components, often made from 

demanding materials, to meet the steadily increasing requirements 

for efficiency and accuracy. It is a great advantage 

that STUDER, a Swiss quality manufacturer with a tradition 

of over 111 years, is among the global innovation leaders in 

grinding technology and continuously works on new features 

that ensure the continued success of its customers. 

Mr. Liao leads his guest back to the showroom. Before saying 

goodbye, the two discuss future trends in the industry. “I 

think Artificial Intelligence will become even more important, 

for example for real-time adjustment of grinding parameters 

or for automatic generation of the optimal machining 

path”, says Liao. Wu nods and says: “That’s also interesting 

for our specialists in development.” Already today STUDER 

machines are characterized by high process adaptability 

thanks to digital processing and analysis technology, which 

enables rapid product line changes and strengthens core competitiveness. 

But whatever the future may bring: Evermore 

and STUDER will walk the path to success together. 

further information: www.studer.com 


33


Guhring UK opens up new markets with VOLLMER 

The English tool manufacturer Guhring UK has 

been using the VHybrid 260 grinding and eroding 

machine since almost a year. With the machine from 

the Biberach-based sharpening specialist, the English 

company has been able to reduce the machining times 

for carbide and PCD (polycrystalline diamond) tools 

by a factor of three to five. 

Thanks to the VOLLMER machine, Guhring UK has also 

opened up new market access in sectors such as electronics 

and medical technology. Various automation features enable 

Guhring UK to operate the VHybrid 260 unmanned and 

around the clock. 

Guhring UK in Birmingham is part of the international 

Gühring KG, which has its headquarters in Albstadt-Ebingen, 

Germany. With around 8,000 employees worldwide, the company 

is one of the leading manufacturers of rotating precision 

tools for metal cutting. The Gühring brand is internationally 

recognised for innovation, precision and flexibility 

in corpo rate management. The foundation being a management 

structure that grants the 48 global subsidiaries a high 

degree of autonomy. At Guhring UK, for example, this can be 

seen even in the company name: the subsidiary of Gühring 

KG is able to omit the umlaut dots, which are not typical in 

English. Flexibility and country-specific independence are 

also evident in production planning, which led Guhring UK 

to purchase a VHybrid 260 grinding and eroding machine 

from Biberach-based sharpening specialist VOLLMER in 

November 2024. 

“We sent some PCD step drills to our long-standing partner 

VOLLMER in the UK for test machining on a VHybrid 

260, followed by some ball nose cutters for one of our pres- 

Guhring UK has been using the VOLLMER VHybrid 260 

grinding and eroding machine since November 2024 

to grind and erode PCD tools in a single set-up 

With the Vollmer VHybrid 260 grinding and eroding machine, 

Guhring UK aims to herald the next generation 

of new PCD tools 

tigious customers – the results were exceptional”, says Alan 

Pearce, PCD supervisor at Guhring UK. “This ultimately 

led us to the decision to buy a VHybrid 260 for our plant in 

Birmingham.” 

At Guhring UK the VHybrid 260 is already the third machine 

from VOLLMER to make the 1,200 km journey from 

Biberach to Birmingham: the English company has been 

using two VOLLMER QWD 750 wire erosion machines for 

profiling and production tools with PCD cutting edges for 

some time now. With the VHybrid 260 Guhring UK is particularly 

keen to herald the next generation of new PCD tools. 

“We have discussed the future direction internally and 

agreed on what we need in order to move forward”, says 

Gary Field, production manager at Guhring UK. “We want to 

develop new product lines in order to be able to offer our 

customers a greater variety and a broader product range. 

With the new VHybrid 260 we want to concentrate on other 

sectors, focussing on micro drills for industries such as electronics 

and medical technology.” 

The VHybrid 260 features innovative and robust kinematics, 

enabling Guhring UK to grind or erode both carbide 

and PCD tools in a single clamping operation with 

100 % accuracy. The machine is based on multi-layer machining, 

which is implemented through two vertically configured 

spindles. The lower spindle can be used both for grinding 

and for eroding. Disc erosion in particular, for which 

Guhring UK did not previously have a machine, now enables 

the company to machine full-head PCD tools, tools with 

central PCD cutting edges and PCD tools with complex 

geometries. 

“The VHybrid 260 allows us to combine several operations 

in one machine, instead of grinding the tool diameter, 



eroding the PCD and then grinding the drill tips again in 

three operations”, adds Alan Pearce. “The effort required for 

various machine operations, production planning and adherence 

to lead times used to be enormous. The VHybrid 260 

has facilitated all of this and has already proved revolutionary 

for Guhring UK in the short time we have been using the 

machine.” 

For some of its OEM customers in the automotive industry 

who require customized PCD step drills, PCD milling 

or reaming tools, Guhring UK has already achieved significant 

benefits thanks to the VHybrid 260: the reconditioning 

of a PCD drill, which previously took 1 h and 25 min in a 

two-step process, was reduced to one 29 min operation. The 

production of a PCD step drill, which previously required 

precise grinding of the outside diameter, was reduced from 

three to two operations, with Guhring UK reducing the 

cycle time from more than 5 h to 1 h and 30 min. For another 

PCD step drill, the machining time was reduced from 

2 h and 25 min to just 30 min, and for another PCD step drill, 

which required center erosion and a step, the machining 

time was reduced from 3 h on two machines to just 36 min 

on one machine – not including the time for machine settings 

and changeover times, which were also eliminated by the 

VHybrid 260. 

Thanks to its steady rest system the VHybrid 260 is able 

to produce PCD tools from 0.2 to 150 mm in diameter. 

During erosive machining the machine achieves a surface 

quality with Ra values of 0.05 μm and can machine edge radii 

of 1.5 μm. Various automation features, such as the ability 

to change up to eight grinding and eroding wheels or the 

automated measurement and calibration of tools, enable 

Guhring UK to operate the VHybrid 260 unmanned around 

the clock. 

“With the VHybrid 260 Guhring UK has opened up additional 

options for mould production from which the entire 

Gühring KG can benefit”, says Martyn Cross, managing 

director of VOLLMER UK. “This also applies to automation, 

which centers on the HC 4 chain magazine. The HC 4 can 

hold up to 160 shank-type tools or up to 40 HSK-63 tools, 

and supports the automated loading and processing of 

carbide and PCD tools.” 

further information: www.vollmer-group.com 

Machining of difficult-to-cut and brittle materials 

Nidec’s OKK is renowned for its “highly rigid 

machining centers”. The grinding centers of the 

“GC series” are particularly well suited for machining 

difficult-to-cut and brittle materials. 

Since launching on the market 40 years ago, Nidec has continuously 

developed essential grinding machine mechanisms 

and functions, such as precise micro-movements, dust 

protection, sufficient coolant delivery and grinding wheel 

di ameter control. 

Are you struggling to achieve stable machining accuracy 

with difficult-to-machine or brittle materials such as ceramics 

and carbide? Would you like to combine multiple grinding 

processes – surfaces, bores, contours, threads, chamfers 

etc. – in a single operation? 

If so, you should consider the GC series. Nidec offers a 

diverse range that covers everything from small to large 

workpieces. 

GC series GC43RII 

The GC43RII model is part of the GC series and enables both 

grinding and cutting operations. It is a grinding center based 

on a machining center that can accommodate large workpiece 

dimensions. It comes standard with all the functions 

required for grinding operations and is equipped with extensive 

variation options and comprehensive software. 

Its rust- and dust-proof design increases durability, and it 

comes with a full cover to prevent grinding waste and coolant 

from escaping. Protective covers for each axis ensure comprehensive 

precision maintenance. 

further information: www.nidec.com 


35


Sales partnership and local WAAM production 

for spare parts up to 8 tons 

The company Begner Agenturer from 

Sweden is taking on the distri bu tion of 

GEFERTEC in the Scandinavian region 

and has invested in an arc80X. This 

marks the establishment of a new production 

facility in Falun for the additive 

manufacturing of spare parts and prototypes 

based on the WAAM process (Wire 

Arc Additive Manufacturing). 

Begner Agenturer, based in Sweden, is investing 

in a new production facility dedicated to 

the additive manufacturing of metal parts. At 

the heart of the site is an arc80X system from 

Berlin-based technology provider GEFERTEC, 

a pioneer in Wire Arc Additive Manufacturing 

(WAAM). Begner aims to produce spare 

parts and prototypes directly at its Falun location, 

reducing supply chain risks and 

strengthening supply security for regional 

industrial partners. The project is part of a 

regional initiative to enhance industrial infrastructure 

in central Sweden. 

In addition Begner is taking on the distribution 

of GEFERTEC technology in Scandinavia, 

positioning itself as a key point of contact for 

WAAM-based manufacturing solutions in the 

region. Interested companies have the opportunity 

to evaluate the options of WAAM-produced 

components directly on-site in Falun – 

a decisive advantage when considering an 

investment in the technology. 

Patrik Fredriksson, managing director of 

Begner Agenturer; Johannes Zuckschwerdt, 

managing director of GEFERTEC; and 

Sebastian Recke, senior key account manager 

at GEFERTEC (left to right) 

The Swedish company Begner Agenturer is relying on an arc80X from 

GEFERTEC to establish a high-performance application center at its site 

“As GEFERTEC’s distribution partner in Scandinavia we aim not only 

to make the technology accessible but also to build up trust”, says Patrik 

Fredriksson, managing director of Begner Agenturer. “With the arc80X installed 

locally, potential customers can experience the quality of the components 

firsthand through a joint manufacturing project – a crucial step be - 

fore investing in their own equipment.” 

Components up to eight tons 

The arc80X system installed by Begner is designed for large-scale metal 

components. In its three-axis configuration it can produce parts with edge 

lengths of up to 2 m and weights of up to 8 t. In the five-axis version, it can 

manufacture rotationally symmetrical components with diameters of about 

0.9 m and heights of 1.4 m, weighing approximately 500 kg. If required, 

the system can operate in a closed shielding gas atmosphere, enabling the 

processing of advanced materials such as titanium. An integrated process 

monitoring system captures all relevant data during production to ensure 

consistent reproducibility. 

Resource-efficient WAAM technology 

WAAM technology is based on arc welding with wire as the feedstock material, 

enabling the layer-by-layer production of metal parts directly from 

CAD data. Compared with conventional methods, such as milling or casting, 

WAAM produces significantly less material waste, increasing both 

resource efficiency and cost-effectiveness. With the commissioning of the 

arc80X Begner Agenturer is expanding its portfolio and positioning itself 

with sales and production as a regional expert of industrial manufacturing. 

For GEFERTEC the project marks another step in the international 

establishment of WAAM technology and the opening of new markets for 

the additive manufacturing of large-scale metal components. 

further information: www.gefertec.de 


Fast and economical machining 

of structural components 


Schwäbische Werkzeugmaschinen 

GmbH (SW) has launched a cost-efficient 

and dynamic solution for the machining 

of structural components: the new 

BF 12-21D. Optimized for the current 

automotive trend toward die-cast aluminum 

body parts, the machine is particularly 

suited for the large-scale production 

of vehicle body and chassis components. 

“Die-cast aluminum parts are being used more 

and more frequently in vehicle body construction”, 

explains Michael Kreuzberger, product 

manager at SW. “Manufacturing accuracy 

plays a less important role for such workpieces 

than for parts like gearbox or stator housings 

– but producing them economically 

is all the more important.” The BF 12-21D, 

which SW presented live for the first time at 

EMO 2025, is the company’s response to this 

trend: thanks to a new machine concept the 

BF 12-21D represents a more cost-efficient solution 

for applications with higher manufacturing 

tolerances. 

Speed meets economy 

The BF 12-21D is built on a new and distinct 

machine platform compared to other SW 

models. It features a hybrid drive system, in 

which the X- and Z-axes are driven by linear 

motors, while the Y-axis is driven by ball screws. 

The drives achieve a maximum dynamic 

speed of up to 120 m/min rapid traverse and 

Thanks to two spindles with independent 

three-axis units, the BF 12-21D is also 

suitable for production lines with 

high manufacturing volumes 

The cost-efficient and dynamic BF 12-21D is 

intended particularly for use in automotive structural components 

20 m/s² acceleration. The machine maintains the same high productivity as 

other SW systems: thanks to its two spindles with independent three-axis 

units, it easily meets the demands of production lines with high manufacturing 

volumes. “As a twin-spindle machine the BF 12-21D ultimately functions 

like two machines in one”, emphasizes Michael Kreuzberger. “In terms 

of performance it replaces two conventional single-spindle machines – but 

only requires one set of machine peripherals, i.e., only one control system, 

one control cabinet, one hydraulic unit, one cooling lubricant system 

and so on. It can thus achieve a significantly higher output with a smaller 

footprint.” 

Maximum productivity 

Both spindles have their own tool magazine and operate in separate working 

areas but can also work together in one working area. For example, 

during automated component changeover in one working area, the second 

spindle can provide support in the other area. The resulting possibility 

of quasi-parallel loading during main processing time further increases 

productivity. Standardized communication interfaces for automation and 

MES systems as well as an integrated tablet allow for easy status and remote 

monitoring of the system, thus maximizing machine availability. 

Trade fair feedback confirms demand 

The BF 12-21D is primarily intended for use in the automotive sector. The 

demand for such solutions proved evident at EMO 2025, where the machine 

made its first appearance: “The impressions we gained at the trade fair 

confirmed that the need for economical solutions is currently particularly 

high in the automotive market”, says Michael Kreuzberger. “We are meeting 

this demand with the BF 12-21D – without companies having to accept any 

loss in dynamics or productivity.” 

further information: www.sw-machines.com 


37


New life for old machinery 

These days, taking the political, environmental 

and, in particular, economic situation into consideration, 

side-stepping the move to energy-saving and 

resource-efficient production is simply no longer an 

option. Many companies have taken note of this and 

are already initiating change. Over 1,600 exhibitors 

from 45 countries came to EMO 2025 to present their 

innovative and environmentally friendly approaches. 

From green technology to the recycling economy, to ener gyflexible 

production processes and sustainable business models: 

“Sustainability in Production” is defining the future of this 

industry, while also strengthening its competitiveness. 

“We cannot ignore the transformation that is happening 

within this industry”, says Dr. Markus Heering, managing 

director of the VDW (German Machine Tool Builders’ 

Association) and organizer of EMO Hannover. 

Starting off small 

The transformation can start small, such as with existing 

machinery. Retrofitting, which not only involves fitting the 

machine with new mechanical components but also upgrading 

it with innovative control technology, rules out the need 

to purchase an expensive new model, while also extending 

the service life of the current machine considerably. This, in 

turn, conserves resource and reduces carbon emissions. 

Retrofitting: a topic with strategic relevance 

“When we speak of retrofitting we are talking about giving 

machine tools a second chance, one that will last just as 

long as the first”, esplains Ralf Glatzeder, head of Reman at 

Liebherr-Verzahntechnik in Kempten, Germany. At Liebherr 

“Reman” stands for “remanufacturing”, the complete reprocessing 

of a machine to the standard of a new one. This is 

also the goal of retrofitting, which involves upgrading a 

machine with new technology and components. The reprocessing 

of existing machinery was a topic being explored at 

EMO 2025. In addition to automation, artificial intelligence 

Kapp Niles also offers retrofitting solutions, 

providing customers with an economic and 

resource-saving opportunity to reuse their machinery 

Kapp Niles 

and digiti zation, sustainability is one of the three key topics 

under the spotlight at the world’s leading trade fair for production 

technology, with sustainable production now long 

considered a key competitive factor. 

Retrofitting pays off, in more ways than one 

Retrofitting is far more than simply the inexpensive alternative 

to a new purchase. Instead it represents a strategic 

investment, particularly in the sustainability of those companies 

from the machine tool industry currently under pressure 

from the economic climate and thus more cautious 

when it comes to investment. Instead of acquiring brand new 

machinery, key components such as CNC controls, drives, 

sensors or Industry 4.0-capable interfaces are updated. 

Precision, process stability and productivity are increased, 

while access is provided to digital services such as condition 

monitoring or networked production control. 

Retrofitting also pays off in terms of energy efficiency and 

sustainability: consumption values are drastically reduced 

through the replacement of old drives and motors, which in 

turn lowers both operating costs and carbon emissions. At 

the same time valuable resources are spared as the existing 

machinery remains in use and is not replaced by entirely new 

models. The machinery is also adapted to current safety standards 

and machine directives, not only meeting legal requirements 

but also improving employee safety standards. 

In economic terms retrofitting brings several benefits for 

companies. According to Glatzeder, depending on the situation, 

investment costs can be reduced by at least a third compared 

to a new acquisition, sometimes significantly more. 

There are far less downtimes due to the generally shorter 

retrofitting phase, while the payback period is noticeably curtailed. 

In a time of global supply chain issues and economic 

uncertainties, retrofitting also allows for greater planning 

security. 

Retrofitting thus combines enhanced technical performance 

with economic reason, along with environmental 

re spon sibility and a clear contribution to sustainability. It is 

a tool used by companies to improve their competitiveness 

even in difficult times and to set the course for a sustainable 

production. With this in mind, it is not hard to see why retrofitting 

was a key topic for quite a few visitors and exhibitors 

attending EMO. 

Liebherr-Verzahntechnik: 

used machinery as good as new 

This also applies to Liebherr-Verzahntechnik, manufacturer 

of machine tools and automation solutions for the cost-efficient 

production of gears. The major international appeal of 

EMO made this a key calendar event for the globally active 



company. Customers with older Liebherr-Verzahntechnik 

machinery have a number of options. Outdated machines 

still performing well can be generally overhauled or repaired. 

With a general overhaul, the reman experts clean, calibrate 

and rework all the basic components. All wear parts, seals, 

drives and motors are replaced and only the machine casting 

and housing remain unchanged, however are optically 

refined. Another option is to purchase reconditioned used 

machinery. “Whereby ‘used’ is technically quite misleading”, 

adds Glatzeder. “The machinery that leaves our factory from 

the reman program represents state-of-the-art manufacturer 

quality and comes with a new warranty. Remanufacturing 

carried out by Liebherr-Verzahntechnik always aims for the 

state-of-the-art and takes the latest innovative approaches 

into consideration. In this respect machinery averaging 20 to 

25 years of service is practically on par with the standard of 

new machinery following its reconditioning and renewal. 

Kapp Niles: retrofitting provides a second chance – 

more productive and sustainable 

For EMO exhibitor Kapp Niles from Coburg, provider of 

machine tools and solutions for the fine machining of gears 

and profiles, the modernization of several machine series 

is also part of the company’s portfolio. As every grinding 

machine is subject to operational wear, the aim is to avoid 

the failure of critical components and, in extreme cases, the 

standstill of the entire grinding machine. Kapp Niles offers 

two solutions here. The “KN Recontrol” involves a complete 

control upgrade, while the “KN Retrofit” also includes a full 

mechanical overhaul. 

“A Kapp Niles machine retrofit offers both an economic and 

resource-saving alternative to a new acquisition”, confirms 

Andreas Paatz, head of service/tools/digitization at Kapp 

Niles. At the same time the renewal of components ensures 

the availability of spare parts. “And”, he continues, “the machines 

are prepared for the collection of process and machine 

data to Industry 4.0 standards.” The crucial advantage of 

receiving upgraded machinery directly from Kapp Niles and 

not a third-party provider lies in the dovetailing of software 

and mechanical engineering. New developments are incorporated 

from current machine series, equipment and functions 

expanded, machine documentation updated, and downtimes 

kept to a minimum during the modernization process. 

Customers receive machinery that not only boasts stateof-the-art 

technology, but also long-term efficiency. “And 

the circular economy is supported through the extension of 

machine service life and component reuse”, adds Paatz. “This 

contributes to a sustainable economic approach that counts 

on recycling and resource conservation.” 

Waldrich Coburg has long championed retrofitting 

Waldrich Coburg has successfully championed retrofitting 

solutions since decades, which represent around 10 % of its 

revenue. “This approach is a key element of our service operations”, 

explains Dr. Tobias Abeln, CTO at Waldrich Coburg. 

The machines are already practically wear-free thanks to the 

hydrostatic guideways and predestined for a lifetime of several 

decades. In this respect it is the ideal basis for a further 

extension of service life. 

The biggest and most powerful portal machining center from 

Waldrich Coburg, often used for milling during power plant 

or turbine construction, before and after a retrofit 

Waldrich Coburg 

Through automation, control modernization and greater 

dynamic efficiency, the company is managing to increase 

the efficiency of its old machinery with retrofitting measures. 

It has also been successful in expanding functionality 

and flexibility through the implementation of new processing 

technologies such as turning, gear-cutting or HSC 

milling. Retrofitting has also contributed to quality improvements, 

improved operability and greater safety. At the same 

time energy- savings and lower maintenance requirements 

as well as shorter processing and downtimes are improving 

cost effi ciency. Retention of the location, foundation and core 

components has also reduced both investment costs and carbon 

footprint considerably. 

From the repair solution to the 

strategic success model 

Though the latest technologies and innovations may be the 

focus of EMO Hannover, retrofitting is also a key interest for 

many exhibitors and trade visitors. It has long represented 

more than simply the overhaul of existing facilities. It is a way 

to upgrade machinery to a technological level on par with 

new models – and involves considerably lower investment. As 

a result companies are strengthening their competitiveness 

without passing up the opportunity to benefit from state-ofthe-art 

technology. This and the environmental benefits it 

brings, are clear advantages for retrofitting. 

further information: www.emo-hannover.de 


39


World premiere as a crowd-puller 

EMO, the leading international trade fair for metal - 

working provided the ideal stage to showcase two 

MILLTURNs on display at WFL booth. The world premiere 

of the new M70 MILLTURN proved to be a real 

crowd-puller. 

The machine impresses with its high standards of productivity 

and precision and attracted great interest from visitors from 

Germany and abroad. “The response to the M70 MILLTURN 

was first-class”, emphasizes the WFL management by Stefan 

Hackl (CCO & CFO), Günther Mayr (CTO & CSO) and Franz 

Schön (COO). The trio adds: “Many visitors took the opportunity 

to experience the new product live and talk to our experts. 

This direct feedback is extremely valuable to us.” 

Another highlight was the storage tower. It illustrates how 

efficiently and space-savingly modern manufacturing solutions 

can be implemented. The interplay of machines, automation 

and intelligent storage was praised by many trade 

visitors as forward-looking. 

Spotlight on the M70 MILLTURN 

The M70 is a multifunctional turning, drilling and milling 

center of the latest generation. It combines the capabilities 

of a powerful lathe, a high-precision 5-axis machining center, 

and – depending on requirements – a gear cutting or deep 

drilling machine. What makes it special is that all machining 

steps can be performed in a single setup. This reduces 

non-productive time, increases accuracy and makes the M70 

a truly complete solution for complex components. 

The M70 is designed for very large and heavy workpieces. 

It can accommodate parts with a center distance of up to 

8000 mm, a maximum swing Ø 850 mm, and a work piece 

weight of up to 5.5 t. For comparison: 5.5 t is roughly equivalent 

to the weight of a full-grown elephant. This means that 

the machine covers an enormously wide range – from long 

shafts and solid housings to complex chuck parts. 

The main spindle delivers up to 5,860 Nm of torque and 

reaches speeds of up to 2,500 r/min. This torque is roughly 

equivalent to the combined power of around 20 modern car 

engines. The robust cast spindle housing, stable spindle bearing 

and backlash-free holding brake guarantee maximum 

rigid ity – even when machining difficult-to-cut materials 

such as Inconel or titanium. 

The milling unit delivers up to 58 kW, reaches 8,000 r/min, 

and has a maximum torque of 640 Nm. Particularly noteworthy 

is the interpolatable B-axis with a swivel range of 

220 ° and a holding torque of 15,000 Nm. This makes the M70 

suitable for long and heavy boring bars, which are held in a 

stable prism interface. The milling spindle is also equipped 

with an internal coolant supply of up to 200 bar, which guarantees 

excellent machining conditions even for deep drilling. 

Despite its dimensions, the M70 MILLTURN achieves max - 

imum precision. This is achieved on one hand by high-resolution 

direct measuring systems in all axes and a structurally 

optimized machine frame made of solid gray cast iron 

with integrated vibration damping. On the other hand it is 

achieved by intelligent measuring technologies: with integrated 

measuring probes, workpieces can be measured directly 

in the working area and deviations can be corrected 

automatically. In addition the iControl software ensures 

continuous cutting force monitoring, enabling maximum 

process reliability even in unmanned production. 

The M70 is fully digitally networked. CrashGuard protects 

the machine from collisions in real time. CrashGuard Studio 

also enables offline simulation directly from the NC program. 

Millturn PRO allows programs to be created graphically and 

interactively. And the myWFL cockpit provides customers 

with functions such as energy consumption analysis, condition 

monitoring and health checks. This makes the M70 fit 

for Industry 4.0 and future-proof manufacturing processes. 

In addition the MILLTURN is designed for continuous 

24/7 production. The WFL machine can be combined with 

robots, gantry loaders or complete manufacturing cells. WFL 

offers customized automation solutions – from workpiece 

handling and tool supply to automatic changing of chucks, 

tailstocks, or even prismatic tools. This bridges shift breaks, 

increases productivity, and significantly reduces unit costs. 

In summary, the M70 MILLTURN is particularly interesting 

for WFL customers due to its maximum flexibility 

in production. Whether small batch sizes or large series, 



simple turned parts or complex components such as crankshafts 

– the M70 covers everything in a single machine. It 

reduces changeovers, shortens throughput times and at the 

same time increases process reliability. For WFL customers 

this means higher productivity, lower costs and a sustainable 

investment in the future. 

Storage tower 

In addition to the M70 MILLTURN visitors had the opportunity 

to learn about the automation solution using a storage 

tower on the proven M20 MILLTURN. With the storage 

tower the raw material and finished parts disappear from the 

production area, resulting in a clean and tidy production hall. 

automation. Also a long-unmanned production phase can be 

provided with WFL. 

Despite the physical removal of the components, transparency 

is maintained through intelligent cell management, 

which cannot be achieved in the conventional way and in 

fact goes far beyond it: interfaces to PDA and customer ERP 

systems allow the inventory and order overview to be integrated 

not only into the cell itself, but also into the entire 

higher-level production planning. 

WFL automation cells can be equipped with numerous 

innovative features, so that their use is not limited to largescale 

production, but also allows small series up to individual 

parts to be produced economically, automatically and highly 

productively in unmanned shifts. 

The operator is supported by a user-friendly, intuitively 

designed user interface and a continuously available system 

status display. This enables precise range analysis in real 

time, taking into account all relevant influencing factors: the 

current stock of raw materials, the release status, the production 

orders, the availability of the necessary clamping devices 

and replacement parts and the remaining tool life. The 

system not only has software interfaces, but is also being 

combined increasingly with AGV connections, depending on 

customer requirements. 

further information: www.wfl.at 

The most versatile solution for flexible demands 

Makino presented the DA500, a 5-axis vertical 

machining center, at last year’s EMO trade exhibition 

in Hannover, Germany. The DA500 features both 

milling and turning with a high degree of reliability, 

the agility to improve production efficiency and a high 

level of autonomy thanks to the pallet magazine. That 

minimizes the number of set-ups, improves machining 

accuracy and saves time and costs. 

One of the DA500’s most significant advantages is its ability 

to combine reliable, high-precision milling and turning 

operations in a single machine. This eliminates the need for 

multiple set-ups and the risk of associated errors, as well as 

reducing cycle times, yet maintaining Makino’s well-known 

strengths regarding volumetric accuracy over long processing 

times. This makes the DA500 ideal for a wide spectrum 

of applications, including aerospace engine and semiconductor 

manufacturing. 

High accuracy and speed 

Following on from Makino’s successful DA300, the DA500 

has also been designed with a symmetric structure to 

minimize thermal influence on the machine and maximize 

rigidity. At the same time elements taken from Makino’s 

a1 series, like the slant column design, have reduced moving 

inertia and increased Z-axis rigidity. The ring-type tool magazine 

with CAM ATC also enables the fastest possible tool 

changes, while Makino’s own Two Vision technology reduces 

the risk of operator set-up errors through visual checks on 

the tool and workpiece. 0.05 μm scales, a direct-drive motor 

and Makino’s Super GI 6 control technology ensure the best 

possible pitch accuracy and repeatability. 

New spindle ideal for toughest work environments 

Work environments in the toughest production shops place 

immense demands on a spindle. For the DA500 Makino 

therefore designed a new 20,000 rpm spindle with 50 % more 

torque, twice the power and just a third of the accelerating 

time of the D500 spindle. Coupled with an axis speed 

similar to the DA300 (60,000 mm/min), the DA500 spindle 

performs extremely well when using fast milling techniques 

with constant chip thickness. As a result, parts can 

be produced in very short cutting times with minimal 

non-cutting periods. 

further information: www.makino.eu 


41

components 

Software-defined cars are already here: 

Are software-defined CNC machines 

now entering job shops? 

written by Dr. Yavuz Murtezaoglu 

founder and managing director of ModuleWorks 

This article takes us to the latest evolution in simulation, 

where we talk about a simulation running live 

inside the CNC control, enabling the machine to become 

fully automated. 

What is the best name for this type of simulation? Other 

industries use the term Digital Twin, which captures its 

essence well. As everything occurs in real time, I would like 

to call it a “Live Digital Twin”. 

The rise of Digital Twins 

The huge success of NVIDIA in driving artificial intelligence 

(AI) with their chips and software platforms has been a catalyst 

for Digital Twins which are now a familiar feature of 

our industry. The Digital Twin is a virtual copy of machines 

and factories that enables AI to find optimal manufacturing 

solutions without having to perform any actual machining. 

With the Digital Twin we can machine millions of scenarios 

virtually on the cloud and train the AI engine to find 

the best machining strategies for any given job. The results 

can help CNC operators, engineers and CAM programmers 

make quicker, smarter decisions that save time and costs on 

the shop floor. 

We have only just begun tapping into the potential of Digital 

Twins for training AI engines. It is an exciting prospect. The 

global Digital Twin market is expected to grow annually by 

36.9 % across all industries, reaching a value of USD 412.0 b 

by 2033 [1]. AI will play a central role along with cloud-based 

solutions. As the technology matures we can look forward 

to the developments it will bring to digital manufacturing. 

But even without training the AI, Digital Twins are already 

generating value of their own and it is this immediate value 

that I would like to focus on. 

Going to live with Digital Twins 

A real time Digital Twin, what I call a “Live Digital Twin 

(LiDiT)” would run in parallel with the CNC machine, and 

would even run one second ahead of the machining process. 

It knows every detail about the positions of the machine’s 

[1] https://www.globenewswire.com/news-release/ 

2024/11/11/2978494/0/en/Digital-T%20wins-Market- 

Is-Expected-To-Reach-a-Revenue-Of-USD-412-O- 

Bn-By-2033-At-%2036-9-CAGR-Dimension- 

Market-Research.html 

components at every millisecond. It knows which tool is 

being used, the in-process workpiece, the work holding, the 

material and the physical capabilities of the machine. With 

this knowledge the LiDiT can stop the machine before a 

collision occurs, as I described in my previous article. It also 

has access to cutting process data, such as the spindle current, 

and feed drive data from the sensors and interprets 

this along with the calculated machine positions to create a 

complete and exact reconstruction of the machining physics. 

The Live Digital Twin would perform all this in real time 

while the machine tool is running, making it a highly effective 

and constantly alert guardian that accurately moni tors 

the cutting process and detects any anomalies, such as tool 

breakage, excessive tool wear or unexpected high loads 

on the tool. It can then take active measures to protect the 

machine, for example adjusting the feed rate to bring cutting 

forces within the specified limits for the tool. Sometimes 

it will stop the machining process altogether when 

excessive forces cannot be corrected. Health monitoring extends 

to the spindle and feed drives, providing comprehensive 

coverage for safer, more efficient and more cost-effective 

machining. (see illustration 1) 

Its ability to monitor the physical cutting process in milliseconds 

with a one second look-ahead into the future is the 

essential basis for automation. Imagine a batch of produced 

parts that is unusable due to tool breakage, undetected chatter 

and other process related issues – a nightmare scenario for 

any machine shop. This is all too common in “high mix – low 

volume” environments, where many different parts are produced 

in small quantities, making it impractical and too 

time-consuming to set up and apply automated process moni - 

toring for each job. Instead operators need to monitor constantly 

the machining process which limits the shop’s ability 

to implement 24/7 production. 

With high-volume jobs that run for several days or weeks, 

setting up and running a monitoring system is somewhat 

easier, but the system still needs careful and accurate programming 

and configuration to ensure optimal operation. 

In either scenario the challenge facing the monitoring 

system is the same – to reliably detect anomalies while not 

raising any false alarms, that would unnecessarily stop a running 

production line. 


components 

The Live Digital Twin platform 

The Live Digital Twin offers the ideal platform 

for building such a system. To be truly 

effective, it requires two essential modules: 

→ A live geometry engine with exact 

geometric knowledge of the shape and 

position of all machine components. 

→ A live cutting physics engine to 

accurately calculate the forces, tool 

bending and other physical variables 

in the machining process. 

Together these two modules form the Live 

Digital Twin Platform that would allow different 

applications like collision avoidance, process 

monitoring, process optimization and 

a host of future modules to be integrated as 

plug-ins. 

Each plug-in would have access to the live 

data supplied by the geometry and cutting 

engines, paving the way for a wide range of 

powerful, new applications. As more modules 

are developed and integrated, the value and 

effectiveness of the LiDiT grows. 

Why do we call this a platform? Very simple: 

machine tool builders and cutting tool manufacturers 

are the machining experts. They 

know exactly which applications and modules 

they need and how the system should be 

configured and customized to run with their 

own solutions. The Live Digital Twin Platform 

would enable them to do this – it is designed 

to work with all major CNC control 

brands and machine tools and allow solution 

pro viders to develop and add their own applications 

as required. 

To achieve its full potential, the platform 

would have to be open, neutral and scalable: 

open – to handle seamlessly a wide variety 

of data formats from multiple sources 

neutral – to enable solution providers 

to develop innovative applications, and 

get them faster to market without 

bearing the cost of maintaining 

the underlying platform 

scalable – so that it grows naturally, 

allowing machine tool builders 

and CNC control makers to focus 

on delivering diverse solutions 

that drive real value for their end users 

illustration 1 

As an independent technology provider ModuleWorks is ideally placed to 

develop and maintain such a platform. Our experience with designing and 

stewarding MDES (Manufacturing Data Exchange Specification) means 

we understand the role of technology as an enabler that not only reduces 

development costs for everyone, but also fosters cooperation and brings the 

manufacturing industry closer together. The Live Digital Twin Platform 

is the next logical step in this direction – a platform where collaboration, 

efficiency and forward-thinking solutions can thrive, shaping the future 

of manufacturing. 

The future is coming 

Is this a dream, a vision or reality? We have been working on many individual 

parts of this solution and are looking forward to presenting the Live 

Digital Twin Platform to our partners soon. 

What about integrating and training the coming AI engines? As a platform 

designed to work with different modules, applications, machine tools and 

solutions, the LiDiT is ready to incorporate future innovations in AI, making 

it a springboard for developing truly automated and intelligent manu facturing 

systems. 

So, watch this space. Software-driven CNC machines may well be on the 

road sooner than you think! 

further information: www.moduleworks.com 


43

components 

Compact space marvel with many features 

Recently added to the SIEB & MEYER product 

range: the exceptionally compact SD4B, successor of 

SD2B plus. The device is designed for optimal operation 

of high-speed low-voltage synchronous and asynchronous 

motors but also suitable as high-dynamic 

servo drive for the operation of rotary and linear lowvoltage 

servo motors. 

This makes SD4B the ideal choice for micro machine tools 

required, for example, in the dental and jewelry industries. 

At the very first glance SD4B stands out for its IP20 housing 

with extremely compact dimensions: thanks to the small 

width of only 25 mm the device requires very little installation 

space. “This makes the device the ideal frequency 

converter for all applications employing a low-voltage 

high-frequency spindle”, explained Markus Finselberger, 

head of sales drive technology at SIEB & MEYER. “These 

spindles are often installed in very compact machines so that 

the available space in the switch cabinet for electronic components 

is limited.” Just as important is the low motor heating 

even at maximum power, which SD4B guarantees owing 

to a high-dynamic control and high switching frequencies. 

This is beneficial especially for the sensitive bearings of the 

spindles but also for the machining quality of the work pieces. 

Especially the jewelry and watchmaking industries but also 

the dental industry have highest requirements regarding the 

surface quality – SIEB & MEYER products like SD4B can fulfill 

these requirements perfectly. 

SD4B is particularly suitable for use in small CAD/CAM 

routing machines that are employed, for example, in small 

machining centers for engraving, milling or grinding works 

e.g. for the watchmaking industry. “Dental milling machines, 

for example, are very compact so that dentists can 

accommodate them on site in their practices without difficulty. 

There are models not much larger than a breadmaker”, 

explained Markus Finselberger. “For this reason the technology 

required for the spindle, namely the control and drive 

elec tronics, must not take up much space.” 

High clock frequencies open up advantages 

Thanks to high clock frequencies of up to 32 kHz, SD4B 

allows sensorless operation of synchronous motors up to 

240,000 rpm and asynchronous motors up to 360,000 rpm. 

The commutation frequency of up to 64 kHz enables an even 

more precise control. 

Besides, the high clock frequencies further reduce the need 

for external filter modules (motor chokes or sine-wave filters). 

In addition to sensorless operation the frequency converter 

SD4B allows a sensor-based operation in the highspeed 

range, e.g. for motors with superimposed synchronization 

function. Therefore the device can operate several highspeed 

motors with angular synchronism via master/slave 

connection, which is useful, for example, in the field of optical 

system applications. The robust speed control can also 

cope with high mass inertia ratios between motor and tool. 

More operator safety 

Since safety technology is playing an increasingly important 

role even for the operation of very small machines, SD4B provides 

the safety function STO (Safe Torque Off) as standard. 

STO ensures that the motor torque is switched off and a restart 

is prevented. “This way the machine manufacturer can 

implement the increasing demands towards machine safety 

at low costs”, Markus Finselberger pointed out. “We are following 

the development towards more operating safety of 

machines in many industry sectors. Therefore, we have integrated 

important safety functions into our devices.” 

In the field of dental CAD/CAM routing machines, 

SD4B ensures optimal operation of 

low-voltage manufacturing spindles 

Fotolia: © zlikovec-fotolia.com 

At a glance: 

The frequency converters of the device generation SD4x 

SIEB & MEYER specializes in frequency converters for 

high-speed applications as well as servo drives for 

high-dynamic motion axes. Based on the new development 

platform SD4x, the Lueneburg based company introduces 

the new, future-proof product series SD4S, SD4B and SD4M. 

The devices support modern interfaces and offer a number 

of additional functions. Users will benefit from higher speeds 

and from a significantly enhanced performance. Besides, 

SIEB & MEYER uses the available processor performance for 

new control functions. As a result the devices operate 

optimally synchronous motors with magnets embedded in the 

rotor, so-called interior permanent magnet motors (IPM). 

The reluctance torque generated by these motors is optimized 

in real-time depending on the operating point. 


components 

The classic application for SD4B is in machine tools for 

micro processing, for example in the watchmaking industry. 

Fotolia: © NorGal-fotolia.com 

Dental milling machines are very compact – 

the SD4B does not require much installation space 

As all other devices by SIEB & MEYER AG, the SD4B features 

the integrated load indicator for highly precise evaluation 

of the torque-forming current. This function can be 

used e.g. for tool monitoring regarding tool breakage, tool 

wear, gap eliminator (GAP and crash) or for an optimal control 

of the feed rate during the manufacturing process. With 

the load indicator, customers benefit from lower system costs 

by saving on expensive monitoring sensors, for example 

acoustic emission sensors. 

In addition SD4B comes with an internal logic supply, 

which makes an external 24 VDC supply redundant and 

therefore reduces the wiring work. Especially for multi-axis 

applications, the DC voltage supply allows using one central 

power supply unit so that customers can realize the complete 

system at lower costs. 

Communication via numerous interfaces 

Parameterizing the device is also very simple: by means of 

the software drivemaster4 the user can easily create parameter 

sets for synchronous and asynchronous motors via basic 

data taken from the motor data sheet. “For the device series 

SD4x we decided on a standard ethernet interface for the parameterization”, 

said Markus Finselberger. “Ethernet is the 

industry standard and especially in high-frequency applications 

less interference-prone than a USB interface.” 

Standardized fieldbus interfaces are available for the communication 

with the higher-ranking control. The SD4B 

supports the communication protocols CAN, CANopen, 

Modbus RTU and Modbus TCP by standard. The communication 

via EtherCAT, PROFINET or POWERLINK is optionally 

available. This is a significant advantage compared to the 

predecessor SD2B plus. Beside a TTL interface, the device 

provides five digital inputs, five digital outputs and the option 

of evaluating hall sensors. A switching power supply can 

be used to supply the device. The SD4B comes with a wide 

range power input between 24 V and 80 V that permits optimal 

adjustment to the specific rated voltage of the motor. In 

many cases, suitable DC voltages are available in the machine 

(e.g. 24 V, 48 V), which makes integrating the drive amplifier 

very easy and cost-efficient. 

SD4B is particularly suitable for use in 

small CAD/CAM routing machines 

SD4B is also used, for example, in the optical industry 

for the operation of synchronized polygon scanners, 

Flexible adaptation and ready to use 

In conclusion the SD4B is a problem solver when installation 

space must be saved in small machine tools with output powers 

up to 1 kW and highest performance in combination 

with state-of-the-art features is desired. Generally the series 

devices by SIEB & MEYER serve as a basic concept for 

customized developments. “Last but not least, it should be 

mentioned that the SD4B housing is identically constructed 

to the predecessor model SD2B plus”, concluded Markus 

Finselberger. “Therefore customers can switch to the new 

device series without any problems.” With the NRTL/CSA 

certification users can integrate the devices into systems for 

the US market without additional approvals. 

further information: www.sieb-meyer.com 


45

components 

Arburg has got the hang of it 

More occupational safety and greater efficiency 

when handling tools weighing several tons: this is now 

the current situation at Arburg. The leading machine 

manufacturer for plastics processing is using the RUD 

Tecdos TM Tool Mover at its headquarters in Lossburg 

(Baden-Württemberg) and now moves tools safely and 

efficiently. 

The RUD Tool Mover turns and rotates tools in seconds with 

the touch of a button. The Tool Mover has the Arburg employees 

ecstatic because it optimizes work safety and ergonomics 

on the floor. 

Arburg offers trials and tool tests together for its customers 

in its 2,100 m 2 customer center at its Lossburg headoffice. It 

has more than 30 allrounder injection moulding machines, 

3D printers for additive manufacturing and laboratories for 

special processes. This facility benefits customers to test tools 

and machines and optimize processes in a practical and professional 

environment. The added benefit for the Arburg 

team is that the RUD Tool Mover looks aesthetically pleasing 

on the turnkey floor. 

In under a minute: turning tools 90 ° 

“When tools arrive at our premises they are usually ‘inverted’ 

so that they must be turned 90 ° for testing. This is now done 

by the RUD Tecdos TM Tool Mover”, explains Roland Gruber, 

group manager application programming & commissioning 

in the Automation & Turnkey department at Arburg. The injection 

moulding machine manufacturer also uses the tool 

mover during the commissioning of turnkey projects, i.e., 

when a customer uses a machine and mould before delivery. 

Arburg uses the RUD Tecdos TM 13/13-10, which rotates 

moulds weighing up to 10 t safely and efficiently. 

Tools up to 1.20 m in size and weighing between 200 kg and 

10 t arrive in Lossburg. The company used a crane for the 90 ° 

turning of the tools. “With the crane the entire turning process 

could take 30 to 45 min; now we have a net turning time 

of around 45 s”, emphasizes Gruber. 

Work safety and flexibility 

However, saving time was not the main factor in Arburg’s decision 

to opt for the RUD Tecdos TM. “Our focus was clearly 

on increasing work safety and ergonomics for our team”, says 

Gruber, who sees the time savings as a nice side effect. The 

tool mover enables BGV-compliance and safe working without 

the risk of injury, for example from diagonal movements. 

For the teams in the customer center and in commissioning, 

the handling process has changed fundamentally: 

Previously employees used to drive the tool to the crane and 

to the attachment points. Now the employees can bring the 

Tool Mover to the tool. The RUD Tecdos TM can be moved 

with an industrial truck, such as a forklift or pallet truck, and 

can be transported easily between the various halls at Arburg 

to the desired location. 

Ergonomics for employees 

In addition to increased work safety the RUD Tecdos TM also 

ensures ergonomics for the team. The customer tools that 

arrive at Arburg are lifted onto the tool turner by crane and 

then rotated by the employees with the touch of a button 

while standing. For the RUD Tecdos TM, which Arburg also 

uses in its customer center, the engineers at RUD have come 

up with a special system: they have lowered the work surface 

to a height of 595 mm. Thanks to the low working height it is 

possible to work directly on the tool if required. 

Gentle on the tool 

The RUD Tecdos TM not only makes work safe for people, 

but also for the tools. The tool turner is designed for axial 

rotational movements of tools and machine components up 

to 64 t (in the largest version). The load is smoothly turned at 

the center of gravity. The RUD Tecdos TM ensures particularly 

smooth starting and stopping and is equipped with a 

high-end drive system from the Tecdos range. 

Individual adaptations 

Depending on requirements and customer wishes, RUD 

equips its tool mover with different table supports made of 

polyethylene; anti-slip polyurethane supports, and custom 

supports are optional. Optional add-on parts such as safety 

bars or guard rails as well as light curtains or safety barriers 

ensure higher safety. The Tecdos TM for Arburg is equipped 

with polyethylene table supports – as increased protection 

for the customer’s tools. Another special feature: RUD has 

branded the tool mover in the Arburg color (dark grey). 

Arburg has also made a special adaptation for the pallet truck 

on the tool mover. “This adaptation was made in consultation 

with us, we calculated everything necessary, for example 

the load capacity. Although we manufacture our mould handling 

products in a standard version, we are open to customizations 

as required”, says Tobias Rathgeb, area sales manager 

for mould handling at RUD. 

further information: www.rud.com 


CAM Assist now used by 

over 1,000 machine shops globally 

to accelerate CNC programming with AI 

components 

CloudNC announced that its CAM Assist solution 

is now used by over 1,000 machine shops and machinists 

worldwide, who use the solution’s AI to accelerate 

the programming of CNC machines, making them 

more efficient. 

CloudNC is now launching CAM Assist 2.0, a major upgrade 

to its AI solution, that accelerates the CAM programming 

journey from CAD model to machine-ready toolpaths, while 

giving users more control over each step. 

CAM Assist 2.0, from now on available, is a substantial 

enhancement to the existing software. It retains the speed of 

CAM Assist, while adding the oversight, feedback and shared 

intelligence elements that machine shops need in order to use 

AI with confidence. 

Programmers using CAM Assist can now stay firmly in 

control of every critical decision while still saving hours as 

they turn CAD models into reliable toolpaths. 

Dr. Andy Cheadle, CTO at CloudNC, said: “CAM Assist is 

being adopted globally by tech-enabled machine shops who 

believe in the power of AI to transform their operations. The 

new 2.0 upgrade shows that AI and human expertise can 

work side by side, improving a machinist’s productivity even 

further. By letting users see and ultimately influence the 

AI’s decisions as they happen, we’re helping shops program 

faster and with higher confidence, resulting in an even more 

useful solution that machinists and programmers can trust 

implicitly.” 

Anthony Stephenson, prototype machinist at Avalanche 

Energy and a CAM Assist user, said: “CAM Assist automates 

the most time-consuming programming work in just a few 

clicks, giving us more time to focus on the fine details. The 

new CAM Assist 2.0 takes this even further: the interface is 

clean and intuitive, making the entire process feel seamless. 

The improved workflow makes programming easier and 

faster, helping us get more parts out of the door.” 

CAM Assist 2.0 is a web-based CAM automation application 

that initiates from the user’s CAM package. 3-axis and 

3+2 operations are supported. 

In the new web UI the user still generates a working toolpath 

by pressing the CAM Assist button. Now CAM Assist 

2.0 breaks out the AI stages so that parts can be assessed 

prior to running. Moreover, as files are being computed, control 

over strategy editing is passed to the user. 

What’s new and better in CAM Assist 2.0: 

→ one-click configuration – 

intelligent defaults and a configuration workflow 

let machinists start programming in minutes 

→ AI guidance at every step – 

context-aware recommendations – shaped by 

part geometry, machine constraints and tools and 

fixtures – appear precisely when choosing strategies, 

tool assemblies or feeds and speeds, 

increasing feedback 

→ human-in-the-loop oversight – 

before any toolpath is committed to a CAM system, 

CAM Assist enables review, letting users inspect, 

adjust and edit each strategy operation so 

shop standards are never compromised 

→ seamless hand-off – 

once approved, the strategies are pushed directly 

back into the user’s preferred CAM package, 

ready for code generation and verification; 

CAM Assist 2.0 also makes machine, material and 

tool assembly management easy, as it is tailored 

to the user’s shop environment and 

configures itself to the customer 

With cloud-storage of these elements CAM Assist can run 

faster, utilize more extensive tool libraries and parameters 

and serve as a common source between CAM programmers. 

This helps standardize output and achieve consistent results 

across a machine shop’s output. 

CloudNC will make CAM Assist 2.0 available to all 

customers across Autodesk Fusion, Mastercam and Siemens 

NX platforms. We expect to announce further integrations 

soon. 

further information: www.cloudnc.com 


47

components 

Keeping tolerances under control 

to optimize your processes 

The modular AGM compensation unit from 

SCHUNK effectively corrects for tolerances in robot-as - 

sisted automated processes – setting new benchmarks 

in automation. This product family offers maximum 

flexibility and reliability for a wide range of applications. 

It is part of the new Robot PLUS portfolio. 

Wherever inaccuracies or tolerances in robot-assisted manufacturing 

process, SCHUNK’s AGM compensation unit truly 

comes into its own. Thanks to its modular design and 

patent ed technologies the AGM handles a wide payload 

range – from just a few grams to 400 kg. The extensive portfolio 

includes over 50 variants for compensation in all directions 

(XY, Z, W, XYZ und WZ), and is tailored perfectly to 

meet the demands of modern manufacturing. With this wide 

variety of options, users are sure to find the right unit for 

every application. 

AGM-XYZ: for reliable and precise machine loading 

During loading and unloading of machine tools, tolerances 

can cause interference between the workpiece and gripper, 

disrupting processes and leading to errors. The AGM-XYZ 

variant compensates for these inaccuracies, thereby enhancing 

process stability. 

Its compensation behavior in the X-, Y-, and Z-directions 

enables precise positioning of components. This reduces interruptions 

and ensures smooth operation. Optionally available, 

patented, manually adjustable spring cartridges keep the 

compensation unit centered. Depending on the size, different 

force ranges are possible, allowing best adjustment of weight 

compensation. Additionally optional sensors can detect the 

locking and unlocking of the AGM without adding interfering 

contours, thereby simplifying process monitoring. 

AGM-XY: optimized joining processes 

deliver reliable quality 

In automated joining processes, positioning or component 

tolerances pose significant challenges that can lead to scrap, 

rework or downtime. Since a wide range of compo nents 

is handled – from delicate electronic boards to large engine 

blocks – a flexible and precise solution is required. The 

AGM-XY variant reliably compensates inaccuracies and offsets 

in the X- and Y-axes, thereby simplifying the joining process. 

Thanks to the manually adjustable stroke the compensation 

path can be flexibly adjusted. The smoothly running 

guidance concept is ideally suited for the handling of delicate 

or fragile components. Additionally the stroke limitation 

allows for adjustment of shorter strokes, enabling the execution 

of challenging joining processes. Its compact design also 

ensures suitability for space-constrained applications. 

During machine loading and unloading, the AGM 

ensures precise positioning through compensation in the 

X-, Y-, and Z-directions, reduces interruptions 

and increases process stability 

AGM-W: boosting efficiency in bin picking 

In bin picking the major challenge is the undefined position 

of the components: their geometry must be detected and 

gripped securely while removed without collision. During 

removal the position of the parts can constantly change, 

causing misgrips and delays. 

Here the AGM-W is compensating angularly, and the 

gripper can safely pick up components arranged in different 

positions without mutual jamming. The compensation force 

of the angle can be precisely adjusted via compressed air, 

allowing accurate compensation even in tilted orientation. 

Here optional sensors also facilitate process monitoring. 

In addition the pneumatic locking and unlocking enables 

highly dynamic processes with fast travel paths. This allows 

efficient, damage-free separation and complete emptying of 

the bin, even with fragile components. The AGM-W thus 

increases productivity and reduces downtime in automated 

storage and logistics processes. 

Designed for customer requirements 

SCHUNK offers a broad portfolio of compensation units 

that can be individually adjusted to various industry requirements 

and applications. The versatile solutions impress with 

flexible applications and ensure efficiency, reliability and precision 

in automation. For specific requirements an experienced 

SCHUNK engineering team is available to work with 

customers to develop tailored solutions. 

further information: www.schunk.com 


Making reverse engineering routine 

with seamless scan-to-CAD workflows 

components 

For the first time at EMO 2025, 

Hexagon showcased how Geomagic 

Design X empowers engineers to modernize, 

improve and replicate parts with 

less effort and higher confidence. 

Hexagon’s Manufacturing Intelligence division 

demonstrated the market-leading capabil 

ities of its new reverse engineering workflows 

utilizing Geomagic Design-X in combination 

with a wide range of 3D scanning 

technologies. 

Successful scan-based reverse engineering 

of mechanical components makes it easier to 

modernize, improve or replicate parts, minimizing 

the costly errors that often occur with 

man ual feature measurements and outdated 

designs. Despite its potential the process is 

often considered too time-consuming, requiring 

spe cialist CAD and scanning expertise to 

translate incomplete scans into usable CAD 

models. 

“Reverse engineering even a single mechanical 

component is often a laborious process that 

might involve several people, un reliable results 

and manual repair”, said Johannes Mann, senior 

director Industry Solutions at Hexagon’s 

Manufacturing Intelligence division. “With 

Geomagic Design X and today’s accessible 3D 

scanning equipment, it’s now feasible to reverse 

engineer directly back into CAD with 

a productive workflow that engineers and 

manufacturing teams can adopt easily.” 

→ capture and convert with confidence: 

Geomagic Design X provides the fastest 

path from 3D scan to fully editable 

parametric CAD models, combining direct 

scanner control with automated tools 

such as Region Segmentation, Modelling 

Wizards and Auto Sketch. Engineers can 

create reliably accurate, editable models 

from as-built parts or prototypes with 

full CAD history and parameterization. 

Today’s products have complex shapes 

that are hard to recreate, here the software 

excels enabling the user to quickly process 

freeform shapes, surfaces to create usable 

NURBS and parametric CAD. 

→ seamless CAD integration removes barriers to adoption: 

LiveTransfer technology enables manufacturers to move complete 

parametric models directly into leading CAD platforms including 

SOLIDWORKS®, Siemens NX®, Autodesk Inventor® and PTC Creo®. 

This streamlined workflow reduces complexity, accelerates design cycles 

and makes up-to-date models available for downstream use in 

assemblies, drawings, simulation and manufacturing. 

→ accuracy that reduces costs and risks: 

Automated Accuracy Analyzer TM tools enable precise verification of 

deviations between constructed surfaces and 3D scan data at every 

stage of the workflow to ensure that the final CAD models are perfectly 

aligned with scan data. This reduces the risk of rework, tooling 

iterations and fit issues. Its advanced mesh and point cloud processing 

make it possible to reverse engineer even complex organic shapes 

and customized designs, that traditional methods miss. 

Known for enabling high-precision industries to deliver quality at speed, 

Hexagon is enhancing support for scanners such as its award-winning 

SmartScan VR800 structured light scanner within Geomagic Design X, 

which was on show at EMO. This lets a single user scan large parts while 

zooming into critical details such as radii and drill holes in a single pass. 

The software’s advanced mesh handling and “Exact Surface” creation tool 

ensure that even intricate geometries are converted with high precision, 

giving manufacturers the flexibility to create parts that integrate seamlessly 

with existing systems or meet specific ergonomic needs. 

“By using purpose built, scanner-agnostic software like Geomagic Design X, 

manufacturers can save time at every step of reverse engineering process”, 

concluded Mr. Mann. “It flips the narrative from a challenging – but essential 

– labor into an accessible, routine capability that compliments CADnative 

design and empowers teams to work with confidence.” 

further information: www.hexagon.com 


49

components 

Precision, load capacity and 

efficiency for tomorrow’s machine tool 

When the international machine tool industry met 

at EMO, HIWIN showcased solutions that are specifically 

tailored to the current requirements of machine 

builders, integrators and users. 

In transition: 

increasing demands on drive technology 

The machine tool industry is facing growing challenges: 

shorter cycle times, increasing accuracy requirements, higher 

energy efficiency and increasing automation are just some 

of the factors that need to be taken into account. For drive 

components, this means that they must be more powerful, 

more compact and more durable without compromising on 

precision and reliability. This is exactly where HIWIN’s components, 

including ball and roller guides, ballscrews, power 

transmission and linear motors, come into play. 

Premiere at EMO: 

upgrade of the proven roller guide 

The new roller guide was the highlight of the HIWIN presentation 

at EMO. The new guide sets new standards in load 

capacity, rigidity and durability. It is ideal for machine tools 

that operate under extreme loads and must guarantee maximum 

precision over long operating times. 

Small, precise, powerful: the miniature ballscrew 

The new miniature ballscrew was also on display at the booth. 

This compact solution offers maximum accurate positioning 

with minimal installation space, opening up new possibilities 

for applications in precision engineering, medical technology, 

and special-purpose machine construction. 

further information: www.hiwin.de 

A smart vision system for fast, intuitive measurement 

Mitutoyo, global leader in precision measurement 

solutions, announces the launch of QM-Fit, a compact, 

high-performance manual vision measuring machine 

designed for quick, accurate inspection of small and 

thin components. QM-Fit redefines ease of use with a 

smart, touch-based interface and works as a next-generation 

alternative to traditional profile projectors. 

No training needed; with 

its intuitive touch-screen 

interface, QM-Fit makes 

precision measurement 

accessible to everyone 

A smarter way to measure 

QM-Fit is built to make precision measurement accessible 

to everyone – regardless of skill level. With its intuitive User 

Interface, touch panel operation and advanced automatic 

part recognition, users can initiate measurement instantly. 

Key advantages & efficiency highlights 

■ Instant measurement with automatic recognition 

QM-Fit offers instant measurement with automatic recognition, 

allowing users to simply place the part on the stage. The 

system identifies the workpiece, detects circles, lines and 

other elements without the need for setup, alignment or 

manual focusing, and begins measurement right away. 

■ Intuitive operation – no skills required 

Its intuitive touchscreen interface ensures that no special 

skills are required to operate the system. Visual guides and 

auto-suggestions minimize training time and reduce user 

errors, while results are displayed graphically in real time 

with clear pass/fail indicators. 

■ Graphically supported caliper snap 

The graphically supported caliper snap, which enables fast 

and precise measurement by snapping digital rulers to part 

edges or geometries, eliminates the time-consuming 

crosshair alignment used in traditional projectors. 

■ Higher throughput, lower costs 

QM-Fit also improves productivity and reduces costs by 

delivering repeatable results, cutting down on variation and 

rework. Automatic detection and digital zoom shorten cycle 

times, helping to remove bottlenecks in quality control and 

first-article inspection processes. 

■ Compact, space-saving design, powerful optics & 

high-resolution imaging 

With its compact, space-saving design (366 × 407 × 621 mm 

and 25 kg), QM-Fit fits easily on any workbench and operates 

as a true stand-alone unit, complete with integrated PC and 

15.6-inch touch monitor. Its powerful 20MP CMOS color 

camera, digital zoom up to 100x, telecentric lens and 36 mm 

depth of field provide high-resolution imaging and 

accurate focus even on uneven parts. 

further information: www.mitutoyo.eu 


impressum 

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copyright © 2026 Dr. Harnisch Publications 

company finder 

CemeCon AG .......................22 Mitutoyo Corporation ................50 

CloudNC ...........................47 ModuleWorks GmbH ............... 42 

EMO 2025 ..........................38 

EMVA 

European Machine Vision Association. 14 

NIDEC CORPORATION ............35 

OTEC Präzisionsfinish GmbH ........30 

RUD Ketten Rieger & Dietz 

Fritz Studer AG .....................32 GmbH u. Co. KG .................. 46 

GEFERTEC GmbH ..................36 SCHUNK SE & Co. KG ............. 48 

GrindingHub Americas ..............18 Schwäbische Werkzeugmaschinen 

Gühring KG .........................9 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ........... 12, 14, 15 

Heule Werkzeug AG .................21 

Hexagon AB ........................49 

GmbH ............................37 

SEW-EURODRIVE GmbH & Co KG ...16 

SIEB & MEYER AG ................. 44 

StarragTornos Group AG .............28 

Sunnen Products Company ...........26 

HIWIN Corporation. ................50 TMTS ........................... 9, 20 

Lach Diamant Jakob Lach 

GmbH & Co. KG ....................6 

LMT Tools GmbH & Co. KG ..........13 

MAKINO Europe GmbH .............41 

MAPAL Dr. Kress SE & CO. KG ... 10, 24 

UCIMU-SISTEMI PER PRODURRE ...19 

VOLLMER WERKE Maschinenfabrik 

GmbH .........................17, 34 

Walter Surface Technologies ..........16 

WFL Millturn Technologies 

MAZAK CORPORATION ...........31 

GmbH & Co. KG .................. 40 

advertising index 

FILTECH ..............................................................page 11 

Lach Diamant Jakob Lach GmbH & Co. KG ..................................cover 


51

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