Commercial Micro Manufacturing - Latest News

SENSOR+TEST 2012 - Focal Topic "Electromobility"

Wed, 01 Feb 2012 00:00:00 GMT

Today's spotlight is focused more on electric mobility than any other technology. The advances here are huge and - especially in the present phase - the contribution made by sensors, measuring, and testing systems towards the fast development of fully operational, successful, and reliable products is crucial.

This is why the Exhibition Committee and the Executive Board of the AMA Association for Sensor Technology have decided to make "Electromobility" the focal topic at the SENSOR+TEST 2012.

The exhibitors at this year's SENSOR+TEST will present their latest developments for electric mobility. Moreover, they will do this not only at their own stands, but also as part of the well-proven action program in which the focal topic "Electromobility" will be dealt with in talks and demonstrations of electric-mobility equipment in operation.

This is also an opportunity for enterprises and institutes to participate economically at the "Special Forum Electromobility." Information on the low-cost all-inclusive exhibition package can be found on the SENSOR+TEST website at http://www.sensor-test.com/direct/special-forum.

Sensors Tech Forum 2011 Changed Engineering Event Landscape

Wed, 25 Jan 2012 00:00:00 GMT

The inaugural SENSORS Tech Forum, which is partnered with NASA Tech Briefs, the world's largest OEM design magazine, took place October 10-12th at the Sheraton Boston Hotel and delivered on its promise of creating a focused, intimate and application-driven event that truly served the needs of attendees and exhibitors alike.

"We had a different vision for building an event that serves the engineering and manufacturing communities charged with applying this incredible technology," said Joel Dunkel, President, EventEvolution Management, Inc., producers of SENSORS Tech Forum. "Based on the feedback we received from exhibitors, speakers and attendees, it appears we delivered on our promise of creating an educationally driven, cost-effective atmosphere in which attendees could learn and do business. "And to accomplish that in this economy really speaks volumes to our steadfast commitment to our formula," continued Dunkel.

SENSORS Tech Forum '11 attracted an extremely qualified audience of engineering professionals from a wide-range of industries (see demographic profile below). Attendees represented twenty-seven different states as well as six countries all of whom converged on Boston for the three-day event. The exhibit floor featured 42 exhibiting companies that were showcased in an exhibit hall featuring dedicated, non-compete hours, which allowed attendees to spend quality time with exhibitors in a pressure-free atmosphere conducive to doing business. "The intimate setting, informative seminars, and the quality of the attendees should be used as a blueprint for how all tradeshows should be handled," said Lori Abfalter, Marketing Manager, Omnetics Connector Corp.

In addition, the Forum featured a four-track, application-driven educational conference that was designed to enlighten and empower engineers involved in designing, building and specifying sensors and the related technology they must coexist with. The event also featured two all-day pre-conference tutorials: MEMS-Enabled High Volume Commercialization Opportunities, produced and chaired by Roger Grace, President of Roger Grace Associates, one of the world's foremost MEMS marketing consulting firms; and CBRNE Sensors for Safety, Security and Sustainability, produced by Ashok Vaseashta, Director, Institute for Advanced Sciences Convergence. "I really liked the ‘intimacy' of the conference, i.e. the small number of sessions allowed me to go to other presentations and not feel rushed. I also thought the ‘time management' aspect of the conference was well planned, allowing a dedicated time to the exhibits as well. The venue was excellent and, all in all, was a very good conference that allowed a balance of networking and learning opportunities," said Nicholas Tiliakos, Ph.D., Senior R&D Engineer/Advanced Concepts, ATK GASL -NY Operations.

Based on the success of SENSORS Tech Forum '11, we are pleased to announce that the second annual SENSORS Tech Forum '12 will take place October 1-3rd at the Hilton Anaheim, Anaheim, CA.

Dover Motion DDM Series Open Frame X-Y Table Suits High-Throughput Image and Bio Processing

Wed, 25 Jan 2012 00:00:00 GMT

Dover Motion Inc. has released a open frame X-Y positioning stage with a dynamic performance and accuracy capability that will suit demanding high throughput automation applications for imaging and biotechnology. The low profile DDM series, available through Dover Motion's exclusive distribution partner Heason Technology, features direct drive ironless linear servomotors and anti-creep cross roller bearings for exceptionally smooth zero-backlash motion combined with integral linear encoders that provide positioning resolution to 0.1 micron (to 5 nanometres on request). The small footprint DDM stage has a nominal travel of 120 mm x 80 mm and an overall height of only 40 mm - with a generous through aperture that will suit both imaging and microscopy use as well supporting microtitres or wellplates with top and underside access for biomedical sampling use. The DDM is designed to provide imaging throughput of up to 30 images/sec with outstanding stability during image capture.

The DDM series has built-in cable management with a single point exit for all motor and encoder connections which reduces the overall stage footprint and facilitates straightforward installation. The combination of direct drive servomotors and non-contact optical encoders plus the absence of moving cables provides the basis for exceptionally long working life with minimal maintenance.

Heason Technology offers a complete range of motion controls and linear servo drives that will enable the highest performance from the Dover Motion DDM series. Dual axis or multi-axis controls with addition positioning mechanics are available for simple point-to point programmed motion to fully system integrated controls for high throughput production or laboratory analytics use.

Heason Technology works closely with its global distribution partners to provide a comprehensive range of first-class motion control components in combination with its own in-house design and assembly service for superior motion system solutions that help its customers to excel in their own technologies, with the advanced positioning performance they require.

Other Dover Motion products, available through Heason Technology, include linear and rotary stages for medium, high and ultra-high precision grades based with both air and mechanical bearing technologies and with linear or rotary servomotor drive systems.

Premium Range of CNC Machines

Wed, 25 Jan 2012 00:00:00 GMT

The Premium range of CNC machines is available in 3 to 5 axis motion for high accuracy micro manufacturing of component parts.

G-code Technology has developed its machines designs to incorporate granite stone base and portal structures to offer long-term reliability with rigid damping, high compressive strength and thermal stability. The individual granite elements are manufactured to DIN876 / quality 00.

Incorporated into the Premium machines is ground-breaking linear motor technology offering crucial high-precision motion with zero backlash, wear and no mechanical friction tolerances and positioning issues.

G-code Technology's control electronic technology is designed to ensure cycle times of <1 ms, simultaneous 8 axis control, fast look ahead with axis path control, jerk free compensation for smooth accelerations and decelerations motions.

The company has options for touch probes, laser scanning, automatic tool changing, high-speed spindle motors up to 100,000 rpm.

The company has many years of experience developing its High Precision CNC Premium machines for dedicated applications or for more complex turnkey solutions.

It can machine many types of material: stainless steel, graphite, copper, titanium, harden steel ceramics, brass, aluminium and plastics.

Graphite machining has always been a difficult process, the Premium machines have developed a solution for machining graphite and copper electrodes using special cyclone extraction and designed to offer complete protection of moving parts. Also a special zero point clamping system ensures complete accuracy of components and milling tools. Linear motors and linear scales offer high-speed motion and precision accuracy.

PEM Concealed-Head Studs and Standoffs Enable Smooth and Sealed Thin-Metal Assemblies

Wed, 25 Jan 2012 00:00:00 GMT

PEM self-clinching concealed-head studs and standoffs provide strong, permanent, and reusable threads for mating hardware in thin-metal assembly applications. Their unique concealed-head feature offers design and esthetic benefits by allowing the side of the sheet opposite installation to remain smooth and untouched. This feature additionally serves as an ideal solution for applications where the host metal sheet must remain completely sealed from air, liquid, dust, gases, or other potential contaminants.

Concealed-head studs and standoffs install permanently in steel or aluminum sheets as thin as .062" / 1.6mm. Studs (aluminum or stainless steel) are available in thread sizes #4-40 through #10-32 and M3 through M5 and in lengths from 0.250" through 1" and 6mm through 25mm. Standoffs (stainless steel) are offered in thread sizes #4-40 through 1/4-20 and M3 through M6 and in lengths from .187" through 1" and 4mm through 25 mm.

Sheet preparation for their installation requires only a blind milled hole to the recommended minimum depth. Using a PEMSERTER or other standard press, installation is quick and easy by placing the fastener in the hole and applying sufficient squeezing force. The fastener head then locks securely in the sheet and can handle substantial loads.

These fasteners are RoHS-compliant and some stud types meet NASM63540 specifications. Detailed specifications (Bulletin CH) and free part drawings (PEM CAD Library) can be accessed at www.pemnet.com

All PEM products are manufactured by PennEngineering, founded in 1942 and this year celebrating 70 years of innovation in fastening technology.

Conference Programme for Smart Systems Integration 2012 Unveiled

Wed, 25 Jan 2012 00:00:00 GMT

More than 60 presentations, 49 poster presentations as well as five keynote speeches from Honeywell, Empa, STMicroelectronics, Phonak Communications and the European Commission await delegates attending Smart Systems Integration 2012 from 21 - 22 March 2012 in Zurich. Top class speakers from well known organizations in science and industry will provide international experts with the latest information on the most recent developments, applications and trends.

The 2012 conference themes: • System integration and packaging
• Assembling and interconnect technologies
• Design of components and systems
• Emerging micro and nano devices and technologies
• Test and reliability of components and systems
• New materials, nano structures and devices
• Manufacturing technologies
• Power management of smart systems/energy efficiency, energy harvesting
• Smart systems for communication and medtech
• Smart systems for automotive applications, green cars and aeronautics

In addition two EPoSS sessions plus two US sessions, led by the MEMS Industry Group and Roger Grace Associates, will complete the program. The MEMS Executive Congress Europe will take place on 20 March 2012 in the neighbouring Novotel. Special conditions are available to Smart Systems Integration delegates. The 2012 supporting program - opportunities for networking and innovations A pre-conference field trip on 20 March 2012 will provide delegates with the chance to gain insight into the innovations of European research at the IBM Research Center in Ruschlikon. The traditional conference dinner on 21 March 2012 will take place at Zurich Zoo and will be rounded off with a guided tour. The exclusive dinner will offer plenty of time for intensive discussions and networking.

The exhibition - showcase for the sector Research institutes, component and system manufacturers, suppliers and service providers in the micro and nano technology, sensors, wireless communications and microelectronic and micromechanics sectors will showcase their products and solutions at the accompanying exhibition. Exhibitors will meet a highly specialised international target group of experts, users and scientists.

Conference registration is possible from the middle of January with early bird prices available until 17 February 2012.

inrekor Sandwich Panel Technology Uses LG Motion Positioning Gantry for Plasma Bonding Process

Tue, 24 Jan 2012 00:00:00 GMT

Dorset based inrekor Ltd has developed an innovative structural sandwich panel technology based upon an ARPRO core material with external layers of steel or aluminium. With far reaching potential for lightweight and low-cost vehicle chassis and many other structural frame applications across all industries, the high strength to weight ratio inrekor panel can be applied to small and large scale manufacture with minimal tooling investment. The finished panels are assembled and bonded to form final three-dimensional structures using a patented process that guarantees exceptional rigidity - offering geometric strength of up to ten times that of traditional honeycomb panels with considerable advantages in cost, design flexibility and ease of manufacture.

Reflecting the design possibilities and the production-volume flexibility of the inrekor system, the external metal surfaces for two-dimensional panels are typically manufactured using the latest water jet or laser cutting methods; for high volume production, punch-pressing these skins can be extremely cost-effective. ARPRO cores can be supplied in flat sheet form or specially moulded for large scale production. inrekor also supply fully assembled three-dimensional assemblies or 'flat-pack' panels for customers to assemble on-site. The technology is fully transferrable for Tier One automotive manufacturers to use directly for high volume production.

Joining these materials together to ensure optimum peel and tear strength is a critical process and inrekor has developed an automated plasma bonding technique that employs a large frame gantry positioning system, manufactured and supplied by motion control and machine building specialists LG Motion Ltd. The atmospheric pressure plasma treatment activates the surfaces to be bonded prior to the application of the adhesives and the lamination is completed using a separate high pressure cold press.

As part of the requirement specification for the gantry system, inrekor requested that flexibility was built into its design in terms of both motion control and mechanics to allow the machine to be adapted, if required, to suit the diverse production levels that the sandwich panel system offers.

As supplied, the LG Motion motorised gantry supports and positions the plasma head over the panel bonding area where flat sheets of core or skin material are supported on a wire-mesh bed. The vertical height of the plasma head is adjusted with a handwheel operated Z-axis stage and panels up to 3 m x 2 m may be processed using a simple PC programmed raster scan where the width of the plasma beam is tracked over the entire surface to be treated.

Using belt-driven linear actuators and Profile System machine framing components from LG Motion's associate MiniTec UK Ltd, the lower X-axis is comprised of two parallel coupled actuators to prevent axis crabbing and supports a single Y-axis linear actuator for the 2 metre span. Motorised axes are open loop stepper motor driven, with in-line gearboxes for increased torque output. Motors are fitted with rear shaft knobs that allow operators to manually move the plasma head if required. Both X and Y axes include chain-type cable management and are fitted with over-travel limit switches for safety and datum switches for homing the gantry before the automated scanning process begins. A simple stepper motor control and drive system allows the operator to set-up individual axis sequential moves using a basic like programming language.

Future mechanical modifications, all made straightforward with the modular MiniTec linear actuators and Profile System, include adding rotary encoders to stepper motors to provide 'position verification' for improved position control, or to replace steppers with servomotors to allow more precision with higher scanning speeds. Control upgrades could be met with higher level motion controls that would permit compound X and Y moves for contoured positioning of the plasma head with the possibility to include GUI programming of complex shapes using customer supplied CAD data. Using controller I/O the plasma process could also be extended to control the plasma source as well as the Z-axis and include adhesive dispensing - further advancing and speeding the entire process.

LG Motion application engineers worked closely with inrekor Ltd from the outset of the project and provided assistance with motion programming as well as installation.

New Brochure Positions Aerotech's Rotary Stages in One Useful Resource

Tue, 24 Jan 2012 00:00:00 GMT

As part of its wide range of advanced motion controls and micropositioning mechanics, Aerotech manufactures a large selection of rotary stages that provide the enabling angular positioning performance for numerous industrial production and test, and scientific research applications. In its newest brochure the leading motion specialist has brought together an important collection of rotary stages in one single 36-page resource that will facilitate comparison of specifications and prominent characteristics for eleven different rotary stage types - from high performance low profile stages with air bearings and direct drive motors to large diameter/large aperture gear driven stages for rotary positioning.

Aerotech's rotary stages form a significant part of single and multi-axis positioning systems complete with advanced motion controls that are used across industrial automation, photonics, medical device, semiconductor, laser micromachining and many other industries. Each rotary stage requirement differs in terms of precision, dynamic performance and budget, and these constraints are reflected in the bearing, drive and build construction technologies used.

The new brochure covers the top-end ABRT and ABRS ranges with brushless and slotless direct drive motors and air bearings for outstanding error motion and wobble performance suited to the exacting requirements called for in wafer inspection, DVD mastering and high precision metrology. For applications where heavier loads, higher torques and increased industrial durability are called for, Aerotech ADRT and ADRS stages introduce similar wobble and runout performance with direct drive motors and angular contact bearing systems. For applications where large through apertures are required (up to 325 mm), the ALAR range provides excellent accuracy and repeatability with continuous rotation speeds up to 300 rpm - much higher speeds and consequently much higher production throughput than gear driven, high resolution stages. Other stages featured in the brochure include the specialist ANT95 and 130 miniature stages which address the high resolution (0.01 arc-sec) positioning needs of MEMS and nanotechnology manufacture and test. Other specialist areas are represented with the fully sealed and IP66 rated ASRT stages which have been developed for hostile environment applications such as laser micromachining and are impervious to cutting fluids. Aerotech's ARMS series feature mechanical bearings and direct drive technologies, specifically aimed at highly accurate motion generation applications such as rate tables and gyro/accelerometer sensor calibration and test. Finally, the AGR series includes a more traditional mechanical bearing and worm-gear design that has a very large aperture and can fulfil general purpose rotary positioning applications in industry and in the laboratory, at very competitive cost.

The new Rotary Stage brochure is available as a PDF download from the www.aerotech.com website. It also includes a brief overview Aerotech's advanced motion controls and its capabilities across other market areas such as alternative energies, medical device and life sciences, government and educational research, and electronics manufacture, assembly & test.

Something New Under the Sun

Tue, 24 Jan 2012 00:00:00 GMT

TRUMPF's new TruMicro Series of ultra-short pulse lasers are lowering the manufacturing cost of photovoltaic cells as well as enhancing their performance. Maximising cell efficiency is the result of extremely precise and fine surface structuring and these lasers do this far better and more cost effectively than alternative processes.

In the production of solar modules from amorphous silicon (aSi) or cadmium telluride (CdTe), conductive and photoactive films are deposited on large substrate areas, such as glass. After every deposition, the laser subdivides the surface so that the cells created are automatically switched in series by the process sequence. In this way cell and module tensions, depending on the cell width, can be set.

The transparent conductive oxides are usually processed with lasers in the infrared wavelength. At typical feed rates, repetition rates of over 100 kHz result. An optimised pulse-to-pulse overlap makes for a clean kerf and minimises negative heat effects.

The small and compact TRUMPF TruMicro Series 3000 with wavelengths of 1064 and 532 nanometres are ideal for P1, P2 and P3 patterning. Thanks to their high pulse-to-pulse stability, these diode-pumped solid-state lasers achieve very good processing results. They can also be easily integrated into existing systems because of their advanced cooling design.

The patterning of thin-film cells made from Cu (In, Ga) (S,Se)2, also known as CI(G)S, presents a particularly high challenge for the laser process. The same applies to the structuring of molybdenum. For this application, nanosecond lasers are still used but picosecond lasers offer a far better solution.

With these lasers, the material is ablated with ultra-short pulses without significant heating of the process edge zone. This prevents cracking, melting and exfoliation of the layers. TRUMPF Series 5000 picosecond lasers are ideal for this task. They have a wavelength of 1030nm for structuring molybdenum and 515 nm for processing photoactive material and patterning the front of the contact.

Additionally these TRUMPF TruMicro picosecond lasers have output power up to 50 W which significantly reduces process costs.

Edge deletion: lasers replace sandblasting

To protect thin-film solar modules against unfavourable environmental influences - especially against moisture - a width of approximately 10mm of the layer system is ablated along the edge and covered with laminated film. The traditional method employed is sandblasting but TRUMPF TruMicro lasers provide a far more suitable process.

The TruMicro 7050 is recommended for this application which can process large areas at production speed, reliably and securely. It generates pulses with 30 nanoseconds duration at an average power of 750W.

Crystalline solar cells; lasers reduce the ‘per Watt' costs Up and coming laser applications include the selective ablation of passivated layers on crystalline solar cells. TRUMPF TruDisk lasers with ultra-short pulses and high pulse energies are particularly well suited to this work thanks to their excellent beam quality.

The simple scalability of the laser output enables a higher production capacity to be achieved. And the high beam quality in the ultra-short pulses significantly improves solar cells efficiency. This will result in a significant reduction of the ‘per Watt' cost of solar cell performance in the future.

Schaublin Machines SA Premiere New Machine at MACH 2012

Tue, 24 Jan 2012 00:00:00 GMT

MACH 2012 will be the UK launch pad for the new 136 7AX-Y turning centre from Schaublin Machines SA. Launched at EMO 2011, the new Schaublin 136 7AX-Y will be shown on stand 5290 in Hall 5 at MACH. Since its recent EMO Premiere, the world's first installation of this new machine has been to a UK F1 subcontractor that is achieving the feat of machining complex components in 62HRc material with tolerances of +/-0.0025 microns on the new Schaublin.

The new machine has been developed equally for production machining and small batch runs, as it combines flexibility with renowned Schaublin Machines precision and quality. The new 136 7AX-Y machine that will be shown at MACH is part of a modular range that includes several models with between 2 and 4 linear axes to suit the exacting needs of the end user. The range enables Schaublin Machines to present a machining solution clearly dedicated to production environments as well as small batch or prototype machining. The 136 7AX-Y is the ideal partner for any company targeting high precision, repeatability and reliability. Schaublin Machines delivers all of this in a compact and rigid turning centre with the A2-4 spindle nose enabling a maximum chucking diameter of 140mm with a throughbore of 36mm for bar working.

The 136 7AX-Y machine is a mill/turn center that can work with bars or billets. With twin spindles and a motorized turret each with 12x12 live tools, it is possible to work on both sides of the part simultaneously. The main and counter-spindle are identical and this simplifies the transition between front and back-end working.

Renowned for its reputation for precision, the latest addition guarantees machining accuracy with a cooling system using glycol water that passes through 12 areas of the machine as well as the main base. This ensures every part of the machine works at the same temperature to avoid any non-mastered dilatation effect that can affect precision.

The turret has been designed to be as small and compact as possible to improve the mounting of live tooling that can operate at up to 12,000rpm on every position. Working in a compact envelope with a high number of tooling demands exceptional chip removal. It is here that the 136 7AX-Y enables cutting fluid to be directed precisely to the cutting edge at a pressure level up to an optional 60 bar. This efficiently evacuates swarf from the work envelope and also prolongs tool life.

With the new machine, Schaublin Machines has identified tool pre-setting as an area where it can minimize downtime and improve productivity. With this in mind, it has developed a tool setting system in conjunction with its partner Sauter Feinmechanik. The company has developed this system rather than use a universal system because accuracy is improved as it guarantees the exact position of the pre-set tools. This allows the customer to quickly change tools whilst obtaining remarkable accuracy levels that are expected from the outstanding Schaublin Machines range.

Paying attention to detail, the new 136 7AX-Y turning centre incorporates a 3D anti-collision system that enables the turret to work in close proximity. With axis feed rates of up to 40m/min and no possibility of collision, this gives the operator confidence when working at high feed and speed rates.

The new 136 series offers modular turning centres that can be rapidly adapted to specific applications whether it is high production runs or small batches with frequent changeovers. This modularity has been an area of particular development and design focus for Schaublin Machines as it has aimed to produce a machine that can be rapidly added to with complementary devices and peripherals. Flexibility can be found throughout the machine, this includes an identical main and counter-spindle that creates balanced machining. For further details on this exciting new machine, please come and visit the Schaublin Machine stand at MACH.

Blum Gives MACH Debut to New Innovations

Tue, 24 Jan 2012 00:00:00 GMT

As the leading suppliers of innovative, high-quality measuring and testing technology, Blum Novotest will be giving a multitude of new innovations their MACH debut on Stand 5250 at the UK's showcase event taking place from 16-20th April at the Birmingham NEC. Demonstrating its capabilities for improving productivity, tool life and component accuracy, Blum will be showing a range of tool setting probes as well as workpiece inspection probes.

For the elimination of broken cutting tools and the resultant damage or scrapping of components, Blum will be showcasing its exciting new TMAC tool monitoring solution. The ingenious new Tool Monitor Adaptive Control (TMAC) system protects your CNC machine while providing valuable information regarding the cutting process.

The TMAC is an addition to the Blum product portfolio that has been developed by Caron Engineering, a technical partner of Blum Novotest. The system reduces the high cost of replacement tools, lost production and rejected parts by effectively measuring tool wear in real time. It operates on the principle that the horsepower required to cut a part increases as the condition of the cutting edges of the tool deteriorates.

Already endorsed in the US by major manufacturers such as Pratt & Witney, Smith & Wesson, John Deere, Smiths Aerospace, Volvo Aerospace, Arvin Meritor, MTU Aero Engines and Stryker Howmedica, the TMAC system comprises of a main controller, horsepower transducer, vibration sensor and the TMS display software - all of which can be simply integrated into any CNC machine tool and Windows based PC. The software conveniently enables the machine to be monitored from the shop floor or remotely from the office.

TMAC can work in conjunction with the Blum laser control system where tool breakage detection and tool wear monitoring is done with TMAC, whilst tool length and radius measurement, compensation of thermal effects or the deviations because of high spindle speeds can be done with the laser. Customers using TMAC and laser systems as a complement to each other can have the complete production (cutting) process under control.

To demonstrate how the TMAC can work in conjunction with the Blum LaserControl, Blum will have its market leading tool setting system on show at MACH 2012. Capable of working on multi-functional Mill/Turn machine tools, the LaserControl NT-H 3D from the German metrology manufacturer will highlight its tool setting advantages at the event.

The LaserControl NT-H 3D is an adaptation of the already established Blum LaserControl non-contact tool setting technology, which will also be on show at MACH. The LaserControl NT-H 3D provides non-contact measurement of rotating tools as well as the mechanical measurement of non-rotating tools in five approach directions.

With the increasing use of mill/turn centres, Blum NovoTest has developed the LaserControl NT-H 3D to cater for the demands of these machine types. Traditionally, turning tools are measured with a mechanical probe and milling tools with a laser, the NT-H 3D eliminates the need for both these types - significantly improving setting times.

The LaserControl NT-H 3D can set the radius & tool length for both turning and milling tools and this reduces set-ups and reduces machine downtime. Measuring both sets of tools in one system, the NT-H3D can eliminate the need for two separate systems. Using one complete system, the LaserControl NT-H3D offers exceptional accuracy for all measuring requirements - ideal for machines where space is limited.

The LaserControl NT-H3D will be complemented by the showing of the established LaserControl NT. The LaserControl NT solves the signal interference problems caused by coolant and swarf affecting the optical measuring system in the machine work envelope by using patented ‘out of the beam' technology that enables the new system to significantly reduce tool setting times.

Focusing upon its renowned Z-Series of probes, Blum will be exhibiting the renowned Z-Nano probing system. The accomplished Z-Nano is an extremely compact tool measuring system that can be used on CNC machining centres to conduct automatic tool length measurement and breakage detection. It can also undertake temperature compensation in one machine axis.

The new Z-Nano works with a ball guideway to reduce measuring forces. The advantage is that now even smaller tools starting from 0.1mm diameter can be measured, depending on tool geometry and material. Furthermore, in its standard version the probe offers an impressively high repeatability of 0.5 µm 2σ. For special applications, it is also available with a ‘High Precision' design with a guaranteed repeatability of 0.2 µm 2σ.

Complementing the Z-Nano will be the Z-Pico probe, an extremely compact tool length setting and breakage control system for machine tools. The tiny Z-Pico can carry out machine compensation of the smallest tools in one machine axis. With a total height of only 55mm and a total width of just 28mm2 the Z-Pico is one of the smallest tool setters on the market, making it ideal for monitoring the smallest of tools like micro drills, small cutters and engraving tools.

ROFIN Subsidiary is Renamed: ROFIN-LASAG AG

Tue, 24 Jan 2012 00:00:00 GMT

ROFIN's new subsidiary Lasag, headquartered in Thun / Switzerland changed it's company name into ROFIN-LASAG AG. The Swiss company with a long tradition is a world leading manufacturer of solid-state laser solutions for high-precision laser processing operating worldwide with production site in Switzerland and is the newest addition to the ROFIN family. The main competences of ROFIN-LASAG are laser cutting, welding, drilling and ablating of metals and other materials which are employed in almost all markets of the manufacturing industry.

New sales manager at ROFIN-LASAG AG

With immediate effect Oliver Jentschke, 41, has taken over the position of sales manager worldwide with the Swiss laser company. He graduated in business administration and has worked in the tool and mold field for the paper converting industry.

Photo: ROFIN-LASAG Managing director Ewald welcomes the new sales manager Oliver Jentschke (left)

ITC Exhibits New Tooling Innovations at MACH 2012

Tue, 24 Jan 2012 00:00:00 GMT

At MACH 2012 Industrial Tooling Corporation (ITC) will be promoting a multitude of new cutting tools that have been developed specifically for the machining of hard and abrasive materials. On Stand 5847, ITC will be demonstrating how it can improve productivity and tool life with its new innovations. The new products will be shown alongside the new range of Widia hole making and tapping products.

Among the new products for machining hard steels and aerospace alloys, ITC will highlight the benefits of its new 5021 Cyber Series of 5 flute harmonic end mills. The new 5021 Series has been developed specifically to deliver high machining performance and productivity benefits when processing difficult materials. As an integrated partner and preferred supplier to many global aerospace OEMs, Tamworth based ITC has worked strenuously with its customers that are renowned as the benchmark in high technology industries to provide an astounding series of new milling cutters.

The new 5021 Series is a straight shank, square end centre cutting range with a radical new flute geometry for staggering material removal rates. The solid carbide 5021 is manufactured from ultra wear resistant micro grain carbide that is Cupro coated to enhance tool life and machining stability. With a long length that offers additional reach benefits for the user, the cutters demonstrate stability and rigidity that far exceeds competitor products. This is credit to the unequal flute spacing that reduces machining noise and vibration by eliminating the harmonic effect of the cutters. With an overall length of up to 150 mm and a cutting length up to 60mm, the 5021 square end series is also available with a range of corner radii to further enhance tool life and meet the customers' wide spectrum of machining needs.

Complementing the 5021 Series will be the new 6051 Cyber Series of End Mills. The remarkably high performance 6 flute series of cutting tools have already made a significant impact on productivity and tool life for many aerospace OEMs and F1 manufacturers.The result of extensive R&D work, testing and consultation with leading blue chip manufacturers. Like the 5021 Series, the 6051 is also a long length, straight shank solid carbide cutter with an unequal flute spacing and Cupro coating. The Cupro coating extends the tool life and stability of the micro grain carbide series whilst the flute spacing reduces machining noise and vibration.

The geometry of the 6051 Series has been tirelessly tested to provide end users with a long reaching cutter that eliminates problems inherent in long series cutting tools. The right hand helix and cutting series is available in 6, 8, 10, 12, 16 and 20mm diameters with each diameter offering the option of a square end, 0.5, 0.75 or 1mm radius. The various radius options serve to further enhance tool life and eliminate potential chipping in extremely difficult applications. The respective cutting diameters have a machining length of 18, 24, 30, 36, 50 and 60mm with an overall length from 75 to 150mm. These dimensions have been designated for each diameter to ensure optimal performance for each individual cutter.

Alongside these new cutters will be ITC's new ball nosed cutters for machining intricate profiles, pockets and complex 5-axis components in extremely hard materials up to 65 Rockwell. The 2152 short series and 2162 long series have been launched to give outstanding machining performance to mould & die and general engineering machine shops working with hard materials.

Both series are produced from ultra wear resistant micro grain carbide that is Cupro coated to provide efficient machining with remarkable tool life. The two flute solid carbide ball nosed cutters are centre cutting with a straight shank and short length of cut for the processing of intricate forms and cavities in hard steels.

The short length of cut enhances rigidity, which is a necessity for hard machining. The extremely rigid design combines with a specially developed geometry and coating to deliver optimum performance under the most demanding of machining conditions. Both the 2152 short series and 2162 long series are available in 1, 2, 3, 45, 6, 8, 10, 12, 16 and 20mm diameters with cutters from 1 to 6mm having a 6mm shank diameter. All additional sizes have a shank diameter identical to the cutting diameter to enhance cutter strength and rigidity. The short and long series both have a length of cut of 3, 4, 5, 6, 7, 8, 10, 12, 16, 20 and 25 mm for the respective diameters.

The 2152 Short Series has an optimal overall length of 53mm for diameters up to 6mm with an overall length of 64mm for the 8 and 10 mm cutters, 80mm for the 12 and 16mm diameters and 105mm for the 20mm diameter cutter. This stub length delivers maximum rigidity, which in turn extends too life, surface finish and machining performance. For a demonstration on the capabilities of these new innovations from ITC, please visit stand 5847 at MACH 2012.

A Radical New Turning Concept From Tornos at MACH 2012

Tue, 24 Jan 2012 00:00:00 GMT

On Stand 5659 at MACH 2012 Tornos UK will give its new MultiSwiss 6x14 turning centre its UK exhibition debut. Globally launched at EMO 2011, Tornos now presents its first numerical sliding headstock multi-spindle machine. Based on a ‘fully integrated' concept, this new machine is aimed at users of multi-spindle turning machines, cam-operated machines and users of single-spindle turning machines.

The exciting new MultiSwiss will appear alongside single spindle innovations that will include the Gamma 20/6b that is a cost effective solution developed for machining relatively complex components and the Sigma 32, the only Swiss type sliding headstock machine capable of producing parts using the machining parameters of a fixed headstock machine.

At the beginning of 2008, the multi-spindle product department at Tornos put in place an ambitious project with clear objectives: To create a multi-spindle turning machine with 14mm capacity at an attractive price offering unrivalled efficiency and a rapid return on investment. The machine also had to be flexible, accurate and easy to use.

The new MultiSwiss now takes Multi-spindle machines to a new plateau. The MultiSwiss is a revolutionary product that bridges the gap between single-spindle and multi-spindle lathes. It is equipped with 6 sliding headstock spindles that use torque motor technology for barrel indexing. Its ultra-high speed makes it possible to achieve near cam driven multi-spindle cycle times. The main benefits are its ergonomic design that provides excellent access and easy control and phenomenal flexibility that enables rapid set-up and changeovers. Additional benefits include its productivity that provides competitive price per part. The MultiSwiss offers quality that provides homogeneity of production compared with the production of the same part on several machines.

With completely open access at the front, Tornos had clearly pushed accessibility further than any other solution on the market by offering a design that enables the operator to 'get right inside the machine'. The tool holders with integrated cutting oil spray via the slides and the option to change the headstock collets from the front of the machine permit users to change the set-up almost as quickly as on a single-spindle machine, which opens up new possibilities. As all the slides are 'vertical', the swarf naturally falls directly onto the conveyor, which increases the efficiency of the machine and reduces swarf removal operations for the operator.

Another strength of the machine is the seamless integration of all the necessary peripherals. As standard, the MultiSwiss includes the feeder, the management system for swarf and oil with dual filtration incorporating a paper filter system (filtration to 50µ) in addition to an ultra fine filter (5µ). The list of options has been reduced as the oil mist extractor, chip conveyor, fire prevention system and high pressure pump have been designed to integrate seamlessly into the machine. The fact that this integration has been incorporated into the machine from its very design means that its footprint is reduced taking up little more space than a single-spindle machine of equivalent capacity.

The machine's temperature is fully controlled via the cutting oil which is monitored by a plate heat exchanger. The machine core is kept at a constant temperature, even when stopped. This ensures normal operation during production. To improve efficiency, the regulation system can be pre-programmed in order to reduce the machine's standard heating times.

As with other Tornos numerical multi-spindle turning machines, the MultiSwiss includes an integrated PC. This system offers a very user-friendly interface with a large colour touch screen. Programming is carried out on TB-Deco. The integrated PC offers a great deal of flexibility. If some small program changes are required, these can be made directly on the machine. The servicing instructions, user and maintenance manuals are also loaded onto the PC. In the event of an alarm, the user can immediately display the file on-screen and read all the comments relating to this problem. Everything is at your fingertips and it is easy to navigate.

With a 14 mm capacity, the machine can hold up to 15 tools in main operations and 3 in counter operation. Each slide and each spindle can be independently programmed, which enables standard tools to be used at the ideal cutting speed for each. The controlled position of each spindle enables drilling and milling operations with precise angular location even between stations. The bar feed is performed via Z-axes integrated on each powered spindle (sliding headstock).

With the MultiSwiss, Tornos has developed a new approach to working on multi-spindle turning machines and the first customers to use this new machine have been very positive. For your opportunity to be among the first UK customers to see the benefits of the MultiSwiss, come and see us on stand 5659 at MACH 2012.

Laser Processing Capabilities

Tue, 24 Jan 2012 00:00:00 GMT

Laserage partners with medical OEMs by providing extensive laser processing capabilities.

The company offers precision laser machining, cutting, drilling and welding of many materials including stainless steel, Nitinol, titanium, platinum, quartz, ceramic and silicone.

Finishing operations include nitinol shape setting, auto micro blasting, pickling, tumbling and electro-polishing to meet strict medical device specifications. Applications include nitinol tubes for medical stent devices and implant delivery devices.

Other advantages include: flat and tubular Nitinol stocking for faster prototype turnaround; metallurgical analysis, R&D and engineering capabilities and a companywide ISO 9001:2008 and ISO 13485 program support prototyping through production services.

Micro Welding Small Parts Using Fibre Lasers

Mon, 23 Jan 2012 00:00:00 GMT

The increasing complexity of micro electronics, medical and engineering devices has placed stringent demands on assembly techniques. A particular challenge facing manufacturers is how to achieve the power levels necessary to micro weld accurately without distortion.

An effective way to weld very small parts is by using fiber lasers. Research carried out by JK Lasers demonstrates how excellent beam quality, low power (100-200W) continuous wave (CW) fiber lasers with modulation consistently achieve high quality spot welds on thin stainless steel foils (20 μm - 150 μm).

Used in the manufacture of hard disk drive flexure arms, these foils help to hold ferrite readers above spinning magnetic media. The high positioning speed and ultra-close proximity of the ferrite reader mean flexure arms must be accurately assembled. Their design must accommodate resonances, stiffness and overall component accuracy in three planes.

Spatter-free welds are critical to ensuring the reliable operation of hard disk drives. Any brittle oxide or melt spatter on the surface may flake-off and contaminate the drive, rendering it useless.

During JK Lasers' trials, a single mode fiber laser with Gaussian beam profile produced spatter-free spot welds between 76μm and 175μm in diameter. A flat top beam profile, available as an optional feature in JK Lasers' fiber laser range, achieved spatter-free welds between 150μm and 270μm in diameter.

The high levels of accuracy achievable using JK Lasers' modulated CW lasers enable high quality, shallow conduction mode spot welding with excellent top bead profile that are tailored to the target.

MM, MEMS & NANO Live UK 2012 - Call For Papers

Fri, 20 Jan 2012 00:00:00 GMT

Fresh from the success of the 2011 edition, Rapid News Communications Group is formally announcing the Call for Papers for MM, MEMS & NANO Live UK 2012.

The events continue to go from strength to strength and 2012 will see MM, MEMS & NANO Live again co-locate with TCT Live and for the first time, Mediplas, which will focus on the highly specialised area of design and manufacture of plastic parts for the medical industry. 2012 also sees a formal co-location with Sensing Technology 2012. This grouping of shows will provide a significant showcase of engineering and manufacturing technology in the UK with a projected attendance approaching 6,000.

In order to maintain the world class nature of this event Rapid News Communications Group is now calling for outstanding abstract submissions for the following sessions.

Micro Moulding of Plastics
Powder (PIM), Ceramic (CIM), Metal (MIM) Micro Injection Moulding
Conventional Micro Machining Techniques
New/Emerging Micro Machining Techniques
Micro Fabrication, Welding, Assembly
Micro Metrology: Optical, Tactile, CMMs
Advances in MEMS & NANO Manufacturing Processes
The Path to Commercialisation for NANO and MEMS Technologies

All submissions must be non-promotional in content and presented by companies or institutions that are utilising and/or researching technologies for an industrial application. Exhibitors are welcome to submit practical application-based case studies.

Interested parties are initially requested to submit an abstract of 250 words of their proposed paper on or before February 28th 2011. This should include the working title, all authors/contributors and their affiliations. All submissions will be reviewed to ensure that they meet the necessary and exacting requirements of the Micro Manufacturing Conference.

MM, MEMS & NANO Live UK will be held at the NEC Birmingham, 25-26 September 2012, and anyone submitting a presentation must be available to present on any of these two days. Please submit abstracts to Aleksandra Wisniewska via email: ola@rapidnews.com.